KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 1218
100312872 2000566139 (Rev. A)
Instruction Manual
COMMERCIAL GAS WATER HEATERS
HLW
HLW
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 efcient water heater. We
appreciate your condence in our products.
MODELS
300(A)/400(A)/500(A)
SERIES 300 & 301
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.
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CONTENTS
SAFE INSTALLATION, USE AND SERVICE...................... 3
APPROVALS ...................................................................... 3
GENERAL SAFETY INFORMATION .................................. 4
Precautions ....................................................................4
Grounding Instructions ...................................................4
Hydrogen Gas Flammable .............................................4
INTRODUCTION ................................................................ 6
Abbreviations Used ........................................................6
Qualications ..................................................................6
iCOMM ...........................................................................6
ICC .................................................................................6
Preparing for the Installation ..........................................6
FEATURES AND COMPONENTS ..................................... 7
Basic Operation ..............................................................7
Modulation ......................................................................7
Blower/Burner Assembly Detail ......................................7
Top View .........................................................................8
Side Views ...................................................................... 9
INSTALLATION CONSIDERATIONS ............................... 10
Rough In Dimensions ....................................................10
Locating the Water Heater .............................................11
Extended Vent Terminations ..........................................11
Optional Direct Vent Terminations .................................12
Hard Water ....................................................................12
Circulation Pumps .........................................................12
Insulation Blankets ........................................................12
INSTALLATION REQUIREMENTS .................................. 13
Gas Supply Systems .....................................................13
Supply Gas Regulator ...................................................13
Power Supply ................................................................13
Mixing Valves.................................................................14
Dish-washing Machines ................................................14
Closed Water Systems ..................................................14
Thermal Expansion .......................................................14
Temperature-Pressure Relief Valve ............................... 15
Condensate Drain .........................................................16
Combustible Material Storage .......................................16
Contaminated Air ........................................................... 16
Air Requirements ........................................................... 17
Unconned Space .........................................................17
Conned Space .............................................................17
Fresh Air Openings For Conned Spaces ..................... 18
INSTALLATION REQUIREMENTS - COMMONWEALTH OF
MASSACHUSETTS .......................................................... 20
VENTING INSTALLATION ............................................... 21
General Venting Information ..........................................21
Category IV Appliances .................................................21
General Venting Instructions .........................................21
Venting Requirements ...................................................22
Common Venting ........................................................... 23
Venting Installation Sequence .......................................23
Power Vent Installation .................................................. 23
Direct Vent Installation ...................................................23
Direct Vent Air Intake Moisture Protection .....................25
Vertical Termination Installation .....................................25
Sidewall Termination Installation ...................................27
Polypropylene Installations ............................................ 28
AL29-4C® Vent Installations .........................................29
Common Venting ........................................................... 30
Concentric Termination Installation ...............................30
6 Inch Concentric Termination Installation ..................... 31
Low Prole Vent Installation ..........................................33
Venting Arrangements ...................................................35
Termination Clearances Sidewall Power Vent ............... 37
Termination Clearances Sidewall Direct Vent ................38
WATER HEATER INSTALLATION .................................... 39
Condensate Drain Installation .......................................39
Supply Gas Line Installation ..........................................39
Gas Line Leak Testing ...................................................41
Purging ..........................................................................41
Electrical Wiring ............................................................. 41
Enable/Disable Circuit ...................................................42
Water Line Connections ................................................42
T&P Valve Discharge Pipe ............................................43
TEMPERATURE REGULATION ...................................... 44
High Temperature Limit Control (ECO)..........................44
THERMOSTAT CONTROL ............................................... 44
Intelligent Demand Response .......................................44
Firing Rate Modulation ..................................................44
CONTROL SYSTEM OPERATION .................................. 46
Overview .......................................................................46
Control System Navigation ............................................46
WI-FI .............................................................................. 46
Lockout Function ...........................................................46
User Settings & Control System Menus ........................49
START UP ........................................................................ 57
Prior to Start up .............................................................57
Lighting & Operation Label ............................................57
LIGHTING THE WATER HEATER ................................... 58
Lighting Operation & Labels ..........................................58
Checking the Firing Rate ...............................................59
High Altitude Installations ..............................................60
TROUBLESHOOTING ..................................................... 61
Installation Checklist ...................................................... 61
Sequence of Operation .................................................61
Sequence of Operation Flow Chart ...............................62
Operational Problems .................................................... 63
Fault and Alert Conditions .............................................64
MAINTENANCE ............................................................... 67
General .......................................................................... 67
Maintenance Schedule ..................................................67
Draining and Flushing ...................................................67
Sediment Removal ........................................................68
Lime Scale Removal .....................................................68
Powered Anode Rods ....................................................68
Drain Valve and Access Panels ..................................... 69
Temperature-Pressure Relief Valve Test .......................69
Vent System ..................................................................69
DIAGRAMS ...................................................................... 70
Central Control Board Layout ........................................70
Wiring Diagram .............................................................. 71
Circulation Pump Wiring Diagrams ...............................72
Water Piping Diagrams ..................................................73
2
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SAFE INSTALLATION, USE AND SERVICE
The proper installation, use, and servicing of this water heater is
extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided
in this manual and on your own water heater to warn you and others
of a potential injury hazard. Read and obey all safety messages
and instructions throughout this manual. It is very important that the
meaning of each safety message is understood by you and others
who install, use, or service this water heater.
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.
APPROVALS
HLW
Note: ASME construction is optional on the water heaters
covered in this manual.
3
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GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately call
a qualied 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 qualied service agency.
1. External re.
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.
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
ammable. 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 ow. THERE SHOULD BE NO SMOKING
OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
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
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
Improper installation, use and service may result
in property damage.
Do not operate water heater if exposed to flooding or
water damage.
•
Inspect anode rods regularly, replace if damaged.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
closed water systems.
•
Refer to this manual for installation and service.
CAUTION
4
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GENERAL SAFETY INFORMATION
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 the water heater
in operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing heater.
Install sediment trap in accordance
with NFPA 54 or CAN/CSA 149.1.
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.
5
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INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• 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 Qualied Agency (as dened by ANSI below) in the eld
involved. Installation skills such as plumbing, air supply, venting,
gas supply and electrical supply are required in addition to electrical
testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any individual,
rm, 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 qualied (as dened by ANSI above) and licensed or
certied 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 dened Alert conditions should occur. The system is expandable
to meet the needs of multiple heaters and groups of heaters.
ICC
This water heater is connectible 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 nd out more about iCOMM™ or ICC devices, log in
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 identied
in
Features and Components
(page 7) in this manual. Use this
reference to locate and identify various components on the
water heater.
See
Installation Checklist
(page 61) and
Troubleshooting
(page
61). 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 Qualied 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 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 Ofce 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).
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FEATURES AND COMPONENTS
BASIC OPERATION
The water heaters covered in this manual have a helical coil shaped
heat exchanger that is submerged in the storage tank. The water
heater’s Main Burner is a radial design burner, it is mounted on the top
and res downward through the heat exchanger. This is a forced draft
burner; hot burning gases are forced through the heat exchanger
under pressure and exit through the exhaust/vent connection located
at the bottom of the water heater. See
Figure 1
and
Figure 2
.
BLOWER
BURNER
ASSEMBL
Y
MAIN
BURNER
(radial design)
HEAT
EXCHANGER
INTAKE AIR
(combustion air)
CONNECTION
4 INCH PVC
HELICAL
COIL
VENT (exhaust)
OUTLET
Figure 1. Water Heater Components
MODULATION
The water heaters covered by this manual are capable of modulating
their ring rate. The CCB monitors the water temperature in the
tank and regulates the ring rate to achieve the target temperature
setpoint. The ring rate is dictated by the hot water draw, proximity
to the tank temperature setpoint, and various other temperature
limitations.
BLOWER/BURNER ASSEMBLY DETAIL
SPARK
IGNITER
FLAME SENSOR
COMBUSTION
BLOWER
MAIN BURNER
(radial design)
BLOWER
FLANGE
INTAKE AIR
(combustion air)
CONNECTION
4 INCH PVC
Figure 2. Blower/Burner Components
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.
Flame Sensor
The control system also monitors the ame sensor to conrm a ame
is present at the Main Burner. If a ame is not veried 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 62).
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TOP VIEW
3
2
4
5
7
9
10
11
2
13
15
1
16
17
14
6
12
8
Figure 3. Top View
COMPONENTS (ALL MODELS)
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. Powered anode rods. The water heater’s covered in this manual
are equipped with two powered (non sacricial) anode rods.
Protective current is fed by the control system to the titanium
electrodes at the end of each anode rod. This current ows
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.
3. Central Control Board (CCB) enclosure. This enclosure houses
the control system’s main circuit board, power supply board,
power transformer, and conguration key. The CCB regulates
water temperature and controls all water heater functions. See
Control System Operation
(page 46).
4. 120 VAC junction box. Incoming power supply, ground
connections, and other eld installed electrical connections
are made here. See
Power Supply
(page 13) and
Power Supply
Connections
(page 41).
5. Intake air connection - 4 inch PVC.
6. Blocked Intake Air switch. Normally closed contacts that open on
fall in pressure. This switch is used to ensure 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.
7. Water heater’s 24 VAC Gas Valve.
8. Supply gas line connection. See the requirements for the supply
gas line in
Table 4
and
Table 5
(page 10).
9. Low Gas Pressure switch. Normally open contacts that close on a
rise in pressure. This switch is used to ensure supply gas pressure
is above minimum requirements. The control system monitors this
switch and will disable heating operation if its contacts are open
during a heating cycle. See
Table 4
and
Table 5
and gas pressure
requirements (page 10).
10. Vent connection (exhaust/condensate elbow) - 4 inch aluminum.
11. Combustion Blower Assembly. Includes Gas Valve and Venturi
gas feed system.
12. Blocked Exhaust (vent) switch. Normally closed contacts that
open on a rise in pressure. This switch is used to ensure the
Exhaust (vent) piping connected to the water heater is not
restricted. The control system monitors this switch and will disable
heating operation if its contacts are open during a heating cycle.
13. Temperature-Pressure Relief Valve. See
Temperature-Pressure Relief
Valve
(page 15).
14. Upper Temperature Probe, 1 of 2 temperature probes. The water
heater’s control system monitors this probe to detect water
temperature in the upper portion of the storage tank.
The Upper Temperature Probe also houses the ECO
(energy cut out) switch. This is a non adjustable high
temperature limit switch. The ECO switch contacts are
normally closed and will open on a temperature rise. See
High Temperature Limit Control (ECO)
(page 44).
15. Water outlet connection 1 1/2” NPT.
16. 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. See
Control
System Operation
(page 46).
17. Spark Ignition Control. When energized, sends the electrical
current to the spark igniter.
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SIDE VIEWS
1. Cleanout access panel, covers water heater cleanout opening
and ASME plate where applicable.
2. CCB enclosure. See
Figure 3
(page 8) for description.
3. 120 VAC junction box. Incoming power supply, ground
connections, and other eld installed electrical connections
are made here. See
Power Supply
(page 13) and
Power Supply
Connections
(page 41).
4. Intake air connection - 4 inch PVC.
5. Supply gas line connection. See the requirements for the supply
gas line in
Table 4
and
Table 5
(page 10).
6. Low Gas Pressure switch. See description under
Figure 3
(page 8). See
Table 4
(page 10) and the Gas Pressure
Requirements on page 10.
7. Water heater 24 VAC Gas Valve.
8. Water outlet - 1 1/2” NPT connection.
9. 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.
See
Control System Operation
(page 46).
10. Temperature-Pressure Relief Valve. See
Temperature-Pressure
Relief Valve
(page 15).
11. Temperature-Pressure Relief Valve discharge pipe. See
T&P
Valve Discharge Pipe Requirements:
(page 15).
12. Lower Temperature Probe, 1 of 2 temperature probes. The water
heater’s control system monitors this probe to detect water
temperature in the lower portion of the storage tank.
13. Water inlet connection - 1 1/2” NPT connection.
14. Water heater drain valve.
15. Combustion Blower.
16. Vent connection (exhaust/condensate elbow) - 4 inch aluminum.
17. Recirculation loop return connection - 3/4” NPT.
18. Spark Ignition Control, When energized, sends the electrical
current to the spark igniter.
10
11
13
14
12
16
3
5
17
2
1
4
6
9
18
17
1
2
4
6
16
810
11
12
13
14
15
9
Figure 4. Left Side Components Figure 5. Right Side Components
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INSTALLATION CONSIDERATIONS
ROUGH IN DIMENSIONS
GAS
INTAKE
CLEANOUT
T&P
DRAIN
EXHAUST
1 1/2" NPT
WATER
OUTLET
FRONT
18°
30°
45°
42°
70°
20°
TOP
RECIRC RETURN
CLEANOUT
3/4" NPT
T&P
3/4" NPT DRAIN
1 1/2" NPT
WATER INLET
52in
132.08cm
32.39cm
12-3/4in
4-3/4in
12.07cm
58.43cm
23in
75-3/4in
192.41cm
FRONT
4" EXHAUST VENT
CONNECTION
CONNECTION
1 1/2" SUPPLY GAS
BACK
4" PVC AIR INTAKE
CONNECTION
74-1/2 in
33-1/8in
189. 23cm
84.12cm
O.D.
69-1/4in
175.9cm
63-1/8in
160.35cm
WATER
OUTLET
HEIGHT
Figure 6. 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 300 and 400 water heaters are Automatic Circulating Tank
or Automatic Storage Water Heaters. The 500 is an Automatic
Circulating Tank or Automatic Instantaneous water heater.
Table 1. Fuel Type/Connection Size by Model
† MODEL SERIES NATURAL GAS PROPANE GAS
300 300/301 1 1/2” NPT 1 1/2” NPT
400 300/301 1 1/2” NPT 1 1/2” NPT
500 300/301 1 1/2” NPT 1 1/2” NPT
† Depending on the installed equivalent length, and/or the number of
appliances connected, the supply gas line size may have to be increased
beyond the minimum required sizes. See
Gas Line Sizing
(page 40).
This table shows connections sizes only. Depending on the installed
equivalent length, and/or the number of appliances connected, the
supply gas line size may have to be increased beyond the minimum
required sizes. See
Gas Line Sizing
(page 40).
Table 2. Storage Capacities
Model
U.S. Gallons Liters
ASME Standard ASME Standard
All 119 119 450.96 450.96
Table 3. Recovery Capacities
U.S. Gallons/hr & liters/hr at temperature rise indicated
Model
Type of
Gas
Input Thermal
Efciency
%
°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
300
Natural
300,000 88 96
GPH 1164 873 698 582 499 436 388 349 317 291 269 249
Propane LPH 4404 3303 2643 2202 1888 1652 1468 1321 1201 1101 1016 944
400
Natural
399,900 117 95
GPH 1535 1151 921 767 658 576 512 460 419 384 354 329
Propane LPH 5810 4357 3486 2905 2490 2179 1937 1743 1585 1452 1341 1245
500
Natural
499,900 146 95
GPH 1919 1439 1151 959 822 720 640 576 523 480 443 411
Propane LPH 7263 5447 4358 3631 3113 2724 2421 2179 1981 1816 1676 1556
Table 4. Gas Pressure Requirement
Model
*Manifold Pressure Minimum Supply Pressure Maximum Supply Pressure
Natural Gas Propane Gas Natural Gas Propane Gas Natural Gas Propane Gas
300 0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.8" W .C. (1.19 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
400 0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.8" W .C. (1.19 kPa) 8.5” W. C. (2.12 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
500 0” W. C. (0 kPa) 0” W. C. (0 kPa) 4.8" W .C. (1.19 kPa) 8.5” W. C. (2.12 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. Minimum Supply Gas Line Size
Model *Natural Gas Propane Gas
300 1 1/4" NPT 1 1/4" NPT
400 1 1/4" NPT 1 1/4" NPT
†500 1 1/2" NPT 1 1/4" NPT
† Note that the model 500 natural gas water heaters require a 1 1/2" minimum supply gas line size. Depending on the installed equivalent length, and/or the number of
appliances connected, the supply gas line size may have to be increased beyond the minimum required sizes shown in this table .See
Gas Line Sizing
(page 40).
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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 oor 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 oors 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
ammable liquids or engine driven equipment or vehicles are stored,
operated or repaired. Flammable vapors are heavy and travel along
the oor and may be ignited by the water heater’s igniter or Main
Burner ames causing re or explosion.
Flammable items, pressurized containers or any other potential
re 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 ooring. 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 an alcove or
closet, the entire oor 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
below.
TOP VIEW
0
0
0
ALCOVE
FRONT VIEW
CLEARANCES TO COMBUSTIBLE
AND NON COMBUSTIBLE
CONSTRUCTION MATERIALS
WATER
HEATER
FRONT
TOP COVER
FRONT
Figure 7. 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).
EXTENDED VENT TERMINATIONS
The water heaters covered by this manual can be installed using 4
inch pipe for the intake air and/or vent piping up to a maximum of
70 equivalent feet (21.3 m). The intake air and/or vent piping can
be extended up to 120 equivalent feet (36.5 m) by installing 6 inch
pipe. See
Venting Requirements
(page 22).
The water heater ships from the factory with two (2) 4 inch
terminations that are 45° PVC elbows with a debris screen installed.
When 6 inch intake air or vent pipe is installed, factory supplied 6
inch terminations must be used.
Contact Technical Support for assistance in ordering the 6 inch
termination(s). See the contact information label on the water heater.
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OPTIONAL DIRECT VENT TERMINATIONS
The water heaters covered by this manual can be installed in a
Direct Vent conguration using optional concentric or low prole
terminations.
See
Venting Requirements
(page 22),
Concentric Termination Installation
(page 30) and
Low Profile Vent Installation
(page 33).
Concentric and low prole terminations must be ordered separately.
Contact Technical Support for assistance in ordering the concentric
terminations or low profile vent terminations. See the contact
information label on the water heater.
HARD WATER
Where hard water conditions exist, water softening or the threshold
type of water treatment is recommended. This will protect the
dishwashers, coffee urns, water heaters, water piping and other
equipment.
See
Maintenance
(page 67) 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 3/4” NPT recirculation loop return
connection. See
Figure 6
(page 10)
for its location. See
Water Piping
Diagrams
(page 73) for the installation location of circulating pumps.
See
Circulation Pump Wiring Diagrams
(page 72) 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 circulators 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
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
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions. See
Features and Components
(page
7) for identication of components mentioned below. Failure to
follow these instructions can restrict the air ow 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 ow.
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INSTALLATION REQUIREMENTS
GAS SUPPLY SYSTEMS
Low pressure building gas supply systems are dened 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 ensure 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 eld 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 specied
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 4.8” W.C. for
natural gas and 8.5” W.C. for propane gas. The minimum supply
pressure is measured while gas is owing (dynamic pressure).
The supply pressure should never fall below 4.8” W.C. for natural
gas and 8.5” W.C. for propane gas. The supply pressure should be
measured with all gas red appliances connected to the common
main ring at full capacity. If the supply pressure drops more than
1.5” W.C. as gas begins to ow 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), the
requirements for the supply gas line in
Table 4
and
Table 5
(page 10),
and the instructions in
Supply Gas Line Installation
(page 39). 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
owing (static pressure).
SUPPLY GAS REGULATOR
1. 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.
2. If a positive lock-up regulator is required follow these instructions:
3. Positive lock-up gas pressure regulators must be rated at or above
the input Btu/hr rating of the water heater they supply.
4. 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
(page 40).
5. 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.
6. 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 dened 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 uctuations 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 lter/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 lters are not covered under the
limited warranty.
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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 inrm
and the physically/mentally disabled.
Table 6
(page 14)
shows
the approximate time-to-burn relationship for normal adult skin. If
anyone using hot water provided by the water heater being installed
ts 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
satises the demand of the application a Mixing Valve should be
installed at the water heater (see
Figure 8
(page 14)) or at the hot
water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualified Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
Table 6. Burn Time at Various Temperatures
Water Temperature
°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) instantaneous 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 ow
pressures between 15 and 25 pounds per square inch (103 kPa and
173 kPa). Flow pressures above 25 pounds per square inch (173
kPa), or below 15 pounds per square inch (103 kPa), will result in
improperly sanitized dishes. Where pressures are high, a water
pressure reducing or ow regulating control valve should be used
in the 180°F (82°C) line to the 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 8. 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 ow by throttling a full port ball valve installed in the circulating
line on the outlet side of the pump. Never throttle ow on the suction
side of a pump. See
Water Piping Diagrams
(page 73).
Note: To comply with NSF Standard 5 installation
requirements the bottom of the water heater must be
sealed to the oor with a silicone based sealant or
elevated 6 inches above the oor.
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
ow 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 42) and the
Water Piping Diagrams
(page 73).
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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 certied
combination Temperature-Pressure Relief Valve (T&P valve) by
the manufacturer. The valve is certied 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 certied 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. Contact Technical Support for assistance in
sizing a Temperature-Pressure Relief Valve for remote
storage tanks. See the contact information label on the
water heater.
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 tting 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 oor 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 ow 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 oor 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
Thermal Expansion
(page 14).
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve contact Technical
Support for assistance. See the contact information label on the
water heater.
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CONDENSATE DRAIN
The water heaters covered in this manual are condensing appliances
and require a building drain to be located in close proximity to allow
the condensate to drain safely.
Condensate drains from the water heater at the exhaust/condensate
elbow located at the bottom. The eld installed condensate drain
line must not be elevated above the condensate drain connection
on the exhaust/condensate elbow. See
Figure 9
(page 16). If the
condensate does not drain properly it will build up in the exhaust
(vent) elbow. This will restrict the ow of ue 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 64).
The Condensate Cleanout Cap must be on and tight when unit is
in operation.
The exhaust elbow has a built in condensate trap. Do not install an
additional trap in the condensate drain piping. See
Figure 9
(page
16).
Note: If the “Blocked Exhaust “ Fault message is ever
displayed on the control system LCD, check the
condensate drain rst and ensure it is not blocked.
EXHAUST (VENT)
ELBOW
THIS SIDE VIEW
OF EXHAUST
ELBOW AND
ARROW INDICATE
THE LOCATION OF
THE PRESSURE
PORT
BUILDING
DRAIN
CONDENSATE
CLEANOUT CAP
CONDENSATE DRAIN
LINE - FIELD INSTALLED
CONDENSATE
DRAIN LINE
CONNECTION
DRAIN LINE TO TERMINATE NO
MORE THAN 6 INCHES (15.2cm)
ABOVE DRAIN
Figure 9. Exhaust/Condensate Elbow
CONDENSATE DRAIN WATER TRAP
Do not remove the factory installed exhaust/condensate elbow for
any reason. See
Figure 9
. The water heater’s vent pipe is under a slight
positive pressure while unit is in operation. The water trap prevents
ue gases from escaping into the installed space. The exhaust
elbow has a “built in” condensate trap. Do not install an additional
trap in the condensate drain piping. See
Figure 9
and
Condensate Drain
Installation
(page 39).
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 39).
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 ammable 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 ue ways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion may
result in failure and risk of asphyxiation.
Combustion air that is contaminated can greatly diminish the life
span of the water heater and water heater components such as hot
surface igniters and burners. Propellants of aerosol sprays, beauty
shop supplies, water softener chemicals and chemicals used in dry
cleaning processes that are present in the combustion, ventilation
or ambient air can cause such damage.
Do not store products of this sort near the water heater. Air which
is brought in contact with the water heater should not contain any
of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outdoor sources. The limited warranty is
voided when failure of water heater is due to a corrosive atmosphere.
(See limited warranty for complete terms and conditions).
If the water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater(s) be installed in
a Direct Vent conguration so that all air for combustion is derived
directly from the outdoor atmosphere through a sealed intake air
pipe. See
Venting Installation
(page 21).
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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 insufcient 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 ame,
causing sooting of the combustion chamber, burners and ue tubes
and creates a risk of asphyxiation.
Do not install the water heater in a conned space unless an
adequate supply of air for combustion and ventilation is brought in
to that space using the methods described in the Conned Space
section that follows.
Never obstruct the ow 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 re or explosion and cause
property damage, serious bodily injury or death.
UNCONFINED SPACE
An Unconned 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 unconned space.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and replaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconned spaces in buildings, inltration may be adequate to
provide air for combustion, ventilation and dilution of ue 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
Conned Space section that follows.
CONFINED SPACE
A Conned 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 conned spaces. The required size for the
openings is dependent on the method used to provide fresh air to
the conned space AND the total Btu/hr input rating of all appliances
installed in the space.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration 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 conned 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, sufcient 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 re 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 specied. 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 xed in the open position.
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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 conned spaces. The illustrations shown
in this section of the manual are a reference for the openings that
provide fresh air into conned 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
Figure 10. 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 10
.
Each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all
appliances installed in the enclosure. Each opening shall not be less
than 100 square inches (645 cm2).
OUTDOOR AIR THROUGH ONE OPENING
Figure 11. 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 11
. The water heater shall have clearances of at least 1 inch (25
mm) from the sides and back and 6 inches (l50 mm) from the front
of the 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. 1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total input
rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the
space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
Figure 12. Outdoor Air Through Two Horizontal Ducts
The conned space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The horizontal ducts shall communicate directly with the
outdoors. See
Figure 12
.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches.
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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 conned 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 13. Outdoor Air Through Two Vertical Ducts
The conned space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See
Figure 13
.
Each duct opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches.
AIR FROM OTHER INDOOR SPACES
Figure 14. Air From Other Indoor Spaces
The conned space shall be provided with two permanent openings,
one commencing within 12 inches (300 mm) of the top and one
commencing within 12 inches (300 mm) of the bottom of the
enclosure. See
Figure 14
.
Each opening shall communicate directly with an additional room(s)
of sufcient volume so that the combined volume of all spaces meets
the criteria for an Unconned 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 MASSACHUSETTS
COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct
vent, and power direct vent gas fueled water heaters installed in every
dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the Commonwealth
and where the side wall exhaust vent termination is less than seven
(7) feet above nished grade in the area of the venting, including
but not limited to decks and porches, the following requirements
shall be satised:
INSTALLING CARBON MONOXIDE DETECTORS
At the time of installation of the side-wall horizontal-vented gas-fueled
equipment, the installing plumber or gas-tter shall observe that a
hard-wired carbon-monoxide detector, with an alarm and battery
back-up, is installed on the oor level where the gas equipment is
to be installed. In addition, the installing plumber or gas-tter 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 qualied licensed
professionals for the installation of hard-wired carbon-monoxide
detectors.
In the event that the side-wall horizontally-vented gas-fueled
equipment is installed in a crawl space or an attic, the hard-wired
carbon-monoxide detector, with alarm and battery back-up, may be
installed on the next adjacent oor level.
In the event that the requirements of this subdivision can not be
met at the time of completion of installation, the owner shall have
a period of thirty (30) days to comply with the above requirements
provided that during said thirty (30) day period, a battery-operated
carbon-monoxide detector, with an alarm, shall be installed.
APPROVED CARBON MONOXIDE DETECTORS
Each carbon-monoxide detector as required in accordance with
the above provisions shall comply with
NFPA 720
and be
ANSI/UL 2034
listed and
CSA
certied.
SIGNAGE
A metal or plastic identication plate shall be permanently mounted
to the exterior of the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent terminal for the
horizontally-vented gas-fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (1/2) inch
in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS.”
INSPECTION
The state or local gas inspector of the side-wall horizontally-vented
gas-fueled equipment shall not approve the installation unless, upon
inspection, the inspector observes carbon-monoxide detectors and
signage installed in accordance with the provisions of
248 CMR 5.08(2)
(a) 1 through 4
.
EXEMPTIONS
The following equipment is exempt from
248 CMR 5.08(2)(a)1 through 4
:
1. The equipment listed in Chapter 10 entitled “Equipment Not
Required To Be Vented” in the most current edition of
NFPA 54
as
adopted by the Board; and
2. Product Approved side-wall horizontally-vented gas-fueled
equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for
residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENT-
ING 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 VENT-
ING SYSTEM NOT PROVIDED
When the manufacturer of a Product Approved side-wall
horizontally-vented gas-fueled equipment does not provide the parts
for venting the ue gases, but identies “special venting systems,”
the following requirements shall be satised by the manufacturer:
1. The referenced “special venting system” instructions shall be
included with the appliance or equipment installation instructions.
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 INSTALLATION
Breathing carbon monoxide can cause brain damage or death.
Always read and understand the instruction manual.
Install vent system in accordance with codes.
Do not operate water heater if exposed to flooding or
water damage
Special consideration must be taken with installations
above 10,000 feet (3,048 m) refer to high altitude
section of this manual.
Breathing Hazard - Carbon Monoxide Gas
•
•
Do not operate if soot buildup.
•
Do not obstruct water heater air intake with insulating
jacket or blanket.
•
Do not place chemical vapor emitting products near
water heater.
•
Gas and carbon monoxide detectors are available.
•
Never operate the heater unless it is vented to the
outdoors and has adequate air supply to avoid risks
of improper operation, fire, explosion or asphyxiation.
•
Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
•
•
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 ue gases. Such conditions
cause sooting of the combustion chamber, burners, and ue 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 conguration.
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 (page 28)
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
AL29-4C Stainless Steel (page 29).
• HeatFab Saf-T Vent
• Duravent FasNSeal
Approved vent pipe materials that must be used in Canada:
• ULC S636 PVC / CPVC
• ULC S636 Polypropylene (page 28)
• AL29-4C Stainless Steel (page 29)
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 (page 28)
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
AL29-4C Stainless Steel (page 29).
• HeatFab Saf-T Vent
• Duravent FasNSeal
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 ttings with thermal insulation is
prohibited.
CATEGORY IV APPLIANCES
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 CONFIGURATIONS
Power Vent congurations derive all combustion air from the room
where they are installed and discharge all ue gases to the outdoor
atmosphere through a sealed vent (exhaust) pipe. Power vent
congurations have one vent pipe connected to the water heater
which can be terminated in a vertical or horizontal arrangement.
See
Figure 39
and
Figure 40
(page 35).
DIRECT VENT CONFIGURATIONS
Direct Vent congurations derive all combustion air directly from the
outdoor atmosphere through a sealed intake air pipe and discharge
all ue gases to the outdoor atmosphere through a sealed vent
(exhaust) pipe. Direct Vent congurations have two pipes connected
to the water heater, one vent pipe and one intake air pipe. Direct
Vent congurations can be terminated in one of seven different
arrangements. See
Figure 41
through
Figure 47
(page 35).
GENERAL VENTING INSTRUCTIONS
These instructions must be followed on all installations.
1. DO NOT install the water heater in a Power Vent conguration
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 conguration.
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 conguration so that all air
for combustion is derived from the outdoor atmosphere.
3. The vent and intake air piping must terminate outdoors.
4. The minimum clearance from combustible materials for the
vent (exhaust) and intake air piping shall be 0 inches. Vent
piping passing through a combustible wall or ceiling must be a
continuous run (no joints).
5. The water heater must be protected from freezing 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.
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10. The vent (exhaust) and intake air 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,
oors 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, concentric or low
prole 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 ue gases. Recirculation
of ue 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 ue gases, maintain
as much distance as possible between the intake air and vent
terminations.
16. Do not locate the vent termination over a public area where
condensate or vapor can cause a nuisance or ice hazard.
17. Ensure the screens in the factory supplied terminations are
securely installed to prevent blockage in the vent system.
18. Stress levels in pipe/ttings can be signicantly increased by
improper installation. If rigid pipe clamps are used to hold the
pipe in place, or if the pipe cannot move freely through a wall
penetration, the pipe may be 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 on page 23.
VENTING REQUIREMENTS
FIELD SUPPLIED FITTINGS
Field supplied ttings should be equivalent to the piping material
being installed. Field installed/supplied ttings will add equivalent feet
to the vent or intake air piping as indicated below. All eld supplied/
installed ttings 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 10
and
Table 11
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 ttings for solvent welding. If CPVC pipe and ttings 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 certied for the use
of 4 and 6 inch pipe for the vent (exhaust) and intake air piping. If
the installed equivalent length for the intake air or vent piping will be
70 feet (21.3 m) or less, 4 inch pipe must be used. If the installed
equivalent length will be more than 70 feet (21.3 m), 6 inch pipe
must be used.
Note: Install the pipe size required for the installed equivalent
length of each pipe independently. IE: If the intake air
pipe will be 70 equivalent feet or less and the vent pipe
will be more than 70 equivalent feet; the intake air pipe
must be installed using 4 inch pipe and the vent must be
installed using 6 inch pipe.
MAXIMUM EQUIVALENT LENGTHS
Four Inch Pipe
The water heaters covered in this manual are certied to a maximum
length of 4 inch pipe for the exhaust venting arrangement of 70
equivalent feet (21.3 m). The certied maximum length of 4 inch pipe
for intake air piping is also 70 equivalent feet (21.3 m). IE: On Direct
Vent installations both pipes can be up to 70 equivalent feet (21.3 m).
Six Inch Pipe
The water heaters covered in this manual are certied to a maximum
length of 6 inch pipe for the exhaust venting arrangement of 120
equivalent feet (36.5 m). The certied maximum length of 6 inch
pipe for intake air piping is also 120 equivalent feet (36.5 m). IE:
On Direct Vent installations both pipes can be up to 120 equivalent
feet (36.5 m).
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
Four Inch Pipe
The water heaters covered in this manual are certied to a minimum
length of 4 inch pipe for the vent (exhaust) of 15 equivalent feet
(4.6 m). There is no minimum equivalent feet requirement for the
intake air pipe.
Six Inch Pipe
The water heaters covered in this manual are certied to a minimum
length of 6 inch pipe for the vent (exhaust) of 70 equivalent feet
(21.3 m). There is no minimum equivalent feet requirement for the
intake air pipe.
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 conguration 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 10
and
Table 11
for equivalent linear pipe length
of AL29-4C® 45° and 90° elbows.
FACTORY SUPPLIED FITTINGS
The water heater ships with two (2) factory supplied 4 inch
terminations (PVC 45° elbows with debris screen). Factory supplied
vent and intake air terminations or concentric and low profile
terminations must be used. Factory supplied terminations and
installed ttings (exhaust elbow and intake air connection) add zero
equivalent feet to the vent and intake air piping.
Note: Three-inch vent and/or intake pipe as well as 3 inch
terminations previously used on older 300 and 400
models must be replaced with 4 inch or 6 inch pipe and
4 inch or 6 inch terminations depending on installed
length.
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Table 7. PVC/CPVC and Polypropylene
Number of
90° Elbows
Installed
4 Inch Pipe 6 Inch Pipe
Maximum Feet (Meters) Maximum Feet (Meters)
One (1) 65 feet (19.8 meters) 115 feet (35.0 meters)
Two (2) 60 feet (18.2 meters) 110 feet (33.5 meters)
Three (3) 55 feet (16.8 meters) 105 feet (32.0 meters)
Four (4) 50 feet (15.2 meters) 100 feet (30.5 meters)
Five (5) 45 feet (13.7 meters) 95 feet (29.0 meters)
Six (6) 40 feet (12.2 meters) 90 feet (27.4 meters)
6 INCH EXTENDED VENT TERMINATIONS
When 6 inch intake air or vent pipe is installed using standard
terminations, factory supplied 6 inch terminations must be used.
Contact Technical Support for assistance in ordering 6 inch
termination(s). See the contact information label on the water heater.
See
Optional Direct Vent Terminations
(page 12) for more information.
The water heaters covered by this manual may be installed in a
Direct Vent conguration using a 6 inch concentric or 6 inch low
prole termination.
Contact Technical Support for assistance. See the contact information
label on the water heater.
• 6” Concentric Termination Part # 100113124 (used for both
4” & 6” diameter piping)
• 6” Low Prole Termination Part # 100187889
COMMON VENTING
The water heaters covered by this manual may be installed using
a common horizontal direct vent kit. Contact Technical Support for
for more information or to order. See the contact information label
on the water heater.
VENTING INSTALLATION SEQUENCE
1. Read
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 conguration and which vent system
arrangement will be used for the installation. See
Venting
Arrangements
(page 35).
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
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 specic for power vent congurations.
2. Determine which power vent arrangement will be used for the
installation; vertical or horizontal termination. See
Figure 39
and
Figure 40
(page 35).
3. Determine the vent pipe size for the installation. See
Venting
Requirements
(page 22).
4. 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.
5. Install the termination rst.
If the vent piping will terminate vertically, through a roof,
see
Vertical Termination Installation
(page 25).
If the vent piping will terminate horizontally, through a
sidewall, see
Sidewall Termination Installation
(page 27).
4” PIPE FIELD
SUPPLIED
ALUMINUM
EXHAUST/
CONDENSATE
ELBOW VENT
CONNECTION
FACTORY
INSTALLED
6” PIPE FIELD
SUPPLIED
6” x 4” REDUCER
FIELD SUPPLIED
VENT (EXHAUST) CONNECTION
Figure 15. Vent Exhaust Connection
6. When installation of the termination is complete install necessary
piping and ttings to route the vent piping back to the water heater.
7. 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.
8. Do not install the vent piping in a manner that will allow water to
be trapped in the piping.
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).
10. If installing 4 inch vent pipe connect the vent pipe to the exhaust
elbow on the water heater.
11. If installing 6 inch pipe transition to 4 inch pipe as shown in
Figure
15
. The eld installed 4” pipe between the exhaust elbow and the
6” x 4” reducer coupling should be 18 inches (45 cm) or less in
length.
DIRECT VENT INSTALLATION
1. Read
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 specic for Direct Vent congurations.
2. Determine which direct vent arrangement will be used for the
installation. There are several direct vent arrangement options.
See
Figure 41 through Figure 47
(page 35).
3. Determine vent and intake air pipe size to be used for the
installation. See
Venting Requirements
(page 22).
4. 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.
5. Install the terminations rst.
If standard terminations are being used and the intake air
or vent piping will terminate vertically, through a roof, see
Vertical Termination Installation
(page 25).
If standard terminations are being used and the intake air
or vent piping will terminate horizontally, through a sidewall,
see
Sidewall Termination Installation
(page 27).
If a concentric termination(s) will be used, see
Concentric
Termination Installation
(page 30). If a low-prole termination
will be used, see
Table 12
in
Low Profile Vent Installation
(page
33).
23
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6. When installation of the termination(s) is complete, Install the
necessary piping and ttings to route the intake air and vent piping
back to the water heater. 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 eld supplied condensate Tee tting 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 oor drain separate from any other condensate
drains. See
Figure 16
(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).
10. If installing 4 inch vent pipe connect the vent pipe to the exhaust
elbow on the water heater.
11. If installing 6 inch vent pipe transition to 4 inch pipe at the exhaust
elbow on the water heater as shown in
Figure 15
(page 23). The
eld installed 4” pipe between the exhaust elbow and the 6” x 4”
reducer coupling should be 18 inches (45 cm) or less in length.
INTAKE AIR CONDENSATE TEE INSTALLATION
INSTALL TEE FITTING AS CLOSE
TO WATER HEATER INTAKE AIR
CONNECTION AS POSSIBLE
FIELD SUPPLIED
4” x 4 ” x 1/2” TEE
WITH HOSE BARB
FITTING INSTALLED
FACTORY
INSTALLED
INTAKE AIR
CONNECTION
(4” x 3” REDUCER)
INTAKE AIR
CONNECT FIELD
SUPPLIED FLEXIBLE
DRAIN HOSE TO BARB
FITTING AND FORM A
LOOP WATER TRAP IN
DRAIN HOSE
RUN DRAIN HOSE
TO SUITABLE FLOOR
DRAIN SEPARATELY
FROM OTHER
CONDENSATE DRAINS
Figure 16. Intake Air Condensate Tee Installation
12. Ensure the Intake Air Screen on the Intake Air Connection is
removed before connecting the intake air pipe to the water heater.
See
Figure 17
.
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.
INTAKE AIR CONNECTION DETAIL
4” x 3” REDUCER
COUPLING - FACTORY INSTALLED
INTAKE AIR SCREEN
(remove for Direct Vent)
Figure 17. Intake Air Screen
13. If installing 4 inch intake air pipe connect the intake air pipe to
the intake air connection on the water heater.
14. If installing 6” intake air pipe transition to 4” pipe at the intake air
connection on the water heater as shown in
Figure 18
. The eld
installed 4” pipe between the intake air connection and the 6” x
4” reducer coupling should be 18 inches (45 cm) or less in length.
3” PIPE FACTORY
INSTALLED
6” PIPE FIELD
SUPPLIED
4” PIPE FIELD
SUPPLIED
6” x 4” REDUCER
FIELD SUPPLIED
4” x 3” REDUCER
FACTORY INSTALLED
INTAKE AIR CONNECTION
INTAKE AIR CONNECTION
INTAKE AIR
COMBUSTION
BLOWER
Figure 18. Intake Air Connection
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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 ows to a waste drain. See
Figure 16
(page 24) and
Figure 39
through
Figure 45
(page 36). A horizontal
section of the air inlet pipe, near the heater should include a 4″ by
4″ by 1/2″ tee and a hose barb tting to drain the water. The tee
should be as close to the heater as is practical. The drain tubing in
any installation should have a loop trap and ow 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
conguration vertically through the roof; ensure that all exterior
vertical clearance requirements, shown in
Figure 19
and
Figure 20
(page 26),
are being maintained. These clearances and those
cited by local and national codes must be maintained.
Note: On at 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 20
(page 26).
3. If installing both intake air and vent piping in a Direct Vent
conguration vertically through the roof; ensure that all exterior
vertical clearance requirements shown in
Figure 20
(page 26)
and
Figure 21
(page 26) are being maintained. These clearances
and those cited by local and national codes must be maintained.
Note: On at 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 20
(page
26).
4. If installing only vent piping in a Power Vent conguration vertically
through the roof, the following instructions must be followed:
The vent termination must be oriented facing downward as
shown in
Figure 19
and
Figure 20
(page 26).
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 19
.
5. If installing both intake air and vent piping in a Direct Vent
conguration 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 21
(page 26).
The intake air and vent terminations must be oriented
facing downward and in the same direction as shown in
Figure 21
(page 26).
The intake air and vent terminations must have a minimum
separation of 24” (61 cm) measured on center line as shown
in
Figure 21
(page 26). 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 19 below
and
Figure 21
(page 26).
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 19. Vertical Termination(s) Installation
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 21
(page 26). In colder climates this
separation should be increased to at least 48 inches (122
cm).
7. Cut a 5 inch (13 cm) diameter hole for 4 inch pipe or 7 inch (18
cm) diameter hole for 6 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 eld supplied
metal strapping or equivalent support materials as shown in
Figure 19
.
9. Slide a roof boot or equivalent ashing over the pipe and secure
roof boot or equivalent ashing to roof (see
Figure 19
) and seal
around the ashing.
10. Install the factory supplied intake air and/or vent termination(s)
using eld supplied pipe and one eld supplied 90° elbow as
shown in
Figure 19
. The short section of pipe that connects
between the eld 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 19
.
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INTAKE AIR AND/OR VENT
TERMINATION(S) MUST BE A
MINIMUM OF 24 INCES (60 cm)
ABOVE ANY PARAPET, VERTICAL
WALL OR STRUCTURE WITHIN
10 FEET (3 m) HORIZONTALLY.
VERTICAL TERMINATION(S) FLAT ROOF CLEARANCE
INTAKE AIR AND/OR VENT (EXHAUST)
24 INCHES (60 cm)
MINIMUM HEIGHT ABOVE
IF LESS THAN
10 FEET (3 m)
Figure 20. Vertical Termination(s) Flat Roof Clearance
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.
VERTICAL TERMINATION - DIRECT VENT
STANDARD TERMINATIONS
24 INCHES (61 cm) MINIMUM
48 INCHES (122 cm) IN COLDER CLIMATES
FACTORY SUPPLIED
STANDARD TERMINATIONS
POINTED DOWNWARD
FIELD
SUPPLIED
90° ELBOW
VENT (EXHAUST)
TERMINATION
INTAKE AIR
TERMINATION
FIELD SUPPLIED
PLUMBING
ROOF BOOTS
OR FLASHINGS
MAINTAIN 12” (30 cm)
18” (45 cm) FOR CANADA
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW LEVEL.
Figure 21. Vertical Termination - Direct Vent
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SIDEWALL TERMINATION INSTALLATION
1. Determine the location for the termination(s).
2. If installing only vent (exhaust) piping in a Power Vent conguration
through a sidewall; ensure that all exterior sidewall clearance
requirements for the termination, shown in
Figure 49
(page 38),
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
conguration through a sidewall; ensure that all exterior sidewall
clearance requirements for the terminations, shown in
Figure 49
(page 38), for the vent and intake air termination 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 conguration 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 22
.
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 conguration through a sidewall the intake air and vent
terminations must be installed at the same elevation measured
on horizontal center line. See
Figure 22
.
VENT (EXHAUST)
TERMINATION
INTAKE AIR
TERMINATION
INSTALL ON
ELEVATION
CENTERLINE
24 INCHES (61 cm) MINIMUM
48 INCHES (122 cm) IN COLDER CLIMATES
KEEP INTAKE AND VENT
TERMINATION SCREENS
CLEAR OF DEBRIS
SIDEWALL TERMINATION - DIRECT VENT
STANDARD TERMINATIONS
Figure 22. 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 22
(page 27).
7. Cut a 5 inch (13 cm) diameter hole for 4 inch pipe or 7 inch (18
cm) diameter hole for 6 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 23
.
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 25).
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 (eld 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 23
.
INTERIOR WALL EXTERIOR WALL
FROM
WATER
HEATER
COUPLING
SIDEWALL TERMINATION INSTALLATION
INTAKE AIR AND/OR VENT (EXHAUST)
METAL PLATES
INSTALL INSIDE
A
ND/OR OUTSIDE
FACTORY SUPPLIED
STANDARD TERMINATION
POINTED DOWN
TOWARDS THE GROUND
INCREASE EXPOSED VENT
PIPING UP TO A MAXIMUM
OF 6 INCHES (15.2 cm) FROM
WALL TO HELP PREVENT VAPOR
FROM DISCOLORING THE WALL
SURFACE IN COLDER CLIMATES
Figure 23. Sidewall Termination Installation
12. Place a bead of silicone caulking (eld supplied) around the gap
between the installed pipe(s) and the wall. Apply enough to ll
the gap between the pipe(s) and wall.
13. Press the wall plate ush 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 23
.
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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POLYPROPYLENE INSTALLATIONS
The water heaters covered by this manual have been approved
to be installed with Polypropylene vent material as shown in
Table
8
and
Table 9
. The approved application of single wall, non-exible,
non-concentric Polypropylene vent material is offered by two
specic manufacturers (Centrotherm ECO Systems and DuraVent
Polypropylene). These listed products must be installed by following
the vent manufacturer’s instructions. See
Table 7
(page 23)
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 the 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 specic vent starter adapter at
the ue 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 4” and 6” diameter pipes.
Table 8. M & G Duravent PolyPro Vent system part numbers
Nominal
Pipe
Diameter
Flue Outlet Adapter
Adapter
Connector
Ring
Connector
90 Degree
Elbow
Vent Material Vent Terminal(s)
4” 4PPS-AD PPS-PAC 4PPS-LB 4PPS-E90B PPS
4PPS-E45B for Exhaust;
4PPS-E45B for Intake (Direct Vent only)
6” 6PPS-06PVCM-6PPF PPS-PACL 6PPS-LBC 6PPS-E90 PPS
6PPS-E45 for Exhaust;
6PPS-E45 for Intake (Direct Vent only)
Table 9. Centrotherm InnoFlue SW Vent system part numbers
Nominal
Pipe
Diameter
Flue Outlet Adapter
Adapter
Connector
Ring
Connector
90 Degree
Elbow
Vent Material Vent Terminal(s)
4” ISAGL 0404 IAFC04 IANS04 ISEL0487 Polypropylene
ISELL0445UV for Exhaust;
ISELL0445UV for Intake (Direct Vent only)
6” ISAGL 0606 IAFC06 IANS06 ISEL0687 Polypropylene
ISELL0645UV for Exhaust;
ISELL0645UV for Intake (Direct Vent only)
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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 10
and
Table 11
below. These listed
systems must be installed using the vent manufacturer’s instructions
including their listed clearances to combustible and noncombustible
materials. See
Table 7
(page 23) for the maximum and minimum
equivalent linear vent lengths and number of elbows that may be
used. However, see
Table 10
and
Table 11
below to nd 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.
See
Table 10
and
Table 11
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 10
and
Table 11
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 10. HeatFab Saf–T Vent AL29-4C® Vent System 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
4" 9401 PVC 9307 9411 5 feet 9414 10 feet 9454CPVC
6" 9601 PVC 9607 9611 5 feet 9614 10 feet 9656CPVC
*Consult vent manufacturer’s catalog for other available lengths.
Table 11. Duravent FasNSeal AL29-4C® Vent System 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
4" 810005545 FSVL3604 FSELB4504 5 feet FSELB9004 10 feet 810009529
6" 810005225 FSVL3606 FSELB4506 5 feet FSELB9006 10 feet 81005572
*Consult vent manufacturer’s catalog for other available lengths.
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COMMON VENTING
The water heaters covered by this manual may be installed using
a common horizontal direct vent kit. Contact Technical Support for
assistance in ordering common vent kits. See the contact information
label on the water heater.
CONCENTRIC TERMINATION INSTALLATION
1. Concentric terminations must be ordered separately. The 300 -
500 models must use the 6 inch concentric termination for both 4”
& 6” vent diameters; Part Number: 100113124. Contact Technical
Support for assistance in ordering concentric terminations. See
the contact information label on the water heater.
2. Determine the location for the termination.
Note: Roof termination is preferred since it is less
susceptible to damage, has reduced chances to
intake contaminants and vent vapors are less visible.
3. When installing a concentric termination vertically through the
roof; ensure that all exterior vertical clearance requirements for
the concentric termination, shown in
Figure 24
and
Figure 26
(page
31), are being maintained. These clearances and those cited
by local and national codes must be maintained.
4. When installing a concentric termination vertically through a at
roof, the termination’s vent cap must be a minimum of 10 feet (3
m) away from any parapet, vertical wall or structure as shown
in
Figure 24
.
Note: If this required distance to a parapet, vertical
wall or structure cannot be maintained, standard
terminations must be used. See
Vertical Termination
Installation
(page 25).
5. When installing a concentric termination through a sidewall;
ensure that all exterior sidewall clearance requirements for the
termination, shown in
Figure 49
(page 38), are being maintained.
These clearances and those cited by local and national codes
must be maintained.
6. When installing multiple concentric terminations vertically through
a roof or horizontally through a sidewall ensure the required
clearances between terminations and groupings of multiple
terminations are maintained. See
Multiple Concentric Termination
Clearances
(page 31)
for more information.
7. Cut a 7 inch (18 cm) diameter hole for 6 inch concentric
terminations where they will pass through the wall or roof.
Note: Beware of concealed wiring and piping when cutting
through the wall or roof.
8. When installing multiple concentric terminations vertically through
the roof in the same location the termination caps for all concentric
terminations must be at the same height measured from ground.
See
Multiple Concentric Termination Clearances
(page 31).
9. Determine if the concentric termination will need to be shortened
to accommodate required clearances or to ensure all vent caps
are tat the same height when installing multiple terminations
vertically through the roof in the same location.
10. See
Figure 25
for the minimum lengths allowed for the 6 inch
concentric termination.
Note: When shortening the length of the termination carefully
measure and cut the larger (intake air) pipe rst. Cut the
same amount of pipe off of the smaller (vent) pipe.
Note: Lengthening of the Concentric Vent Termination is not
permitted.
CONCENTRIC TERMINATION(S)
MUST BE A MINIMUM OF 10 FEET
(3 m) AWAY FROM ANY PARAPET,
VERTICAL WALL OR
STRUCTURE.
VENT PIPE
INTAKE AIR PIPE
6 INCH CONCENTRIC TERMINATION
FLAT ROOF CLEARANCE
Figure 24. Six-inch Concentric Termination - Flat Roof Clearance
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6 INCH CONCENTRIC TERMINATION INSTALLATION
6 INCH CONCENTRIC TERMINATION KIT
FIELD ASSEMBLY REQUIRED
VENT PIPE
INTAKE AIR CONNECTION
VENT CONNECTION - 4 INCH PVC
INTAKE AIR PIPE
Y FITTING ASSEMBLY
VENT CAP
VENT PIPE ASSEMBLY
VENT PIPE IS 4 INCH SDR-26 PIPE
SUPPLIED LENGTH 46.50” (118 cm)
MINIMUM ALLOWABLE LENGTH 16.38” (41.6 cm)
INTAKE AIR PIPE IS 6 INCH SDR-26 PIPE
SUPPLIED LENGTH 25.38” (64.5 cm)
MINIMUM ALLOWABLE LENGTH 12” (30 cm)
VENT CAP
INTAKE AIR PIPE
6” x 6” x 6”
Y FITTING
6” x 4” BUSHING
(FACTORY
INSTALLED)
Figure 25. Six-Inch Concentric Termination Kit
Assemble and install the 6 inch concentric termination. See
Figure
25
,
Figure 26,
and
Figure 27
for these instructions:
1. Cement the Y tting to the larger diameter intake air pipe.
2. Slide the intake air pipe and Y tting assembly from inside the
building through the hole cut for the termination in the roof
or sidewall. Ensure no foreign materials such as insulation
accumulate inside the assembly.
3. Secure the intake air Y tting assembly using eld supplied metal
strapping or equivalent support materials.
4. On installations installed through the roof slide a eld supplied
plumbing boot or roof ashing over the intake air Y tting assembly
and secure it to the roof.
5. Seal around the plumbing boot or roof ashing.
6. Cement the vent cap onto the vent pipe. Alternately a eld-
supplied stainless steel screw may be used to secure the 2
components together when eld disassembly is desired for
cleaning. A pilot hole must be drilled for the screw to prevent
damage/cracking of the vent cap and/or vent pipe.
7. Install the vent cap/vent pipe assembly into the intake air Y tting
assembly, Ensure small diameter vent pipe is cemented and
bottomed in the Y tting.
8. Connect the intake air and vent piping from the water heater to the
6 inch concentric termination using eld supplied 6” x 4” reducer
couplings as needed. Cement all ttings and pipe in place.
9. Return to
Direct Vent Installation
(page 23) to complete the
installation of the intake air and vent piping between the concentric
termination and the water heater.
NOTE: SECURING STRAP
MUST BE FIELD INSTALLED
TO PREVENT MOVEMENT
OF TERMINATION KIT
MAINTAIN 12” (30 cm)
18” (45 cm) FOR CANADA
MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL. MAXIMUM OF
24” (60 cm) ABOVE ROOF.
ROOF FLASHING
(field supplied)
STRAP
(field supplied)
VENT
PIPE
INTAKE
AIR PIPE
COMBUSTION
AIR
VENT
6 INCH CONCENTRIC TERMINATION
VERTICAL INSTALLATION
Figure 26. Six-Inch Concentric Termination - Vertical Installation
6 INCH CONCENTRIC TERMINATION
SIDEWALL INSTALLATION
INTAKE AIR PIPE
STRAP
(field supplied)
VENT PIPE
COMBUSTION
AIR
VENT
1 INCH
MAXIMUM
NOTE: SECURING STRAP MUST BE
FIELD INSTALLED TO PREVENT
MOVEMENT OF TERMINATION KIT
IN SIDEWALL.
Figure 27. Six-Inch Concentric Termination - Sidewall Installation
MULTIPLE CONCENTRIC TERMINATION CLEARANCES
When installing multiple concentric terminations vertically through a
roof or horizontally through a sidewall ensure the required clearances
(separation) between terminations are maintained. Ensure multiple
terminations are arranged or grouped as required.
Note: These clearances must be maintained to prevent the
recirculation of vent (exhaust) gases to the intake air.
Clearances are measured between the edges of the
concentric termination caps.
When installing multiple concentric terminations through a roof or
through a sidewall, the clearances shown in
Figure 28
(page 32)
must be maintained.
See
Multiple Concentric Termination Arrangements
(page 33).
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Close Proximity & Standard Clearance
1. The clearance between multiple termination caps must be 0
inches (touching) to a maximum of 2 inches (5 cm), dimension
A -
Figure 28
(page 32), when installing concentric terminations
in close proximity. See
Figure 28
through
Figure 32
(page 32).
2. The clearance between multiple termination caps must be
increased to a minimum of 24 inches (61 cm), dimension B -
Figure
28
(page 32), when installation in close proximity (above) is
not possible. This is the standard clearance.
A
OR
B
A
= 0 - 2 INCHES (0 - 5 cm)
CONCENTRIC
TERMINATION CAPS
END VIEW
TWO CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
B = 24 INCHES (61 cm)
OR GREATER
CLOSE PROXIMITY STANDARD CLEARANCE
Figure 28. Two Concentric Terminations
Three Concentric Terminations
1. When installing three concentric terminations through a roof or
through a sidewall the third termination may be installed in close
proximity as indicated by dimension A in
Figure 29
.
2. If close proximity installation of the third termination is not possible
the third termination may be installed as indicated by dimension
B in
Figure 29
.
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
CONCENTRIC
TERMINATION
CAPS END VIEW
THIRD
TERMINATION
THREE CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
A
A B
B = 24 INCHES (61 cm)
OR GREATER
Figure 29. Three Concentric Terminations
Four Concentric Terminations
1. When installing four concentric terminations through a roof or
through a sidewall in close proximity they may be arranged into
stacked rows of two as shown in
Figure 30
or lateral rows of two
as shown in
Figure 31
.
2. Four is the maximum number of concentric terminations that
may be installed in a group where all terminations are in close
proximity as shown in
Figure 30
.
A
A
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
CONCENTRIC
TERMINATION
CAPS END VIEW
FOUR CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
Figure 30. Four Concentric Terminations - Close Proximity
A B
A
FOUR CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
A
= 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
B = 24 INCHES (61 cm)
OR GREATER
CONCENTRIC
TERMINATION
CAPS END VIEW
Figure 31. Four Concentric Terminations in a Line
Groups Of Terminations
1. When installing multiple groups of concentric terminations through
a roof or through a sidewall in close proximity they can be installed
into stacked groups of four as shown in
Figure 32
. Lateral groups of
four as shown in
Figure 31
may be a more convenient installation
arrangement for multiple groups depending on available space.
A
A B
A = 0 - 2 INCHES (0 - 5 cm)
CLOSE PROXIMITY
CONCENTRIC
TERMINATION
CAPS END VIEW
EIGHT CONCENTRIC TERMINATIONS
(THROUGH A ROOF OR SIDEWALL)
B = 24 INCHES (61 cm)
OR GREATER BETWEEN
GROUPS OF FOUR
Figure 32. Eight Concentric Terminations
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MULTIPLE CONCENTRIC TERMINATION ARRANGEMENTS
The illustrations on this page show some of the installation
arrangements for multiple concentric terminations that are allowed.
See
Multiple Concentric Termination Clearances
(page 31) for detailed
information on clearances and additional arrangement options.
Note: When multiple concentric terminations are installed
through a roof in the same location all termination caps
must be at the same height measured from the ground.
Two Concentric Terminations
Two concentric terminations may be installed in close proximity as
shown in
Figure 33
or with standard clearances when this arrangement
is not possible. See
Figure 28
(page 32) for detailed information
on clearances. See
Figure 29
(page 32) when installing three
concentric terminations.
SIDEWALL
ROOF
Figure 33. Two Concentric Terminations - Sidewall and Roof
Four Concentric Terminations
Four concentric terminations may be installed in close proximity as
shown in
Figure 34
. See
Figure 30
and
Figure 31
(page 32) for detailed
information on clearances and additional arrangement options.
SIDEWALL
ROOF
Figure 34. Four Concentric Terminations - Sidewall and Roof
Eight Concentric Terminations
Eight concentric terminations may be installed in two stacked groups
of four, in close proximity, as shown in
Figure 32
(page 32). See
Figure 32
for detailed information on clearances.
Lateral groups of four as shown in
Figure 31
(page 32) may be
a more convenient installation arrangement for multiple groups
depending on available space.
SIDEWALL
ROOF
Figure 35. Eight Concentric Terminations - Sidewall and Roof
LOW PROFILE VENT INSTALLATION
This water heater is certied for sidewall direct venting with IPEX
System 636 Low Prole Vent Kit. Follow instructions below for proper
installations.
All termination kits must be located and installed in accordance with
local building code and
CSA B149.1 Natural Gas and Propane Installation
Code
.
Once the proper location has been determined, cut 2 holes in the
wall large enough to accommodate the pipe. Pipe diameters and
distance between hole centers can be found in
Table 12
(page 34).
Slide both the intake and exhaust pipes through the holes. Solvent
cement both pipes to the base of the vent termination kit, follow the
solvent cementing procedures outlined in the IPEX System 636
Installation Guide, which is available on the web www.ipexinc.com.
To fasten the Base to the wall, use the supplied screws and anchors.
A 3/16” (5mm) hole, 1-3/16” (30mm) deep, will need to be drilled for
the anchors. Locate the anchor hole using the base as a template.
Screw the Cap to the Base using the supplied screws.
Once the vent termination and pipes are secured, the wall
penetrations will need to be sealed from the interior using a PVC-
compatible sealant material.
All vent pipes and air inlets must terminate at the same height to
avoid possibility of severe personal injury, death, or substantial
property damage.
Operate heater through 1 heat cycle to ensure combustion-air and
vent pipes are properly connected to concentric vent termination
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Figure 36. Inlet and Vent Flow in Low Profile Installation
Figure 37. Inlet and Vent Flow in Low Profile Vent Installation
Figure 38. Multiple Low Profile Vent Clearances
Table 12. Low Prole Termination Kits - Dimensions
AOS Kit Number
IPEX
Part Number Description
Pipe Outside
Diameter
Hole Spacing
(Center to Center)
100187888 196986 4" Flush Mount Vent Kit 4.50" 5.63"
100187889 196080 6" Flush Mount Vent Kit 6.61" 7.63"
Each Kit Contains
Qty Item Description
1 Base (two holes)
1 Cap (one hole)
8 Stainless Steel Screws
4 Plastic Anchors
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VENTING ARRANGEMENTS
Figure 39. Power Vent Vertical
Figure 40. Power Vent Horizontal
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 41. Direct Vent Vertical
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 42. Direct Vent Horizontal
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 43. Direct Vent Vertical Vent
Horizontal Intake
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
*
Figure 44. Direct Vent Horizontal Vent
Vertical Intake
*Direct Vent combustion air intake drains are required in certain situations. See
Direct Vent Air Intake Moisture Protection
(page 25).
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*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 45. Direct Vent Vertical Concentric
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 46. Direct Vent Horizontal Concentric
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 47. Direct Vent Horizontal Low-Profile
*Direct Vent combustion air intake drains are required in certain situations. See
Direct Vent Air Intake Moisture Protection
(page 25).
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TERMINATION CLEARANCES SIDEWALL POWER VENT
G
H
C
D
E
L
B
B
B
B
J
I
B
B
F
M
K
Figure 48. Sidewall 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
appliances ≤ 10,000
Btuh (3 kW)
• 12 in (30 cm) for
appliances > 10,000
Btuh (3 kW) and ≤
100,000 Btuh (30
kW),
• 36 in (91 cm) for ap-
pliances > 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 permanent-
ly closed window
12 inches (30 cm)* 12 inches (30 cm)*
D Vertical clearance to
ventilated soft 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 unventilated
soft
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)*
H
Clearance to each side
of center line extended
above meter/regulator
assembly
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
Clearance in
accordance with
local installation
codes and the
requirements of
the gas supplier
Termination Clearances for Sidewall Power Vent
Type of Clearance Canadian Installations
1
US Installations
2
I
Clearance to service
regulator vent outlet
Above a regulator, within
3 ft (91 cm) horizontally
of the vertical center
line of the regulator vent
outlet, to a maximum
vertical distance of 15 ft
(4.5 m)
Clearance in
accordance with
local installation
codes and the
requirements of
the gas supplier
J
Clearance to a non me-
chanical air supply inlet
into building or combus-
tion air inlet to any other
appliance
• 6 in (15 cm) for
appliances ≤ 10,000
Btuh (3 kW)
• 12 in (30 cm) for
appliances > 10,000
Btuh (3 kW) and ≤
100,000 Btuh (30
kW)
• 36 in (91 cm) for
appliances >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 mechani-
cal 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 drive-
way located 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.
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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TERMINATION CLEARANCES SIDEWALL DIRECT VENT
G
H
C
D
E
L
B
B
B
B
J
I
B
B
F
M
K
H
Figure 49. 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
appliances ≤ 10,000
Btuh (3 kW)
• 12 in (30 cm) for
appliances > 10,000
Btuh (3 kW) and ≤
100,000 Btuh (30
kW),
• 36 in (91 cm) for ap-
pliances > 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 permanent-
ly closed window
6 inches (15 cm)* 6 inches (15 cm)*
D Vertical clearance to
ventilated soft 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 unventilated
soft
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)*
H
Clearance to each side
of center line extended
above meter/regulator
assembly
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
Clearance in
accordance with
local installation
codes and the
requirements of
the gas supplier
Termination Clearances for Sidewall Direct Vent
Type of Clearance
Canadian Installations
1
US Installations
2
I
Clearance to service
regulator vent outlet
Above a regulator, within
3 ft (91 cm) horizontally
of the vertical center
line of the regulator vent
outlet, to a maximum
vertical distance of 15 ft
(4.5 m)
Clearance in
accordance with
local installation
codes and the
requirements of
the gas supplier
J
Clearance to a non me-
chanical air supply inlet
into building or combus-
tion air inlet to any other
appliance
• 6 in (15 cm) for
appliances ≤ 10,000
Btuh (3 kW)
• 12 in (30 cm) for
appliances > 10,000
Btuh (3 kW) and ≤
100,000 Btuh (30
kW)
• 36 in (91 cm) for
appliances >100,000
Btuh (30 kW)
• 6 in (15 cm)
for appliances
≤ 10,000 Btuh
(3 kW)
• 9 in (23 cm)
for appliances
> 10,000 Btuh
(3 kW) and ≤
50,000 Btuh
(15 kW)
• 12 in (30 cm)
for appliances
> 50,000 Btuh
(15 kW)ng.
K
Clearance to a mechani-
cal 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 drive-
way located 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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WATER 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 ttings (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 eld 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. DO NOT remove, modify or alter the factory
condensate trap.
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 Exhaust/Condensate Elbow and a suitable
building drain. The exhaust elbow has a “built in” condensate trap.
Do not install an additional trap in the condensate drain piping. See
Figure 50
.
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. See
Figure 50
(page 39)
.
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.
See
Figure 50
.
5. Brace the condensate drain line with oor mounted standoffs every
three feet.
6. Ensure the condensate drains freely during start up. See
Start Up
(page 57)
.
7. Condensate clean out cap must be on and tight when unit is in
operation.
CONDENSATE DRAIN
LINE - FIELD INST
ALLED
DRAIN LINE TO
TERMINATE NO
MORE
THAN 6
INCHES (15.2 cm)
ABOVE DRAIN
BUILDING
DRAIN
1/2” NPT
CONDENSATE
DRAIN
CONNECTION
CONDENSATE
CLEANOUT
EXHAUST/CONDENSATE
(VENT) ELBOW
PRESSURE PORT
Figure 50. Condensate Drain Installation
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 sufcient capacity to supply the
rated gas input of the water heater as well as the requirements of
all other gas red 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
39
Printed on 2/7/2019 9:09 AM CT
propane gas supply pressure. See
Table 4
(page 10). 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 re 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 Qualied 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, re
or explosion. If copper supply lines are used they must be internally
tinned and certied for gas service.
REGULATED GAS
SUPPLY LINE
MAIN GAS
SHUTOFF VALVE
TEE FITTING
PIPE CAP
SEDIMENT TRAP
Figure 51. 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
Figure 51
. The sediment trap must be
readily accessible and not subject to freezing conditions. Install
in accordance with the recommendations of the local gas utility
company.
GAS LINE SIZING
Minimum required supply gas line sizes are shown in
Table 5
(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 13
or
Table
14
. The values given in
Table 13
and
Table 14
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: 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
Table 13. Supply/Main Gas Line Sizing (feet - Btu/hr)
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
Table 13. Supply/Main Gas Line Sizing (feet - Btu/hr)
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”
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
Table 14. Supply/Main Gas Line Sizing (meters - kW)
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
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 1 1/2” 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. See
Figure 52
(page 41).
2. BTH 500 natural gas models require a 1 1/2” minimum supply
gas line. All other water heaters covered by this manual require
a 1 1/4” minimum supply gas line. See
Table 5
(page 10).
3. 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 rst two threads. Use pipe dope
or Teon tape marked as being resistant to the action of liquid
petroleum (LP/propane) gases.
4. 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 rst 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.
5. Use a standard pipe wrench (Stillson wrench) as a back up on
the rst pipe nipple installed above when connecting other ttings
and pipe in the supply gas line to prevent 24 VAC Gas Valve on
water heater from twisting during installation.
6. To prevent damage, care must be taken not to apply too much
torque when connecting the supply gas line to the water heater.
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7. Install a sediment trap as shown in
Figure 51
(page 40).
8. Install a Main Gas Shutoff valve in the supply gas line as shown
in
Figure 51
(page 40).
Note: Should overheating occur or the gas supply fail to
shut off, turn off the Main Gas Shutoff valve to the
water heater.
Gas Line
Connection
Figure 52. Supply Gas Line Connection
GAS LINE LEAK TESTING
Fire and Explosion Hazard
Leak test gas connections
before placing the water heater
in operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing heater.
Install sediment trap in accordance
with NFPA 54 or CAN/CSA 149.1.
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 re 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 51
(page 40). 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, ame
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 dened in NFPA 70, CSA
C22.1 and UL 943.
POWER SUPPLY CONNECTIONS
See 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 53
.
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 3
(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 junction box
Figure 53
and wiring
diagram
Figure 62
(page 71).
4. Connect the 120VAC 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
junction box with a properly sized wire nut and wrap electrical
tape around the wire nut and wire end. See junction box
Figure
53
and wiring diagram
Figure 62
(page 71).
Note: If electrical connections are made directly to the
terminal block remove the jumper wires before making
connection.
5. 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 junction box
Figure 53
and wiring diagram
Figure 62
(page 71).
6. 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 lled
with water.
Heater Wiring
(Factory Installed)
MOV
Ground
Ground
Terminal
Jumper Wire
L1
Neutral
Figure 53. Power Supply Connections
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ENABLE/DISABLE CIRCUIT
The water heaters covered in this manual are equipped with an
enable/disable circuit for use with eld 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 hot water.
To use the enable/disable circuit it must rst 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 eld 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.
CONNECTING AN EXTERNAL SUPERVISORY CONTROL
The enable/disable circuit is accessed from the CCB’s J17 plug
inside the CCB enclosure. See
Figure 3
(page 8) to locate the
CCB enclosure and
Figure 61
(page 70) for the CCB layout.
1. Install eld wiring to the enable/disable circuit:
2. Turn off power at the water heater’s enable/disable switch and
the breaker that supplies power to the water heater.
3. Locate the CCB enclosure.
4. Carefully remove the Temperature Probe connectors and CCB
enclosure cover.
5. Locate pins 1 and 2 on the CCB J17 plug. See
Figure 61
(page
70).
6. Connect the two eld supplied control wires to pins 1 and 2 on
the CCB J17 plug.
7. 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.
8. Reinstall the CCB enclosure cover.
9. Route the control wires inside the junction box on the top of the
water heater. See
Figure 8
(page 14) to locate the junction
box. Use an available knock-out to route the wires inside the
junction box.
10. Install eld 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.
11. Connect the control wiring to a set of dry contacts on the external
control. Follow the control manufacturer’s instructions for making
connections.
12. Restore power to the water heater.
13. From the water heaters UIM “Heater Information Screen” select
“Use External Enable” and change to “Yes”. See
Figure 3
(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 16
(page 47).
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.
Dish-washing Machines
(page 14).
3.
Temperature-Pressure Relief Valve
(page 15).
4.
Closed Water Systems
(page 14)
and
Thermal Expansion
(page
14).
5. For multiple water heater installations, see
Water Piping Diagrams
(page 73).
WATER PIPING DIAGRAMS
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters. See
Water Piping Diagrams
(page 73).
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 ow rate
should be slow so that there will be a minimum of turbulence inside
the water heater storage tank.
Adjust ow by throttling a full port ball valve installed in the circulating
line on the outlet side of the pump. Never throttle ow on the suction
side of a pump. See
Water Piping Diagrams
(page 73).
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.
Contact Technical Support for further assistance in sizing a T&P
Relief valve for remote storage tanks. See the contact information
label on the water heater.
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 73).
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.
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 xtures a mixing valve must
be installed. See
Mixing Valves
(page 14).
5. These water heaters cannot be used in space heating applications
only.
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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
certied 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 oor 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 ow 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 oor 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
protection 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 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 3
(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 Qualied 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 15
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
ts 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
satises the demand of the application a mixing valve can be installed
at the water heater (see
Figure 8
(page 14)) or at the hot water taps
to further reduce system water temperature.
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 specic lower temperatures.
Table 15. Burn Time at Various Temperatures
Water Temperature
°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
Table 15. Burn Time at Various Temperatures
Water Temperature
°F (°C)
Time for 1st Degree
Burn
(Less Severe Burns)
Time for Permanent
Burns
2nd & 3rd Degree
(Most Severe Burns)
140 (60) 2 seconds 5 seconds
149 (65) 1 second 2 seconds
154 (68) instantaneous 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 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 54
(page 45).
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 49) 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 efcient 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 satised.
This functionality is preset at the factory to enable this feature. If the
feature is not required, it can be disabled in the eld through the
user interface module (UIM).
FIRING RATE MODULATION
The water heaters covered by this manual are capable of modulating
their ring rate. The central control board (CCB) monitors the water
temperature in the tank and regulates the ring rate to achieve the
target temperature setpoint. The ring rate is dictated by the hot
water draw, proximity to the tank temperature setpoint, and various
other temperature limitations.
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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.
Tank Temperature 103°F
Operating Set Point 120°F
Status: Heating
MENU HELP
GAS
OFF
O
N
Figure 54. Tank Temperature Set Point
Contact Technical Support for assistance. See the contact information
label on the water heater.
.
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CONTROL 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), ame sensor, pressure switches
and temperature probes are monitored by the control system. The
Combustion Blower, Spark Ignition Transformer, 24 Volt Gas Valve
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 on top of
the water heater 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
SUPPL
Y
BOARD
TRANSFORMER
CCB
BOARD
Figure 55. 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).
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 rst 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 16
(page 47) for a description
of the various operational states.
• The Desktop screen also displays animated “Status Icons”
to convey operational information, see
Table 15
(page 44)
for descriptions of the Status Icons.
WI-FI
The water heaters covered in this manual feature a wi- functionality
that is enabled at the factory. If wi- 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.
Tank Temperature 103°F
Operating Set Point 120°F
Status: Heating
GAS
OFF
O
N
HELPMENU
LCD Touch Display
Information
Display
Status Icons
Title Ba
r
Enable/Disable Switch
Operational menus are multi functional.
UIM (user interface module)
Desktop Screen Shown
Figure 56. User Interface Module 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 56
(page 46). 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 61).
Table 16. 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 4
(page 9) and
Figure 5
(page 9) for location 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
(page 42)
Note: When the water heater is in disabled mode, a text message appears next to this icon identifying
the reason that it went into disabled mode.
The Combustion Blower is being energized.
The Spark Igniter is being energized. See
Figure 2
(page 7) for Spark Igniter location.
GAS
OFF
O
N
The 24-volt gas valve is being energized.
The control system has sensed ame at the Main Burner from the ame sensor. See
Sequence of Operation Flow
Chart
(page 62) and
Figure 2
(page 7).
The control system has declared a fault condition and must be inspected/serviced by a Qualied 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 Qualied Service Agent.
The water heater will continue to operate during an alert condition.
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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 56
(page 46). 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 61).
Table 17. Operating States
State 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 Verication 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 Man-
agement system Enable/Disable is an open circuit.
Pre-Purge The Combustion Blower is energized to ush residual ue 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 ow to the Main Burner.
Ignition Verication The control system is monitoring the ame sensor for the required minimum ame sensing current.
Ensure the water heater is properly grounded. Flame sensing requires an adequate earth ground. If the water heater is not prop-
erly grounded it will cause ignition failure.
Inter-Purge The Combustion Blower is energized to ush residual fuel gas from the combustion chamber after a failed ignition attempt.
Heating Ignition was successful, ame sensing current has been established. The water in the storage tank is being heated.
Post-Purge The Combustion Blower is energized to ush residual ue 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 18. Control System 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 Com-
bustion Blower, gas valve, Spark Igniter, ame 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.
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 rst 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 Differential Adjustment
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
two (upper and lower) 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
efcient 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 18
(page 48) 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
efcient operation and longer life.
Temperatures
HELPBACK
Operating Setpoint 120°F >
Differential Mode Auto >
Differential 8°F >
Tank Temperature 120°F
Tank Probe Offset 0°F >
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 same 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
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Temperatures Menu
Description/Action Display
• 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 that 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 eld 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 sensed 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 in the same way described in
Operating Set Point and Differential Adjustment
(page 49).
Temperatures
HELPBACK
Operating Setpoint 120°F >
Differential Mode Auto >
Differential 8°F >
Tank Temperature 120°F
Tank Probe Offset 0°F >
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ICOMM MENU
iCOMM Screen
Description/Action Display
Wi- Status - displays status of wi- connection.
Ethernet - displays status of Ethernet connection.
iCOMM Server - displays status the iCOMM server.
Wi- MAC - displays the wi- MAC number.
Ethernet MAC - displays the Ethernet MAC number.
DSN - displays the Device Serial Number (DSN). Used for regis-
tration of the heater.
Wi- Strength - displays wi- signal strength as a series of bars.
Wi- Strength - displays wi- signal strength dBm units.
Wi- - Wi- functionality is enabled at the factory. In the bottom
portion of the menu, the wi- 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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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 18
(page 48).
• ECO Contact, Low Gas PS, Blocked Inlet PS, Blocked
Outlet PS, Blower Prover 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 ame during ignition from the
ame 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
Anode Current 51.500mA
Anode Tank Voltage 2.641V
Bottom of Menu
Heater Status
HELPBACK
Flame Detected No
Blower RPM CMD 0
Blower RPM 0
Anode Current 51.500mA
Anode Tank Voltage 2.641V
Anode Drive Voltage 3.539V
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 as
described
Operating Set Point and Differential Adjustment
(page 49).
Display Settings
HELPBACK
Temperature Units °F >
Brightness 5 >
Backlight Delay 30s >
Language English >
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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.
Cong CRC - Veries the conguration 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.
Historical data is stored in the conguration key. If this "key" is
replaced during servicing the historical data will be lost. The data
stored in the new conguration key will no longer reect the entire
history of the water heater. The conguration 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 rasing the Differential setting to avoid
short cycling and excessive component wear. See
Operating Set
Point and Differential Adjustment
(page 49).
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.
Top of Menu
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 >
Bottom of Menu
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
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 Messages
(page 65) 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
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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 Te mp 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 rst installed.
Note: Historical data is stored in the conguration key. If this
"key" is replaced during servicing the historical data will
be lost. The data stored in the new conguration key will
no longer reect 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
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 conrming the factory default
settings have been restored.
Press NO to exit the Restore Factory Defaults menu.
NoYes
Restore Defaults
Are you sure you want to restore
the system to the factory
defaults?
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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.
Table 19. Service Contact Information
Description/Action Display
From the Desktop Screen press and hold down the middle (unmarked)
area located between the "MENU" and "HELP" buttons for 15 seconds
to activate the "Contact Information" screen. See
Figure 59
(page 45).
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.
Top o Menu
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
Press the "+", "-", "<", and ">" icons to enter your name or the name
of your company.
When nished press "ACCEPT" to save the new Contact Name. The
control system will return to the discrete menu.
Follow these instructions to change the Contact Phone Number.
ACCEPT
<
>
>
BACK
Change Contact Name
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Table 19. Service Contact Information
Description/Action Display
When the new Contact Name and Contact Phone number have both
been updated, press "BACK" to return to the Desktop screen.
Contact Information
HELPBACK
Show Contact Yes >
Change Contact Name >
Change Contact Phone >
Current Contact Info:
YOURCOMPANYNAMEHERE
(123) 456-7890
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 re rate.
Calibration Speed - Used by service agents to adjust blower speed to
minimum re 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/eld service agent should rst 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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START 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 eld involved,
see
Qualifications
(page 6).
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately call
a qualied 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 qualied service agency.
1. External re.
2. Damage.
3. Firing without water.
Light the water heater in accordance with the Lighting and Operation
Instruction label on the water heater and in this manual on page 53.
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, the spark generator, the 24
VAC Gas Valve, Main Burner ignition, and ame sensing. See
Control
System Operation
(page 46).
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
Sequence of Operation
(page
61) and the
Sequence of Operation Flow Chart
(page 62).
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 that all inlet water valves are open.
FILLING THE WATER HEATER
Follow these steps to ll 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 ll with water.
4. Close the hot water faucet opened in Step 2 as water starts to ow.
5.
Start Up
(page 57).
REQUIRED TEST 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 49).
2. Turn the water heater’s Enable/Disable switch to the “Disable”
position.
3. Close the Main Gas Shut Off Valve. See
Figure 61
(page 70).
4. Wait ve minutes for any residual gas to clear.
5. Connect manometer to the supply gas pressure port on the gas
valve. See
Figure 57
.
On the water heaters covered by this manual there are test
ports for supply and manifold gas pressure readings on the
gas valve. Using a small at tip pocket screw driver - open
the needle valve inside the supply gas pressure test port
one full turn only; turn the needle valve screw counter-
clockwise to open the valve. Slide the manometer sensing
tube over the top of the test port. See
Figure 57
.
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 ring.
Adjust supply gas pressure as necessary. See
Supply Gas Pressure
Adjustment
(page 59).
Note: The manometer tubing should be purged before taking
any readings.
Air Intake Pressure Reference Connection
Supply Gas Pressure
Test Port
Manifold Pressure
Test Port
(NON-ADJUSTABLE)
Figure 57. Gas Valve Assembly
LIGHTING & OPERATION LABEL
The instruction label below is afxed to the water heater’s covered
by this manual at the factory and must be followed when lighting
and operating the water heater.
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LIGHTING THE WATER HEATER
LIGHTING OPERATION & LABELS
The instruction label below is afxed to the water heaters that are covered by this manual at the factory and must be followed when
lighting and operating the water heater.
SNOITCURTSNI GNITAREPO
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ELBAMMALF
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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Set the Enable/Disable switch on the control panel
to the Enable position.
.4
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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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to the Disable position.
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ELBASID/ELBANE
HCTIWS
Tank Temperature 120°F
Operating Set Point 120°F
Status: Standby
MENU HELP
58
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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 ring (static pressure) AND while the water heater is ring 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 10)
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 Installations:
In multiple water heater installations or in installations where the
installed water heater(s) share a common gas supply main with other
gas red appliances; the supply gas pressures shall be measured
at each water heater with all gas red appliances connected to a
common main ring 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 10) with all gas red appliances connected to a
common gas main ring 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 the requirements for the supply gas line in
Table 4
and
Table 5
(page 10) and the instructions in
Supply
Gas Line Installation
(page 39). See the requirements for
Supply Gas Regulator
(page 13). Ensure all requirements
and installation instructions are maintained.
CHECKING THE FIRING RATE
Follow these instructions to determine the actual ring rate of the
water heater:
Note: The heaters covered by this manual are capable of
modulating their ring rate. The ring rate should be
checked with the heater operating at it’s full ring rate.
1. Ensure there are no other gas red appliances connected to the
gas meter ring 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 ring.
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 ring with a stop watch.
6. Use the formula below to “clock” the gas meter and determine
the actual ring 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 = 300,000 Btu/hr (87.9 kW)
3600
12.6
Example:
• 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 ring 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 49).
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 51
(page 40).
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HIGH ALTITUDE INSTALLATIONS
The water heaters covered by this manual are certied for use without
modication for altitudes up to 10,100 feet.
Most gas utility companies de-rate their gas for high altitudes, making
it unnecessary to install high altitude orices.
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 ring 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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TROUBLESHOOTING
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.
Note: 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 sufcient room to service the water heater. See
Clearance
to Combustible Materials
(page 11).
2. Ensure the area is free of corrosive elements and ammable
materials. See the instructions in
Contaminated Air
(page 16).
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
Table 7
(page
23).
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 conguration. See
Figure 17
(page 24).
5. Ensure all exterior clearances for the intake air, vent, concentric,
and low profile terminations are maintained. See
Vertical
Termination Installation
(page 25),
Sidewall Termination Installation
(page 27),
Concentric Termination Installation
(page 30),
Low
Profile Vent Installation
(page 33). 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
Concentric Termination
Installation
(page 30).
2. Ensure the supply gas line to each water heater meets the
minimum supply gas line size requirements. See the requirements
for the supply gas line in
Table 4
and
Table 5
(page 10) and the
instructions in
Supply Gas Line Installation
(page 39).
CONDENSATE DRAIN
1. Ensure the condensate drain is properly connected to the exhaust
elbow on the water heater with a water trap to prevent vent gases
from escaping into the installed space and draining freely to a
suitable oor drain. See
Figure 9
(page 16) and
Condensate Drain
Installation
(page 39).
ELECTRICAL CONNECTIONS
1. Ensure the power supply connections to the water heater are
polarity correct. See the requirements for the
Power Supply
(page
13) and
Electrical Wiring
(page 41).
2. 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.
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
Sequence of Operation Flow Chart
(page 62).
1. When the control system is rst 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 conrming the low gas pressure, 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 ow to the Main Burner.
7. The control system monitors the ame sensor to conrm a ame
is present at the Main Burner. If a ame is not veried during the
ignition trial period the control system will try for ignition up to
two more times. If ame can not be veried after three trials for
ignition, the control system will lock out and display the “Ignition
Failure” Fault message.
8. If a ame is veried, the control system will de-energize the Spark
Ignition Control and enter the heating mode where it will continue
heating the water until the Operating Set Point is reached. At this
point, the control system will de-energize the 24 VAC Gas Valve
and enter the post-purge cycle (approximately 30 seconds).
9. The water heaters covered by this manual are capable of
modulating their ring rate. The ring 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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SEQUENCE OF OPERATION FLOW CHART
YES NO
Water is heated to
set point
24 VAC Gas Valve
de-energized
Inter-Purge cycle
24 VAC 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 Control is energized.
24 VAC 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
Control System performs diagnostic checks
Normal State of all pressure switches and ECO are checked
Pressure switches and ECO are verified closed
Sequence is shown with Enable/Disable Switch in the Enable position
Figure 58. Sequence of Operation
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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 rst put into operation or when it is
re-red after a prolonged shutdown. However, only qualied service
agents, as dened in
Qualifications
(page 6), using appropriate
test equipment, should perform any service procedures on the
water heater.
Note: Contact Technical Support for assistance in locating a
qualied service agent in your area. See the contact
information label on the water heater.
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
Installation Checklist
(page
61).
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 the requirements for the supply gas line in
Table 4
and
Table
5
(page 10) and the instructions in
Supply Gas Line Installation
(page 39).
• 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 10) and
Supply Gas Pressure Adjustment
(page 59).
• 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
17
(page 24) and
Figure 22
(page 27).
• Debris clogging/blocking the Main Burner. See
Figure 2
(page
7).
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 the requirements for the supply gas line in
Table 4
and
Table
5
(page 10) and the instructions in
Supply Gas Line Installation
(page 39).
• 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
Messages
(page 65).
• Debris clogging/blocking the intake air screen(s). See
Figure
17
(page 24) and
Figure 22
(page 27).
• Debris clogging/blocking the Main Burner
Figure 2
(page 7)
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 xtures closed.
• Operating Set Point is set too low, Differential setting is set
too high. See
Control System Operation
(page 46).
• Tank Probe Offset is causing the heating cycles to terminate
prematurely. See
Temperatures Menu
(page 49).
• 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.
• 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 67) for sediment
and lime scale removal procedures.
• Water heater not ring at full input rating. See
Checking the
Firing Rate
(page 59).
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Note: The water heaters covered by this manual are capable
of modulating their ring rate. The ring 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 49).
• If installed check Thermostatic Mixing Valve settings.
• Tank Probe Offset setting improperly set. See
Temperatures
Menu
(page 49).
• Lime build-up on temperature probes. Inspect and clean.
• Improper water piping. See
Water Piping Diagrams
(page 73).
NOISY OPERATION
• Sediment or lime scale accumulations can cause rumbling
and pounding noises during heating cycles. See
Maintenance
(page 67) 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 4
(page 9).
• 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
Thermal Expansion
(page 14).
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 afxed to the water heater.
See the parts list included with the water heater from the factory for
more information or contact Technical Support for assistance. See
the contact information label on the water heater.
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 qualied 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 qualied 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 on page 60 and 61,
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 qualied service agents, as dened in Qualications on page
6, using appropriate test equipment, should perform any service
procedures on the water heater.
Note: If you are not qualied and licensed or certied 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.
Contact Technical Support for assistance in locating a qualied
service agent in your area. See the contact information label on the
water heater.
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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FAULT AND ALERT MESSAGES
Contact Technical Support for assistance in locating a qualied service agent in your area. See the contact information label on
the water heater.
Fault and Alert Messages
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 res.
Ensure wire connections to gas valve are clean and tight.
Ensure wire connections to ame sensor are clean and tight.
Ensure wire connections to spark igniter are clean and tight.
Inspect ame 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
Conrm supply gas is turned on.
Using a manometer, ensure the supply gas pressure is above
minimum pressure requirement listed on heater’s data plate
before and during operation.
Ensure wire connections to gas pressure switch are clean and tight.
If all above conditions are met, replace gas pressure switch.
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: A6-501
Low Gas Pressure
Low Gas Pressure
Press the Advanced button for
more information
If Blocked Exhaust error occurs when blower is running, check for
restrictions in exhaust pipe, including exhaust elbow, condensate
drain, and outside termination. Also check exhaust pipe installation
(size/length) per manual.
If Blocked Exhaust error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch should be closed (continuity/0
ohms). Replace switch if open (no continuity).
Other possible causes: high wind conditions and excessive negative
air pressure in building.
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
If Blocked Intake error occurs before blower runs, make sure
pressure switch connections are clean and tight. Check pressure
switch continuity/resistance. Switch s h o u l d b e c l o s e d
(continuity/0 ohms). Replace switch if open (no continuity).
If 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, excessive
negative air pressure in building.
ADVANCEDBACK
0 days 0 hr 0 min ago
Error Code: A7-1201
Blocked Air Intake
Restriction in air intake.
Check intake pipe and
termination for blockage.
Press the Advanced button for
Ensure wire connections to upper temperature probe are clean
and tight.
Using a thermometer, check the water temperature of the 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 electric power and
gas supply and call Tech Support for further instructions.
ADVANCEDBACK
0 days 0 hr 0 min 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
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Fault and Alert Messages
Possible Causes - Check/Repair Displayed Fault/Alert Message
Conrm the water heater is full of water.
Conrm the powered anode wire connections are tight and free of
debris or moisture (i.e. rust, solder, metal pipe shavings).
Conrm proper electrical ground to the water heater.
Inspect powered anode(s), clean/replace as needed.
ADVANCEDBACKACCEPT
0 days 0 hr 0 min ago
Error Code: D6-8
No Water
No water detected by Powered
Anode.
The control indicates a problem
with the anode protection. By
• Conrm that the lower probe cable is plugged into the CCB
and the lower probe connector.
• Measure resistance of probe to check for an open or shorted
circuit
• Inspect lower probe cable for damage.
• Inspect the lower probe. Replace as needed.
ADVANCEDBACK
0 days 0 hrs 0 mins ago
Error Code: 48-0
Lower Temp Probe Open
The indicated temperature probe
may be shorted or open.
Check connector and resistance
of probe.
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MAINTENANCE
GENERAL
Keep water heater area clear and free from combustible materials,
gasoline, and other ammable vapors and liquids. See
Locating the
Water Heater
(page 11).
Water heater maintenance includes periodic tank ushing and
cleaning, and removal of lime scale. The water heater should be
inspected and adjusted to maintain proper combustion. See
Start
Up
(page 57). 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 rst being certain it is lled
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.
Should overheating occur or the gas supply fail to shut off, turn off
the Main Gas Shutoff valve. See
Figure 51
(page 40).
MAINTENANCE SCHEDULE
Table 20. Maintenance Schedule
Component Operation Interval Required
Tank Sediment Re-
moval
Semi Annually Flushing
Tank Lime Scale
Removal
Semi Annually UN-LIME®
Anode Rods Inspection
Cleaning
Annually Clean Scale De-
posits
T&P Valve Test Operation Semi Annually Test
Vent System Inspection Annually Termination Screens
Clean
Reseal/Repair
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained and
ushed 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 storage 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 steps:
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.
6. Ensure the drain hose is secured before and during the entire
ushing procedure. Flushing is performed with system water
pressure applied to the water heater.
7. Open the water heater drain valve to ush the storage tank.
8. Flush the water heater storage tank to remove sediment and
allow the water to ow until it runs clean.
9. Close the water heater drain valve when ushing is completed.
10. Remove the drain hose.
11. Fill the water heater. See
Filling The Water Heater
(page 57)
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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 efciency 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 rst. 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 59
.
TANK
CLEANOUT
OPENING
CLEANOUT
COVER
CLEANOUT
GASKET
CLEANOUT
ACCESS PANEL
Figure 59. Cleanout Access
MANUAL LIME SCALE REMOVAL
Note: Contact Technical Support for assistance in ordering a
new cleanout gasket. See the contact information label
on the water heater. Have the new gasket available
before removing the cleanout cover.
The cleanout opening is shown in
Figure 59
. 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
67). 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 57).
10. Turn on the electrical supply to place the water heater back in
operation. See
Start Up
(page 57).
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 specically 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: Contact Technical Support for assistance in ordering the
UN-LIME
®
Professional Delimer.
POWERED ANODE RODS
To ensure 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.
Note: Follow the instructions in
To drain the water heater storage
tank:
(page 67) rst. 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. Remove the entire
anode rod from the water heater prior to inspection.
Clean the anode rods with a soft cloth and reinstall.
Follow the instructions for
Filling The Water Heater
(page
57) when nished.
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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
59
(page 68).
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 61
. The valve should seat properly and operate
freely.
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 67). 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 60. 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
Thermal Expansion
(page 14).
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
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 22
(page 27).
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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DIAGRAMS
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 61. Central Control Board (CCB)
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WIRING DIAGRAM
P/N 100312909
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
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
4 White
3 Black
2 Red
Green
Neutral
L1
Aux 2 Common
Aux 2 NO
Aux 1 NO
Aux 1 Common
Aux 1 NC
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
Gas Pressure
Switch
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
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
1 Black
2 Black
CCB J10
Lower Probe
Thermistor
Thermistor
Black
Black
Lower
Temperature
Probe
Splice
Blue
Blue
Anode
Rod
Anode
Rod
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
CCB J13
FACTORY
USE
ONLY
Neutral
Figure 62. Wiring Diagram
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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 63. Recirculating Loop with 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 64. Recirculating Loop with Dish Washer and Toggle Switch
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
ONE WATER HEATER, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
ONE WATER HEATER, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
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.
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
HOT WATER
TO FIXTURES
PIPE T&P TO
OPEN DRAIN
FINISHED FLOOR
HOT WATER
RETURN
COLD WATER
SUPPLY
EXPANSION
TANK
73
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
ONE WATER HEATER, TWO TEMPERATURE
WITH HIGH TEMPERAURE LOOP RECIRCULATION
WITH BUILDING RECIRCULATION
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.
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
MIXING VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
FINISHED FLOOR
HOT WATER
RETURN
OUTLET
HOT
TEMPERED WATER
RETURN
TEMPERED
WATER
OUTLET
PIPE T&P TO
OPEN DRAIN
COLD WATER
SUPPLY
COLD
EXPANSION
TANK
74
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
ONE WATER HEATER, SINGLE TEMPERATURE
WITH VERTICAL STORAGE TANK FORCED RECIRCULATION
WITH BUILDING RECIRCULATION
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.
4. The tank temperature control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the tank temperature control.
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
FINISHED
FLOOR
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
COLD WATER
SUPPLY
HOT WATER
TO FIXTURES
ALT. COLD WATER
CONNECTION
EXPANSION
TANK
STORAGE TANK
75
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
ONE WATER HEATER, SINGLE TEMPERATURE
WITH HORIZONTAL STORAGE TANK FORCED RECIRCULATION
WITH BUILDING RECIRCULATION
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.
4. The tank temperature control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the tank temperature control.
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
FINISHED
FLOOR
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
HOT
WATER
TO FIXTURES
CIRCULATING
PUMP
ALTERNATE
LOCATION
COLD WATER
SUPPLY
EXPANSION
TANK
STORAGE TANK
76
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
TWO WATER HEATERS, SINGLE TEMPERATURE
W
ITH BUILDING RECIRCULATION
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.
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
FINISHED
FLOOR
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
COLD WATER
SUPPLY
EXPANSION
TANK
77
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
THREE WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
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.
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
FINISHED
FLOOR
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
COLD WATER
SUPPLY
EXPANSION
TANK
78
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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
Thermal Expansion
(page 14).
5. See
Water Line Connections
(page 42).
6. If a pump is being installed between a water heater and storage tank or on a building
recirculation loop wire according to
Figure 63
(page 72).
7. If a pump is being installed in a recirculation loop between the water heater and a
commercial dishwasher wire according to
Figure 64
(page 72).
FOUR WATER HEATERS, SINGLE TEMPERATURE
WITH BUILDING RECIRCULATION
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.
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
ANY MATERIAL, COMPONENT OR VENDOR CHANGE
MUST HAVE PRIOR APPROVAL BY THE APPLICABLE
PRODUCT ENGINEERING DEPARTMENT.
FINISHED
FLOOR
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
COLD WATER
SUPPLY
TANK TEMPERATURE
CONTROL
EXPANSION
TANK
LEGEND
TEMPERATURE &
PRESSURE RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TEMPERATURE CONTROL
PROBE
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
79
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Copyright © 2018. All rights reserved.
80
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