PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS
REQUIRED.
100401844_2000855206APRINTED 0326
Instruction Manual
HIGH-EFFICIENCY COMMERCIAL GAS WATER HEATERS
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
•
•
•
•
Thank you for buying this energy efficient water heater. We
appreciate your condence in our products.
MODELS FLEX 60G/100G/119G
SERIES 410
INSTALLATION - OPERATION - SERVICE - MAINTENANCE
Failure to follow these instrucons and safety
messages could result in death or serious injury.
Read and understand this instrucon manual and the
safety messages herein before installing or. operang
or servicing this water heater.
This manual must remain with the water heater.
⚠
WARNING
Safety Hazard
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
LOW LEAD
CONTENT
HLW
2
CONTENTSCONTENTS
APPROVALS ................................................................................ 3
GENERAL SAFETY INFORMATION .......................................... 3
Do Not Operate If Damaged ..................................................... 3
Limiting the Risk of Scalding ..................................................... 3
Grounding Instructions .............................................................. 3
Hydrogen Gas Flammable ........................................................ 4
Important Denitions ................................................................. 4
Hazard Messages ..................................................................... 4
INTRODUCTION ......................................................................... 8
Abbreviations Used ................................................................... 8
Qualications ............................................................................. 8
ICOMM™ .................................................................................. 8
Building Management System .................................................. 8
Leak Detection .......................................................................... 8
Automatic Water Shut-O Valve ................................................ 8
Preparing for the Installation ..................................................... 8
FEATURES AND COMPONENTS ............................................ 10
Basic Operation ....................................................................... 10
Modulation ............................................................................... 10
Gas Valve ................................................................................ 10
Blower/Burner Assembly Detail ............................................... 10
Top View Components ............................................................ 11
Side View Components ........................................................... 14
INSTALLATION CONSIDERATIONS ....................................... 17
Rough In Dimensions .............................................................. 17
Locating the Water Heater ...................................................... 18
Optional Terminations ............................................................. 19
Hard Water .............................................................................. 19
Circulation Pumps ................................................................... 19
Insulation Blankets .................................................................. 19
INSTALLATION REQUIREMENTS .......................................... 21
Gas Supply Systems ............................................................... 21
Supply Gas Regulator ............................................................. 21
Power Supply .......................................................................... 21
Mixing Valves .......................................................................... 22
Dish-washing Machines .......................................................... 22
Closed Water Systems ............................................................ 22
Thermal Expansion ................................................................. 22
Temperature-Pressure Relief Valve ........................................ 22
Condensate Drain ................................................................... 24
Combustible Material Storage ................................................. 25
Contaminated Air ..................................................................... 25
Air Requirements .................................................................... 25
Fresh Air Openings For Conned Spaces ............................... 26
Massachusetts Installation Requirements .............................. 29
VENTING INSTALLATION ........................................................ 30
General Venting Information ................................................... 30
Category IV Appliances ........................................................... 30
Venting Requirements ............................................................. 32
Venting Installation Sequence ................................................. 35
Power Vent Installation ............................................................ 35
Direct Vent Installation ............................................................ 35
Vertical Termination Installation ............................................... 36
Sidewall Termination Installation ............................................. 38
Polypropylene Installations (Rigid) .......................................... 39
Flexible Polypropylene ............................................................ 39
AL29-4C
®
Vent Installations .................................................... 40
Common Venting ..................................................................... 40
Concentric Termination Installation ......................................... 41
Low Prole Vent Installation .................................................... 44
Venting Arrangements ............................................................. 46
Termination Clearances Sidewall Power Vent ......................... 48
Termination Clearances Sidewall Direct Vent ......................... 49
INSTALLING THE WATER HEATER ........................................ 50
Condensate Drain Installation ................................................. 50
Leak Detection Module Installation ......................................... 50
Supply Gas Line Installation .................................................... 51
Gas Line Leak Testing ............................................................. 53
Electrical Wiring ...................................................................... 53
Water Line Connections .......................................................... 54
START UP .................................................................................. 56
Prior to Start up ....................................................................... 56
Initial Start Up and AIQ™ Calibration ...................................... 56
Gas Type Calibration ............................................................... 57
Start Up Conditions ................................................................. 58
Operational Conditions ............................................................ 58
Lighting the Water Heater ....................................................... 60
Checking the Firing Rate ......................................................... 61
High Altitude Installations ........................................................ 62
TEMPERATURE REGULATION ............................................... 63
High Temperature Limit Control (ECO) ................................... 63
Thermostat Control ................................................................. 63
CONTROL SYSTEM OPERATION ........................................... 65
Limiting the Risk of Scalding ................................................... 65
Wi-Fi ........................................................................................ 65
Lockout Function ..................................................................... 65
Control System Overview ........................................................ 65
Control System Navigation ...................................................... 65
User Settings & Control System Menus .................................. 67
MAINTENANCE ......................................................................... 79
Maintenance Schedule ............................................................ 79
Draining and Flushing ............................................................. 79
Sediment Removal .................................................................. 80
Lime Scale Removal ............................................................... 80
Burner Flame Inspection ......................................................... 81
Anode Rod Maintenance ......................................................... 81
Drain Valve and Access Panels .............................................. 81
Temperature-Pressure Relief Valve Test ................................. 82
Vent System Maintenance ...................................................... 82
TROUBLESHOOTING .............................................................. 83
Installation Checklist ............................................................... 83
Sequence of Operation ........................................................... 83
Sequence of Operation ........................................................... 84
Operational Problems ............................................................. 85
Fault and Alert Conditions ....................................................... 86
Fault and Alert Conditions ....................................................... 87
Checking for Leaks ............................................................... 100
Checking the Threaded Fittings ............................................ 100
DIAGRAMS .............................................................................. 101
Wiring Diagrams .................................................................... 101
Water Piping Diagrams ......................................................... 105
3
APPROVALSAPPROVALS
HLW
Note: ASME construction is optional on the 60G and 100G water
heaters covered in this manual.
GENERAL SAFETY INFORMATIONGENERAL SAFETY INFORMATION
DO NOT OPERATE IF DAMAGED
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.
LIMITING THE RISK OF SCALDING
For a variety of reasons, water heaters can produce water that is
much hotter than its temperature setting. Take precautions to prevent
this higher temperature water from reaching the water xtures.
The temperature of the water in the water
To reduce the risk of unusually hot water
of use.
⚠
WARNING
Burn Hazard
According to a national standard,
Performance Requirements for Water
Temperature Limiting Devices (ASSE 1070)
and many local plumbing codes,
the water heater’s gas control valve should not be used as the sole
means to regulate water temperature and avoid scalds.
A properly adjusted thermostatic mixing valve at each point of use
allows you to set the tank temperature to a higher setting without
increasing risk of scalds. A higher temperature setting allows the
tank to provide much more hot water and can help provide proper
water temperatures for appliances such as dishwashers and washing
machines.
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.
4
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
ame near the faucet at the time it is open.
Flammable hydrogen gases can form in water pipes.
The hydrogen can explode if it is exposed to flame and
can cause severe injury or death.
Keep all ignion sources away from faucet when
turning on hot water.
⚠
WARNING
Explosion Hazard
Verify the power to the water heater is turned off before performing any service procedures. The Enable /Disable switch on
front panel disables the gas valve. Electrical supply must be turned off at circuit breaker serving water heater.
IMPORTANT DEFINITIONS
Qualied Installer: A qualied installer must have ability equivalent
to a licensed tradesman in the fields of plumbing, air supply,
venting and gas supply, including a thorough understanding of the
requirements of the
National Fuel Gas Code, ANSI Z223.1/NFPA
54
as it relates to the installation of gas red water heaters. The
qualied installer must also be familiar with the design features and
use of ammable vapor ignition resistant water heaters and have a
thorough understanding of this Installation and Operating manual.
Service Agency: A service agency also must have ability equivalent
to a licensed tradesman in the fields of plumbing, air supply,
venting and gas supply, including a thorough understanding of the
requirements of the
National Fuel Gas Code”, ANSI Z223.1/NFPA 54
as it relates to the installation of gas red water heaters. The service
agency must also have a thorough understanding of this Installation
and Operating manual, and be able to perform repairs strictly in
accordance with the service guidelines provided by the manufacturer.
Gas Supplier: The Natural Gas or Propane Utility or service who
supplies gas for utilization by the gas burning appliances within
this application. The gas supplier typically has responsibility for the
inspection and code approval of gas piping up to and including the
Natural Gas meter or Propane storage tank of a building. Many gas
suppliers also oer service and inspection of appliances within the
building.
HAZARD MESSAGES
The proper installation, use, and servicing of this water heater is
extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided
in this manual and on your own water heater to warn you and others
of a potential injury hazard. Read and obey all safety messages
and instructions throughout this manual. It is very important that the
meaning of each safety message is understood by you and others
who install, use, or service this water heater.
This is the safety alert symbol. It is used to
alert you to potential personal injury
hazards. Obey all safety messages that
follow this symbol to avoid possible injury or
death. Keep this manual near the water
heater.
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in 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.
DANGER⚠
WARNING⚠
CAUTION⚠
CAUTION
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.
5
Failure to follow these instrucons and safety
messages could result in death or serious injury.
Read and understand this instrucon manual and the
safety messages herein before installing or. operang
or servicing this water heater.
This manual must remain with the water heater.
⚠
WARNING
Safety Hazard
The temperature of the water in the water
To reduce the risk of unusually hot water
of use.
⚠
WARNING
Burn Hazard
Flammable hydrogen gases can form in water pipes.
The hydrogen can explode if it is exposed to flame and
can cause severe injury or death.
Keep all igni�on sources away from faucet when
turning on hot water.
⚠
WARNING
Explosion Hazard
CAUTION
Property Damage Hazard
can begin to leak and cause water damage.
• Locate the water heater near an adequate drain
and in an area where water leakage from the
the area or the lower floors of the structure.
• Install the water heater in a drain pan.
• Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
• Avoid all ignion sources if you smell gas.
• Do not expose water heater controls to excessive gas
pressure.
• Use only the gas shown on the water heater rang
label.
• Maintain required clearances to combusbles.
• Keep ignion sources away from faucets aer
extended periods of non-use.
⚠
WARNING
• Do not obstruct water heater air intake
• Gas and carbon monoxide detectors are
• Install water heater in accordance with the
instrucon manual.
Breathing carbon monoxide can cause brain damage or death. Always read
and understand instrucon manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
Because of the increased risk from scalding, if you
set the water heater’s gas control knob higher than
120°F (49°C), install thermosta�c point-of-use
mixing valves at each point of use. Due to the
increased risk of scalding, do not set the tempera-
ture of the thermosta�c mixing valves above 120°F
(49°C).
⚠
DANGER
Burn Hazard
To avoid this hazard, you must install a properly-
sized temperature-pressure relief valve in opening
provided.
• The temperature-pressure relief valve must
comply with
and ASME
code.
• Do not plug, block, or cap the discharge line.
⚠
WARNING
Property Damage Hazard
While the water heater is in roune operaon, it can
release hot water from the temperature-pressure relief
valve discharge pipe in quanes that could cause
damage to the surroundings.
Locate the water heater near an adequate drain and
in an area where water from the temperature-pres-
sure relief valve discharge pipe will not result in
damage to the area or the lower floors of the
structure.
⚠
CAUTION
6
⚠
DANGER
Burn Hazard
The discharge water from the temperature-pressure
relief valve is hot enough to cause burns.
Keep clear of the temperature-pressure relief valve
discharge outlet.
• 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 instruc�on manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Do not use water heater with any gas other than
the gas shown on the rang label.
• Excessive gas pressure to gas valve can cause
serious injury or death.
• Turn off gas lines during installaon.
• Contact a qualified installer or service agency for
installaon and service.
⚠
WARNING
Fire and Explosion Hazard
The temperature of the water in the water
⚠
WARNING
Burn Hazard
Breathing carbon monoxide can cause brain damage or death. Always
read and understand instruc�on manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with codes.
•
Do not operate water heater if any part has been
exposed to flooding or water damage.
• High altitude models should be installed at
elevations above 5,300 feet (1,615 m). For
operation above 10,100 feet (3,079 m), a high
altitude orifice must be installed.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake with
insulating jacket.
• Do not place chemical vapor emitting products
near water heater.
•
Gas and carbon monoxide detectors are available.
• No vent damper installation is compatible with
this power vented water heater.
•
Do NOT elevate any portion of the field supplied
drain line beyond the 1/2” adapter above the
adapter. This must be true for the entire length
of the drain line including the exit into an
appropriate drain.
•
Condensate lines must be free and clear of debris
and must not allow back flow through the hose.
The condensate lines must be able to flow freely
to an appropriate drain.
• Do not allow condensate lines to become
crimped closed.
•
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.
Gas piping can leak gas from fi�ngs and connec�ons if
it is not sealed properly. Gas leaks can cause fires and
explosions resul�ng in severe injury or death.
• Use joint compound or thread sealer tape compatible
with the type of gas you are using.
• Leak test all gas connections before placing the water
heater in operation.
• Disconnect gas piping at main gas shutoff valve before
leak testing.
• Install sediment trap in accordance with NFPA 54 or
CAN/CSA B149.1.
⚠
WARNING
Fire and Explosion Hazard
CAUTION
Property Damage Hazard
• Fill tank with water before operang.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold water inlet.
• Contact qualified installer or service agency.
7
• Under no circumstances should the input exceed
the rate shown on the water heater’s rang label.
• Over-firing could result in fire or explosion.
• Gas and carbon monoxide detectors are available.
⚠
WARNING
• Under no circumstances should the input exceed
the rate shown on the water heater’s rang label.
• Overfiring could result in damage to the water
heater and soong.
• Gas and carbon monoxide detectors are available.
Breathing carbon monoxide can cause brain damage or death. Always
read and understand instrucon manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
Burn Hazard
• The combustion chamber and burner
sleeve and housing become very hot
during operation.
• 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.
⚠
CAUTION
Servicing this water heater exposes you to
electrified components that can cause severe
injury or death if you touch them.
• Turn off power at the branch circuit breaker
serving the water heater before performing any
service.
• Label all wires prior to disconnecng when
performing service. Wiring errors can cause
improper and dangerous operaon.
• Verify proper operaon aer servicing.
⚠
WARNING
Electrical Shock Hazard
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 i
n
any way could result in permanent damage to the
controls or water heater and is not covered under
the limited warranty.
• Any bypass or alteraon of the water heater
controls and/or wiring will result in voiding the
appl
iance warranty.
⚠
WARNING
Safety Hazard
⚠
CAUTION
Safety Hazard
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.
• Soong.
Do not operate the water heater unl all correcve steps
have been made by a qualified service technician.
• Overheated water can cause water tank explosion.
• A properly sized temperature and pressure relief
valve must be installed in the opening provided.
⚠
WARNING
Explosion Hazard
⚠
DANGER
Burn Hazard
The discharge water from the drain valve is hot enough
to cause burns.
Keep your hands clear of the drain valve discharge
outlet.
8
INTRODUCTIONINTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include:
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
QUALIFICATIONS
Qualied 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.
To order or to nd out more about ICC devices, Technical Support.
To connect your water heater to iCOMM, download the A. O. Smith
app from the Apple App Store or Google Play store and follow the
instructions for how to add your water heater.
BUILDING MANAGEMENT SYSTEM
This water heater is connectible to BACnet or Modbus compliant
Supervisory controls via the optional BMS Gateway. This allows
connection of the water heater to local Building Management
Systems using Serial RS-485 (MS/TP) or IP connections.
LEAK DETECTION
The water heaters covered in this manual are equipped with a leak
detection device that continuously tests for the presence of water
in the immediate location of the water heater. If water is detected,
it generates an alarm.
AUTOMATIC WATER SHUT-OFF VALVE
The optional Automatic Water Shut o Valve and Valve Control Board
work in conjunction with the TRC to help reduce the risk of further
water damage if a leak is detected by the leak detection device.
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 3). 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 10) in this manual. Use this
reference to locate and identify various components on the
water heater.
See
Installation Checklist
(page 83) and
Troubleshooting
(page
83). 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 o 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.
9
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 17) and
Locating the Water Heater
(page 18).
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 Oce 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
Massachusetts Installation Requirements
(page 29).
10
FEATURES AND COMPONENTSFEATURES 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
ASSEMBLY
INTAKE AIR
(combustion air)
CONNECTION
MAIN
BURNER
(radial design)
HEAT
EXCHANGER
HELICAL
COIL
VENT (exhaust)
OUTLET
Figure 1. Operational Components
MODULATION
The water heaters covered by this manual are capable of adjusting
their ring rate. The combustion blower is controlled by the CSC.
The TRC and CSC monitor the water temperature in the tank and
regulate the ring rate to achieve the target temperature set-point.
The ring rate is dictated by the hot water draw, proximity to the tank
temperature set-point, and various other temperature limitations.
GAS VALVE
This heater is equipped with a gas adaptive system and motor driven
throttle. It is controlled by the CSC in conjunction with the TRC.
BLOWER/BURNER ASSEMBLY DETAIL
Intake Air Connection Pipe
Combustion
Blower
Assembly
Spark Igniter
Flame
Sensor
Main Burner
(radial design)
Burner Flange
Figure 2. Blower/Burner Assembly - 60 Gallon
Intake Air Connection Pipe
Combustion
Blower
Assembly
Spark Igniter
Flame
Sensor
Main Burner
(radial design)
Burner Flange
Figure 3. Blower Burner Assembly -100 Gallon
Intake Air Connection Pipe
Combustion
Blower
Assembly
Spark Igniter
Flame
Sensor
Main Burner
(radial design)
Burner Flange
Figure 4. Blower-Burner Assembly -119 Gallon
11
Spark Igniter
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 the control system will immediately deenergize
the Gas Valve. See
Sequence of Operation
(page 84).
TOP VIEW COMPONENTS
60 Gallon Top View
13
11
7
6
5
4
17
16
15
14
1
2
18
3
20
10
12
19
8
9
Figure 5. Top View, 60 Gallon
The Enable/Disable switch listed in this manual is NOT an “on/o”
switch and does not disconnect 120 volt power to the control boards
and other heater components.
1. Enable/Disable Switch. When in the “Disabled” position the
switch removes electrical power from the gas valve so that
water heating is disabled. The UIM, TRC, CSC, and other
electrical components will still be energized and the display
will read “Water Heating Disabled.”
2. Temperature-Pressure Relief Valve (T & P Valve). See
Temperature-Pressure Relief Valve
(page 22).
3. Control boards (TRC and CSC) enclosure. This enclosure
houses the control system’s TRC and CSC. The temperature
regulation control (TRC) and combustion and safety control
(CSC) regulate water temperature and control all water
heater functions. See
Control System Operation
(page
65).
4. Combustion Blower Assembly. Includes Gas Valve and
Venturi gas feed system.
5. Spark Ignition Transformer. When energized, sends the
electrical current to the spark igniter.
6. 120 VAC junction box. Incoming power supply, ground
connections, and other eld-installed electrical connections
are made here. See
Power Supply
(page 21) and
Power
Supply Connections
(page 53).
7. Supply gas line connection. See the requirements for the
supply gas line in
Table 4
(page 18) and
Table 5
(page 18).
8. Water heater’s Gas Valve.
9. Intake air connection - PVC. Refer to
Venting Installation
(page 30).
10. 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.
11. Powered anode rod 31.5”. The water heaters covered in
this manual are equipped with a powered (non sacricial)
anode rod. 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 eect
of water when it in contact with a steel tank which diminishes
the corrosive eect of water when it comes in contact with
steel.
12. Main Temperature Probe. The water heater’s control system
monitors this probe to detect water temperature in the upper
portion of the storage tank.
13. Water outlet connection 1 1/2” NPT.
14. Flex Memory Module (FMM) under cover: The FMM board
is located inside the plastic display enclosure. The FMM
board enables an FMM device to communicate information
with the heater.
DO NOT REMOVE OR DAMAGE THE FMM
BOARD.
15. User Interface Module (UIM). 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 65).
16. Vent connection (exhaust/condensate elbow) -
aluminum. Refer to
Venting Installation
(page 30).
12
100 Gallon Top View
9
8
6
7
5
4
14
13
12
11
1
3
17
15
16
2
10
Figure 6. Top View, 100 Gallon
The Enable/Disable switch listed in this manual is NOT an “on/o”
switch and does not disconnect 120 volt power to the control boards
and other heater components.
1. Water Heater’s Dual Voltage Enable/Disable Switch.
When in the “Disabled” position the switch removes electrical
power from the gas valve so that water heating is disabled.
The UIM, TRC, CSC, and other electrical components will
still be energized and the display will read “Water Heating
Disabled.”
2. Powered anode 13.78”. The water heaters covered in this
manual are equipped with 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 eect
of water when it comes in contact with steel.
3. Temperature-Pressure Relief Valve (T & P Valve). See
Temperature-Pressure Relief Valve
(page 22).
4. Control boards (TRC and CSC) enclosure. This enclosure
houses the control system’s TRC and CSC. The temperature
regulation control (TRC) and combustion and safety control
(CSC) regulate water temperature and control all water
heater functions. See
Control System Operation
(page
65).
5. Spark Ignition Transformer. When energized, sends the
electrical current to the spark igniter.
6. 120 VAC junction box. Incoming power supply, ground
connections, and other eld-installed electrical connections
are made here. See
Power Supply
(page 21) and
Power
Supply Connections
(page 53).
7. Supply gas line connection. See the requirements for the
supply gas line in
Table 4
(page 18) and
Table 5
(page 18).
8. Water heater’s Gas Valve.
9. Intake air connection - PVC. Refer to
Venting Installation
(page 30).
10. Combustion Blower Assembly. Includes Gas Valve and
Venturi gas feed system.
11. 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.
12. Powered anode 48”.
13. Main Temperature Probe. The water heater’s control system
monitors this probe to detect water temperature in the upper
portion of the storage tank.
14. Water outlet connection 1 1/2” NPT.
15. Flex Memory Module (FMM) under cover: The FMM board
is located inside the plastic display enclosure. The FMM
board enables an FMM device to communicate information
with the heater.
DO NOT REMOVE OR DAMAGE THE FMM
BOARD.
16. User Interface Module (UIM). 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 65).
17. Vent connection (exhaust/condensate elbow) -
aluminum. Refer to
Venting Installation
(page 30).
13
119 Gallon Top View
13
11
7
6
5
4
17
16
15
14
1
2
18
3
20
10
12
19
8
9
Figure 7. Top View, 119 Gallon
The Enable/Disable switch listed in this manual is NOT an “on/o”
switch and does not disconnect 120 volt power to the control boards
and other heater components.
1. Water Heater’s Dual Voltage Enable/Disable Switch.
When in the “Disabled” position the switch removes electrical
power from the gas valve so that water heating is disabled.
The UIM, TRC, CSC, and other electrical components will
still be energized and the display will read “Water Heating
Disabled.”
2. Temperature-Pressure Relief Valve (T & P Valve). See
Temperature-Pressure Relief Valve
(page 22).
3. Powered anode rod 19.69”. The water heaters covered
in this manual are equipped with 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 eect
of water when it comes in contact with steel.
4. Control boards (TRC and CSC) enclosure. This enclosure
houses the control system’s TRC and CSC. The temperature
regulation control (TRC) and combustion and safety control
(CSC) regulate water temperature and control all water
heater functions. See
Control System Operation
(page
65).
5. Combustion Blower Assembly. Includes Gas Valve and
Venturi gas feed system.
6. Spark Ignition Transformer. When energized, sends the
electrical current to the spark igniter.
7. 120 VAC junction box. Incoming power supply, ground
connections, and other eld-installed electrical connections
are made here. See
Power Supply
(page 21) and
Power
Supply Connections
(page 53).
8. Intake air connection - PVC. Refer to
Venting Installation
(page 30).
9. Supply gas line connection. See the requirements for the
supply gas line in
Table 4
(page 18) and
Table 5
(page 18).
10. Powered anode, shielded,118 dia. x 31.5. Approximate
location (not visible),
11.
CPAM Power Supply:
Provides power to the CPAM.
12. Water heater’s Gas Valve.
13. CPAM (Powered Anode Module): Axillary control for the
operation of powered anodes.
14. 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.
15. Powered anode 48”.
16. Main 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.
17. Water outlet connection 1 1/2” NPT.
18. Flex Memory Module (FMM) under cover: The FMM board
is located inside the plastic display enclosure. The FMM
board enables an FMM device to communicate information
with the heater.
DO NOT REMOVE OR DAMAGE THE FMM
BOARD.
19. User Interface Module (UIM). 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 65).
20. Vent connection (exhaust/condensate elbow) -
aluminum. Refer to
Venting Installation
(page 30).
14
SIDE VIEW COMPONENTS
5
8
10
2
1
16
3
9
4
7
6
14
11
17
15
Figure 8. Left-Side Components
3
11
7
6
5
13
1
17
4
2
14
8
9
12
15
16
18
Figure 9. Right-Side Components
60 and 100 Gallon Models
1. Temperature-Pressure Relief Valve. See
Temperature-
Pressure Relief Valve
(page 22).
2. User Interface Module (UIM). 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 65).
3. Control boards enclosure. See
Figure 5
,
Figure 6,
and
Figure 7
(page 12) for description.
4. Spark Ignition Transformer. When energized, sends the
electrical current to the spark igniter.
5. Combustion Blower.
6. Water heater Gas Valve.
7. Supply gas line connection. See the requirements for the
supply gas line in
Table 4
(page 18) and
Table 5
(page 18).
8. Intake air connection - PVC.
9. 120 VAC junction box. Incoming power supply, ground
connections, and other eld installed electrical connections
are made here. See
Power Supply
(page 21) and
Power
Supply Connections
(page 53).
10. Water outlet - 1 1/2” NPT connection.
11. Vent connection (exhaust/condensate elbow) -
Aluminum.
12. Water heater drain valve.
13. Leak Detection Module. This feature senses the buildup of
water in the vicinity of the appliance. (Must be plugged in to
operate the unit).
14. Water inlet connection - 1 1/2” NPT connection.
15. Blocked Exhaust (vent) switch. Normally closed contacts
that open on a rise in pressure. This switch is used to ensure
that 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.
16. Clean-out access panel. Covers water heater clean-out
opening and ASME plate where applicable.
17. 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.
18. Recirculation loop return connection - 3/4” NPT.
19. Optional BMS Module. This feature enables the heater
to communicate with a building management system. *Not
shown/visible.
15
1
3
4
15
14
8
13
12
11
10
8
7
6
9
2
5
18
16
Figure 10. Left Side
87
6
10
11
12
5
4
3
2
1
16
15
14
9
17
13
18
Figure 11. Right Side
119 Gallon Models
1. Control boards enclosure. See
Figure 5
,
Figure 6,
and
Figure 7
(page 12) for description.
2. Water outlet - 1 1/2” NPT connection.
3. User Interface Module (UIM). 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 65)
4. Temperature-Pressure Relief Valve. See
Temperature-
Pressure Relief Valve
(page 22).
5. 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.
6. Clean-out access panel. Covers water heater clean-out
opening and ASME plate where applicable.
7. Water heater drain valve.
8. Water inlet connection - 1 1/2” NPT connection.
9. Leak Detection Module. This feature senses the buildup of
water in the vicinity of the appliance. (Must be plugged in to
operate the unit).
10. Blocked Exhaust (vent) switch. Normally closed contacts
that open on a rise in pressure. This switch is used to ensure
that 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.
11. Vent connection (exhaust/condensate elbow) -
Aluminum.
12. Recirculation loop return connection - 3/4” NPT.
13. Combustion Blower.
14. Water heater Gas Valve.
15. Supply gas line connection. See the requirements for the
supply gas line in
Table 4
(page 18) and
Table 5
(page 18).
16. Intake air connection - PVC.
17. 120 VAC junction box. Incoming power supply, ground
connections, and other eld installed electrical connections
are made here. See
Power Supply
(page 21) and
Power
Supply Connections
(page 53) .
18. Spark Ignition Transformer. When energized, sends the
electrical current to the spark igniter.
19. Optional BMS Module. This feature enables the heater
to communicate with a building management system. *Not
shown/visible.
16
RECOVERY AND STORAGE CAPACITIES
Table 1. Storage Capacities
Model U.S. Gallons Liters
60 gallon 60 227
100 gallon 100 379
119 gallon 119 451
Table 2. Recovery Capacities
U.S. Gallons/hr & liters/hr at temperature rise indicated
Model
Input °F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F
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
100 100,000 29
GPH 384 288 230 192 165 144 128 115 105 96 89 82
LPH 1453 1090 872 726 623 545 484 436 396 363 335 311
120 120,000 35
GPH 461 345 276 230 197 173 154 138 126 115 106 99
LPH 1743 1308 1046 872 747 654 581 523 475 436 402 374
150 150,000 44
GPH 576 432 345 288 247 216 192 173 157 144 133 123
LPH 2179 1634 1308 1190 963 817 726 654 594 545 503 467
199 199,900 58
GPH 768 576 461 384 329 294 288 256 230 209 192 177
LPH 2906 2179 1744 1453 1245 1112 1090 967 872 739 726 671
250 250,000 73
GPH 960 720 576 480 411 360 320 288 262 240 221 206
LPH 3632 2724 2179 1816 1557 1362 1211 1090 991 908 838 778
251 251,000 74
GPH 963 723 578 481 413 361 321 289 263 241 222 206
LPH 3647 2735 2188 1823 1563 1368 1214 1094 995 912 842 781
300 300,000 88
GPH 1152 864 661 576 494 432 384 345 314 288 266 247
LPH 4359 2769 2615 2179 1868 1635 1453 1307 1189 1090 1005 934
400 400,000 117
GPH 1535 1152 921 768 658 576 512 461 419 384 354 329
LPH 5812 4358 3487 2906 2491 2179 1937 1744 1585 1453 1341 1245
500 500,000 146
GPH 1919 1439 1152 960 823 720 640 576 523 480 443 411
LPH 7265 5448 4358 3632 3114 2724 2421 2179 1981 1816 1677 1557
Recovery capacities are based on 95% thermal eciency.
17
INSTALLATION CONSIDERATIONSINSTALLATION CONSIDERATIONS
ROUGH IN DIMENSIONS
GAS
INTAKE
CLEANOUT
T&P
DRAIN
EXHAUST
1 1/2" NPT
WATER
OUTLET
FRONT
18°
TOP
40°
45°
30°
22°
TOP VIEW
INTAKE
CLEANOUT
T&P
DRAIN
EXHAUST
1 1/2" NPT
WATER
OUTLET
FRONT
18°
TOP
44°
45°
30°
64°
64°
TOP VIEW
60 Gallon
100 Gallon
65°
GAS
SUPPLY GAS
CONNECTION
INTAKE AIR
CONNECTION
3 INCH PVC
WATER
OUTLET
HEIGHT
F
I
H
SUPPLY GAS
CONNECTION
INTAKE AIR
CONNECTION
3 INCH PVC
WATER
OUTLET
HEIGHT
F
I
H
FRONT
VENT
CONNECTION
3 INCH
(exhaust elbow)
T & P VALVE
CLEANOUT
3/4” NPT
DRAIN
3/4” NPT
RECIRCULATION
RETURN
1 1/2” NPT
WATER
INLET
LOWER
TEMPERATURE
PROBE
D
E
A
J
G
C
B
FRONT
VENT
CONNECTION
3 INCH
(exhaust elbow)
T & P VALVE
CLEANOUT
3/4” NPT
DRAIN
3/4” NPT
RECIRCULATION
RETURN
1 1/2” NPT
WATER
INLET
LOWER
TEMPERATURE
PROBE
D
E
A
J
G
C
B
GAS
INTAKE
CLEANOUT
T&P
DRAIN
EXHAUST
1 1/2" NPT
WATER
OUTLET
FRONT
18°
TOP
42°
45°
30°
15°
30°
119 GALLON
SUPPLY GAS
CONNECTION
INTAKE AIR
CONNECTION
4 INCH PVC
WATER
OUTLET
HEIGHT
F
I
H
FRONT
VENT
CONNECTION
3 INCH
(exhaust elbow)
T & P VALVE
CLEANOUT
3/4” NPT
DRAIN
3/4” NPT
RECIRCULATION
RETURN
1 1/2” NPT
WATER
INLET
LOWER
TEMPERATURE
PROBE
D
E
A
J
G
C
B
&
Figure 12. Rough-in Dimensions
18
Model
(Gallon)
Table 3. Dimensions by Model
APPROX. SHIP
WEIGHT STD
APPROX. SHIP
WEIGHT ASME
A B C D E F G H I J
in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) LBS (KG) LBS (KG)
60
55-1/2
(141)
35
(88.9)
27-3/4
(70.5)
6-5/16
(16)
3
(7.62)
42-1/4
(107.32)
11-1/4
(28.6)
48-1/2
(123.2)
53-1/2
(135.9)
18-1/4
(46.36)
460
(208)
490
(220)
100
76-1/2
(194.9)
56-3/8
(143.2)
27-3/4
(70.5)
6-5/16
(16)
3
(7.62)
64
(162.6)
11-1/4
(28.6)
70
(177.8)
75-1/2
(191.8)
18-1/4
(46.36)
523
(237)
553
(251)
119
75-3/4
(197.5)
52
(132)
33-1/8
(84.1)
4-3/4
(12.1)
4-3/4
(12.1)
63-1/8
(160.3)
12-3/4
(32.4)
69-1/4
(175.9)
74-1/2
(189.2)
23
(58.4)
855
(388)
855
(388)
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 100K-400K input water heaters are Automac Circulang Tank or Automac Storage Water Heaters. The 500K-input water heater is
an Automac Circulang Tank or Automac Instantaneous water heater.
Table 4. Fuel Type/Connection Size by Model
† MODEL SERIES NATURAL GAS PROPANE GAS
60 Gallon 410 3/4” NPT 3/4” NPT
100 Gallon 410 3/4” NPT 3/4” NPT
119 Gallon 410 1 1/4” NPT 1 1/4” NPT
† Depending on the installed equivalent length, and/or the number of appliances
connected, the supply gas line size may have to be increased beyond the minimum
required sizes. See
Gas Line Sizing
(page 51).
Table 4
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 51).
Table 5. Gas Pressure Requirement
Model
*Manifold Pressure Minimum Supply Pressure Maximum Supply Pressure
Natural Gas Propane Gas Natural Gas Propane Gas Natural Gas Propane Gas
60G 0” W. C. (0 kPa) 0” W. C. (0 kPa) 3.5” W .C. (0.87 kPa) 8.0” W. C. (1.99 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
100G 0” W. C. (0 kPa) 0” W. C. (0 kPa) 3.5” W .C. (0.87 kPa) 8.0” W. C. (1.99 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
119G 0” W. C. (0 kPa) 0” W. C. (0 kPa) 3.5” W .C. (0.87 kPa) 8.5” W. C. (1.99 kPa) 14” W. C. (3.49 kPa) 14” W. C. (3.49 kPa)
* The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without the Gas Control Valve open.
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.
CAUTION
Property Damage Hazard
can begin to leak and cause water damage.
• Locate the water heater near an adequate drain
and in an area where water leakage from the
the area or the lower floors of the structure.
• Install the water heater in a drain pan.
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 21) 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 25).
9. Locate the water heater where the vent and intake-air piping,
when installed, will remain within the maximum equivalent lengths
allowed. See
(page 31).
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 30).
• Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
• Avoid all ignion sources if you smell gas.
• Do not expose water heater controls to excessive gas
pressure.
• Use only the gas shown on the water heater rang
label.
• Maintain required clearances to combusbles.
• Keep ignion sources away from faucets aer
extended periods of non-use.
⚠
WARNING
19
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 13. 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).
OPTIONAL TERMINATIONS
The water heaters covered by this manual can be installed in a
Direct Vent conguration using optional concentric or low prole
terminations.
See
Low Profile Vent Installation
(page 44), and
Low Profile Vent
Installation
(page 44).
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, coee urns, water heaters, water piping and other
equipment.
See
Maintenance
(page 79) 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 8
through
Figure 11
(pages 14 and
15) for its location. See
Water Piping Diagrams
(page 105) for the
installation location of circulating pumps.
See
Circulation Pump Wiring Diagrams
(page 101) for electrical hookup
information. Install in accordance with the current edition of the
National Electrical Code
,
NFPA 70
or the
Canadian Electrical Code
,
CSA C22.1
.
Stainless Steel circulating pumps are recommended for use with
commercial water heaters.
See the circulating pump manufacturer’s instructions for its operation,
lubrication and maintenance instructions.
INSULATION BLANKETS
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. The water heaters covered
by this manual meet or exceed the
Energy Policy Act
standards with
respect to insulation and standby heat loss requirements, making
an insulation blanket unnecessary.
20
• Do not obstruct water heater air intake
• Gas and carbon monoxide detectors are
• Install water heater in accordance with the
instrucon manual.
Breathing carbon monoxide can cause brain damage or death. Always read
and understand instrucon manual.
⚠
WARNING
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
10) 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.
21
INSTALLATION REQUIREMENTSINSTALLATION 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
o (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. can cause
rough starting, noisy combustion or nuisance outages. Increases
or spikes in static pressure during o 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.
60/100/119 gallon model units require a minimum gas supply
pressure of 3.5” W.C. for natural gas and 8” W.C. for propane gas.
The supply pressure should never fall below 3.5” W.C. for natural
gas and 8” W.C. for propane gas.
The minimum supply pressure is measured while gas is owing
(dynamic pressure). The supply pressure should never fall below
the minimums. 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, the supply gas system, including the gas
line and/or the gas regulator, might be restricted or undersized. See
Supply Gas Regulator
(page 21), the requirements for the supply
gas line in
Table 4
(page 18) and
Table 5
(page 18), and the
instructions in
Supply Gas Line Installation
(page 51). 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:
A. Positive lock-up gas pressure regulators must be rated at or
above the input Btu/hr rating of the water heater they supply.
B. Supply gas regulators shall have inlet and outlet connections
not less than the minimum supply gas line size for the water
heater they supply. See
Table 20
(page 51) and
Table 21
(page 52).
C. 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.
3. 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 additional 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.
Ensure that the gas line is properly supported to reduce the weight
on the gas train support.
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 are commercially
available and must be installed if the above conditions exist.
Note: Malfunctions caused by the power supply and the costs to
install power supply lters are not covered under the limited
warranty.
22
MIXING VALVES
Because of the increased risk from scalding, if you
set the water heater’s gas control knob higher than
⚠
Burn Hazard
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
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 satisfies the demand of the application a means, such as a
thermostatic point-of-use mixing valve, for example, can be used
at the hot water taps used by these people to reduce the water
temperature.
Check State and/or local codes for thermostatic point-of-use mixing
valve requirements and installation practices.
Mixing valves are available at plumbing supply stores. Consult
a Qualified Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
Table 6. Burn Time at Various Temperatures
Water 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)
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 14. Mixing Valve
DISH-WASHING MACHINES
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.
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-o 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 105).
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
A properly sized and pressurized thermal expansion tank must
be installed on all closed systems to control the harmful eects of
thermal expansion. Contact a local plumbing service agency to have
a thermal expansion tank installed.
See
Water Line Connections
(page 54) and the
Water Piping Diagrams
(page 105).
TEMPERATURE-PRESSURE RELIEF VALVE
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
23
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.
To avoid this hazard, you must install a properly-
sized temperature-pressure relief valve in opening
provided.
• The temperature-pressure relief valve must
comply with
and ASME
code.
• Do not plug, block, or cap the discharge line.
⚠
WARNING
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 6
inches 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. Position the end of the discharge pipe directly
above the drain, pointing downward, with an air gap of 6” (15.3
cm) above a suitable drain. 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 or personal injury.
Property Damage Hazard
While the water heater is in roune operaon, it can
release hot water from the temperature-pressure relief
valve discharge pipe in quanes that could cause
damage to the surroundings.
Locate the water heater near an adequate drain and
in an area where water from the temperature-pres-
sure relief valve discharge pipe will not result in
damage to the area of the lower floors of the
structure.
⚠
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 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.
⚠
DANGER
Burn Hazard
The discharge water from the drain valve is hot enough
to cause burns.
Keep your hands clear of the drain 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 22)
and
Thermal
Expansion
(page 22).
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.
24
Property Damage Hazard
While the water heater is in roune operaon, it can
release hot water from the temperature-pressure relief
valve discharge pipe in quanes that could cause
damage to the surroundings.
Locate the water heater near an adequate drain and
in an area where water from the temperature-pres-
sure relief valve discharge pipe will not result in
damage to the area of the lower floors of the
structure.
⚠
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 30 cm (11.8 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.
⚠
DANGER
Burn Hazard
The discharge water from the drain valve is hot enough
to cause burns.
Keep your hands clear of the drain 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 22) and
Thermal
Expansion
(page 22).
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.
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 15
(page 24).
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 lockout and disable heating
operation. The “Blocked Exhaust” Fault message will be displayed on
the control system’s LCD. See
Fault and Alert Conditions
(page 86).
The Condensate Clean-out 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 15
(page
24).
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 (15.2
cm)
ABOVE DRAIN
Figure 15. Exhaust/Condensate Elbow
Secondary Condensate Drain
• The overow tee must be oriented upwards. See
Figure 16
.
• Route the overow pipe to a drain pan or appropriate drain.
The secondary condensate drain incorporates an integrated drain
path designed to discharge water externally in the event of internal
coil perforation or failure within the heat exchanger. This feature
enables early detection of coil leakage, allowing corrective action to
be taken prior to system damage or operational hazards.
This feature functions strictly as an indicator of internal leakage and
is not intended to contain, prevent, or mitigate coil failure. Upon
observation of water discharge through the drain, the appliance
must be immediately inspected and serviced by qualied personnel.
The manufacturer assumes no responsibility for property damage,
personal injury, or performance issues resulting from failure to
respond appropriately to evidence of leakage or from improper
installation, maintenance, or operation.
25
To appropriate
drain
Overflow Tee
(always oriented upward)
Overflow: optional configuration
using drain pan.
Figure 16. Secondary Condensate Drain
Condensate Drain Water Trap
Do not remove the factory installed exhaust/condensate elbow for
any reason. See
Figure 15
. 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 15
(page
24) and
Condensate Drain Installation
(page 50).
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: 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 50).
COMBUSTIBLE MATERIAL STORAGE
Read instruction manual before installing, using or servicing water
heater.
⚠
WARNING
Fire or Explosion Hazard
Under certain circumstances, the water heater can
explode and catch fire, resulng in property damage,
personal injury, or death.
Do the following to avoid these condions:
• Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
• Avoid all ignion sources if you smell gas.
• Do not expose water heater controls to excessive gas
pressure.
• Use only the gas shown on the water heater rang
label.
• Maintain required clearances to combusbles.
• Keep ignion sources away from faucets aer
extended periods of non-use.
Keep appliance area clear and free of combustible materials,
gasoline and other ammable vapors and liquids.
CONTAMINATED AIR
• 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 instruc�on manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
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
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 30).
AIR REQUIREMENTS
• 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 instruc�on manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
For safe operation an adequate supply of fresh uncontaminated air
for combustion and ventilation must be provided.
An insucient 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.
26
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 Conned Space.
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.
Unconned 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
Confined Space
.
Conned 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, sucient 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.
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 30) for complete venting installation instructions.
Outdoor Air Through Two Openings
Figure 17. Outdoor Air Through Two Openings
The conned space shall be provided with two permanent openings,
one commencing within 12 inches (30 cm) of the top and one
commencing within 12 inches (30 cm) of the bottom of the enclosure.
The openings shall communicate directly with the outdoors. See
Figure 17
.
Each opening shall have a minimum free area of one square inch
per 4,000 Btu/hr (550 mm
2
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 cm
2
).
27
Outdoor Air Through One Opening
Figure 18. Outdoor Air Through One Opening
Alternatively a single permanent opening, commencing within 12
inches (30 cm) of the top of the enclosure, shall be provided. See
Figure 18
. The water heater shall have clearances of at least 1 inch
(2.5 cm) from the sides and back and 6 inches (15 cm) 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:
One square inch per 3000 Btu/hr (700 mm2 per kW) of the total input
rating of all appliances located in the enclosure, and
Not less than the sum of the areas of all vent connectors in the space.
Outdoor Air Through Two Horizontal Ducts
Figure 19. Outdoor Air Through Two Horizontal Ducts
The conned space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (30 cm) of the top and one
commencing within 12 inches (30 cm) of the bottom of the enclosure.
The horizontal ducts shall communicate directly with the outdoors.
See
Figure 19
.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm
2
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.
28
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 30) for complete venting installation
instructions.
Figure 20. Outdoor Air Through Two Vertical Ducts
The conned space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (30 cm) of the top and
one commencing within 12 inches (30 cm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See
Figure 20
.
Each duct opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm
2
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 21. Air From Other Indoor Spaces
The conned space shall be provided with two permanent openings,
one commencing within 12 inches (30 cm) of the top and one
commencing within 12 inches (30 cm) of the bottom of the enclosure.
See
Figure 21
.
Each opening shall communicate directly with an additional room(s)
of sucient 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 mm
2
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 cm
2
).
29
MASSACHUSETTS INSTALLATION REQUIREMENTS
Commonwealth Of Massachusetts
For all side wall terminated, horizontally vented power vent, direct
vent, and power direct vent gas fueled water heaters installed in every
dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the Commonwealth
and where the side wall exhaust vent termination is less than seven
(7) feet above 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 o
248 CMR 5.08(2)
(a) 1 through 4
.
Exemptions
The following equipment is exempt from
248 CMR 5.08(2)(a)1 through 4
:
1. The equipment listed in Chapter 10 entitled “Equipment Not
Required To Be Vented” in the most current edition of
NFPA 54
as
adopted by the Board; and
2. Product Approved side-wall horizontally-vented gas-fueled
equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for
residential purposes.
Manufacturer Requirements - Gas Equipment Venting System
Provided
When the manufacturer of Product Approved side-wall horizontally-
vented gas-fueled equipment provides a venting system design or
venting system components with the equipment, the instructions
provided by the manufacturer for installation of the equipment and
the venting system shall include::
1. Detailed instructions for the installation of the venting-system
design or the venting-system components
2. A complete parts list for the venting-system design or venting
system.
Manufacturer Requirements - Gas Equipment Venting System
Not Provided
When the manufacturer of a Product Approved side-wall
horizontally-vented gas-fueled equipment does not provide the parts
for venting the 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.
30
VENTING INSTALLATIONVENTING INSTALLATION
Breathing carbon monoxide can cause brain damage or death. Always read
and understand instruction manual.
• Install vent system In accordance with codes.
• Do not operate water heater if flood
damaged.
• Install water heater in accordance with the
instrucon manual.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake(s)
with insulang jacket or blanket.
• Do not place chemical vapor eming
products near water heater.
• Install gas and carbon monoxide detectors for
addional safety.
• Never operate the heater unless it is vented
to the outdoors and has adequate air supply
to avoid risks of improper operaon, fire,
explosion or asphyxiaon.
•
Analyze the enre vent system to make sure
that condensate will not become trapped in a
secon of vent pipe and therefore reduce the
open cross seconal area of the vent.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
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 B137.33
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 39)
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system (includes ex)
AL29-4C Stainless Steel
• HeatFab Saf-T Vent
• Duravent FasNSeal
Approved vent pipe materials that must be used in Canada:
• ULC S636 PVC / CPVC
• ULC S636 Polypropylene
• AL29-4C Stainless Steel
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:
• SDR Series ASTM-D2241 or CSA B137.3
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
Polypropylene
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system (includes ex)
AL29-4C Stainless Steel
• HeatFab Saf-T Vent
• Duravent FasNSeal
Where applicable, the installation of the venting system should
be done in accordance with the venting system manufacturer’s
instructions.
Note: The use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel
®
(polyphenolsulfone) in non-metallic venting
systems is prohibited. Covering non-metallic vent pipe and
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 Congurations
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 56
and
Figure 57
(page 46).
Direct Vent Congurations
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 dierent
arrangements. See
Figure 58
through
Figure 64
(page 46).
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 25). 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
31
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
(page 31).
9. Do not install the vent or intake-air piping in a manner that will
allow water to be trapped in the piping.
10. The vent (exhaust) and intake-air piping must be pitched at a
minimum of 2% grade 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
(page 31).
13. Use only factory supplied vent and intake-air, concentric or low
prole terminations. See
(page 31).
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 public walkways or a
public area where condensate or vapor can cause a nuisance
or ice hazard.
17. Ensure that 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
and then proceed to the
Venting Installation
Sequence
(page 35).
32
VENTING REQUIREMENTS
Field Supplied Fittings
Field-supplied ttings should be equivalent to the piping material
being installed. Field-installed/supplied ttings will add equivalent
length to the vent or intake-air piping as indicated below. All eld-
supplied/installed ttings and piping must be factored into the
equivalent length 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 16
(page 40)
and
Table 17
(page 40) 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 tested and certied
to use exhaust vent and intake air pipe diameters of 2”, 3”, 4”, and
6”. See
Table 7
,
Table 8
, and
Table 9
(page 32) for correct pipe
diameter, lengths, and amount of 90˚ and 45˚ bends.
Note: See
Table 16
(page 40)
and
Table 17
(page 40)
for
equivalent linear pipe length of AL29-4C
®
45° and 90° elbows.
There is no minimum equivalent length requirement for the intake
air pipe.
The minimum equivalent length requirement for the exhaust
pipe is 7 feet for all models.
Factory Supplied Fittings
The 119 gallon water heater ships with two (2) factory supplied 4 inch
terminations (PVC 45° elbows with debris screen). If 6 inch intake-air
or vent pipe is installed, factory supplied 6 inch terminations must
be used (PN: 100111626).
The 60 gallon and 100 gallon water heaters ship with two factory
supplied 3 inch terminations (PVC 45 deg elbows with debris screen).
Factory supplied vent and intake-air terminations or concentric and
low prole terminations must be used. If 2 or 4 inch intake-air or vent
pipe is installed, factory supplied terminations must be installed. (PN:
100386033 for 2 inch and 100110909 for 4 inch). Factory supplied
terminations and installed ttings (exhaust elbow and intake-air
connection) add zero equivalent length 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 four-inch or six-inch pipe and four-inch
or six-inch terminations depending on installed length.
Table 7. PVC/CPVC Equivalent Length and
Maximum Number of Elbows - 60 Gallon
Elbow Qty.
(Model BTUs)
Maximum Feet (Meters)
2” Pipe 3” Pipe 4” Pipe
One (1)
(all models)
70 (21.3) 95 (28.9) 145 (44.1)
Two (2)
(all models)
65 (19.8) 90 (27.4) 140 (42.6)
Three (3)
(all models)
60 (18.2) 85 (25.9) 135 (41.1)
Four (4)
(all models)
55 (16.7) 80 (24.3) 130 (39.6)
Five (5)
(all models)
N/A N/A 125 (38.1)
Six (6)
(all models)
N/A N/A 120 (36.5)
Table 8. PVC/CPVC Equivalent Length and
Maximum Number of Elbows - 100 Gallon Models
Elbow Qty.
(Model BTUs)
Maximum Feet (Meters)
2” Pipe 3” Pipe 4” Pipe
One (1)
(150k BTU models)
45 (13.71) 145 (44.20) 195 (59.44)
One (1)
(199k BTU models
35 (10.67) 145 (44.20) 195 (59.44)
One (1)
(250k BTU models)
15 (4.57) 145 (44.20) 195 (59.44)
Two (2)
(150k BTU models)
40 (12.19) 140 (42.67) 190 (57.91)
Two (2)
(199k BTU models
30 (9.14) 140 (42.67) 190 (57.91)
Two (2)
(250k BTU models)
10 (3.05) 140 (42.67) 190 (57.91)
Three (3)
(150k BTU models)
35 (10.67) 135 (41.15) 185 (56.39)
Three (3)
(199k BTU models
25 (7.62) 135 (41.15) 185 (56.39)
Three (3)
(250k BTU models
NA 135 (41.15) 185 (56.39)
Four (4)
(150k BTU models)
30 (9.14) 130 (39.62) 180 (54.86)
Four (4)
(199k BTU models
20 (6.10) 130 (39.62) 180 (54.86)
Four (4)
(250k BTU models
NA 130 (39.62) 180 (54.86)
Five (5)
(150k BTU models)
NA NA 175 (53.34)
Five (5)
(199k BTU models)
NA NA 175 (53.34)
Five (5)
(250k BTU models)
NA NA 175 (53.34)
Six (6)
(150k BTU models)
NA NA 170 (51.82)
Six (6)
(199k BTU models)
NA NA 170 (51.82)
Six (6)
(250k BTU models)
NA NA 170 (51.82)
Table 9. PVC/CPVC Equivalent Length and
Maximum Number of Elbows - 119 Gallon Models
Elbow Qty.
(Model BTU)
Maximum Feet (Meters)
4” Pipe 6” Pipe
One (1)
(all models)
95 (28.9) 145 (44.1)
Two (2)
(all models)
90 (27.4) 140 (42.6)
Three (3)
(all models)
85 (25.9) 135 (41.1)
Four (4)
(all models)
80 (24.3) 130 (39.6)
Five (5)
(all models)
75 (22.8) 125 (38.1)
Six (6)
(all models)
70 (21.3) 120 (36.5)
33
INTAKE AIR CONNECTION
The water heaters covered in this manual are factory equipped with a
unique Combustion Blower and intake-air connection Tee tting. The
Tee is a 3” x 3” x 1/2” tting. The intake-air connection Tee tting has
a hose barb installed in the 1/2 inch branch to connect the Blocked
Intake Air switch sensing tube.
Figure 22. Intake Air Connection (60 Gallon)
Figure 23. Intake Air Connection (100 Gallon))
Figure 24. Intake Air Connection (119 Gallon)
Ensure that the hose barb installed in the Tee tting IS NOT facing
down towards the ground (180° - 6 o’clock position) before venting
installation begins. The barb tting must be angled between 90° and
no more than 130° as shown in
Figure 25 (page 33)
. If the barb tting
is facing down, residual condensate that occasionally forms in the
intake-air pipe can drain into the Blocked Intake Air switch through
the attached sensing tube and damage the switch. This condition
can also lead to Blocked Intake Air fault conditions and associated
control system lockouts.
90° TO 130°
END VIEW
Figure 25. Intake Air Connection Hose Barb Angle Range for Proper
Operation
The intake-air Tee tting is factory-installed with the 1/2 inch branch
and hose barb angled to the right at approximately 130° when viewed
from the end. See
Figure 25
. The Tee tting’s 1/2 inch branch and
hose barb must not be angled any lower (towards the ground) than
this factory specication. Angling higher, up to a 90° position, will
not adversely aect operation and is acceptable.
Large Hose Clamp
Figure 26. Intake Air Tee Fitting - Side View
Inspect/ Adjust Intake Air Tee Fitting
Inspect the angle of the tee tting’s 1/2 inch branch and hose barb
while viewing from the end of the tee. See
Figure 25
. If the angle of
the tee tting 1/2 inch branch and hose barb is lower than shown,
adjustment will be necessary. To adjust the intake-air tee tting angle,
follow the steps listed below.
1. Ensure that the water heater is turned o at the on/o switch on
the front of the water heater.
2. Disconnect the blocked intake-air switch sensing tube. See
Figure
27
for the location.
3. Loosen the large hose clamp on the Fernco coupling that
connects the intake-air connection pipe to the combustion blower.
See
Figure 26
(page 33).
4. Adjust the angle of the tee tting so that the 1/2 inch branch and
hose barb are at the proper angle as shown in
Figure 25
.
5. Re-tighten the large hose clamp on the combustion blower intake-
air Fernco coupling.
34
Blocked Intake
Sensing Tube
Figure 27. Blocked Intake Air Switch Sensing Tube
Required Terminations for Six-Inch Intake Air or Vent Pipe
When a six-inch intake-air or vent pipe is installed using standard
terminations, factory-supplied six-inch terminations must be used.
Contact Technical Support for assistance in ordering six-inch
termination(s). See the contact information label on the water heater.
See
Optional Terminations
(page 19)
for more information.
A
ccessory Inlet Diverter Installation
Kit Part Numbers:
• 60/100 gallon: 100397866
• 119 gallon: 100397867
The intake-air Tee tting is installed with the 1/2 inch branch and
hose barb angled to the right at 90° when viewed from the end.
See
Figure 28
.
90°
Figure 28. Intake Air Connection Hose Barb Angle for Proper
Operation - End View
Inlet Diverter Assembly Installation
To install the intake-air tee tting angle, follow the steps listed below.
1. Ensure that the water heater is turned o at the on/o switch on
the front of the water heater.
2. Disconnect the blocked intake-air switch sensing tube. See
Figure
30
for the location.
3. Loosen the large hose clamp on the Fernco coupling that
connects the intake-air connection pipe to the combustion blower.
See
Figure 29
.
4. Remove the factory installed inlet.
5. Install the inlet diverter assembly.
6. Adjust the angle of the tee tting so that the 1/2 inch branch and
hose barb are at the proper angle as shown in
Figure 28
.
7. Re-tighten the large hose clamp on the combustion blower intake-
air Fernco coupling.
8. Reconnect the block intake-air switch sensing tube.
9. The diverter assembly should be glued in place once the
orientation has been determined.
Large Hose Clamp
Figure 29. Intake Air Tee Fitting - Side View
Blocked Intake
Sensing Tube
Rotate diverter to
required angle
Figure 30. Diverter Assembly Rotation
35
VENTING INSTALLATION SEQUENCE
1. Read
General Venting Instructions
(page 30) and
(page 31)
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 46).
3. Proceed to the applicable installation instructions:
•
Power Vent Installation
(page 35)
or
•
Direct Vent Installation
(page 35).
POWER VENT INSTALLATION
1. Read
General Venting Instructions
(page 30) and
(page 31)
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 termination arrangement will be used for the
installation: vertical or horizontal termination. See
Figure 50
and
Figure 51
(page 44).
3. Determine the vent pipe size for the installation. See
(page 31).
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
36).
If the vent piping will terminate horizontally through a sidewall,
see
Sidewall Termination Installation
(page 38).
PIPE FIELD
SUPPLIED
ALUMINUM
EXHAUST/
CONDENSATE
ELBOW VENT
CONNECTION
FACTORY
INSTALLED
PIPE FIELD
SUPPLIED
REDUCER
FIELD SUPPLIED
VENT (EXHAUST) CONNECTION
Figure 31. 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 ft (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 1/4 in
(7 mm) per foot back to the water heater (to allow drainage of
condensate).
10. 60/100 gallon - If installing three-inch vent pipe, connect the vent
pipe to the exhaust elbow on the water heater. If installing two- or
four-inch pipe, transition to three-inch pipe at the exhaust elbow
on the water heater. The eld-installed three-inch pipe between
the elbow and the reducer coupling should be 18 in (45 cm) or
less in length.
11. 119 gallon - If installing four-inch vent pipe, connect the vent
pipe to the exhaust elbow on the water heater. If installing six-
inch pipe, transition to four-inch pipe at the exhaust elbow on
the water heater. The eld-installed four-inch pipe between the
exhaust elbow and the 6” x 4” reducer coupling should be 18 in
(45 cm) or less in length.
DIRECT VENT INSTALLATION
1. Read
General Venting Instructions
(page 30) and
(page 31)
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
Figure 50
(page 44)
and
Figure 51
(page 44).
3. Determine the vent and intake-air pipe sizes to be used for the
installation. See
(page 31).
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 in-
take-air or vent piping will terminate vertically through a
roof, see
Vertical Termination Installation
(page 36).
• If standard terminations are being used, and the in-
take-air or vent piping will terminate horizontally through
a sidewall, see
Sidewall Termination Installation
(page 38).
• If a low-prole termination will be used, see
Table 18
(page
45).
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 ft (152 cm) of vertical run and every 3 ft (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
drain hoses. See
Figure 32
(page 36).
Note:
Snow being pulled into the intake-air piping and
then melting can lead to excessive amounts of
water accumulation and damage to the 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. The intake-air and vent (exhaust) piping must be pitched a
minimum of 1/4 in (7 mm) per foot back to the water heater (to
allow drainage of condensate).
10. 10. 119 gallon - If installing four-inch vent pipe, connect the vent
pipe to the exhaust elbow on the water heater. If installing six-
inch vent pipe, transition to four-inch pipe at the exhaust elbow
on the water heater. The eld-installed four-inch pipe between
the exhaust elbow and the 6” x 4” reducer coupling should be 18
in (45 cm) or less in length.
38
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 37. Vertical Termination - Direct Vent
SIDEWALL TERMINATION INSTALLATION
1. Determine the location for the termination(s).
2. 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 66
(page 49), 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 66
(page 49), 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
in (61 cm) separation, measured on a vertical center line, between
the intake-air and vent terminations. See
Figure 38
.
Note:
In colder climates, this separation should be increased
to at least 48 in(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 38
.
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
Figure 38. 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 in (0
cm) / touching. The intake-air terminations can also be grouped
together in close proximity - 0 in (0 cm) / touching.
However, the distance between the closest vent and intake-air
terminations must be a minimum of 24 in (61 cm). In colder
climates, this separation should be increased to at least 48 in
(122 cm). See
Figure 38
(page 38).
7. Cut a hole where the pipe(s) will pass through the wall. See
Table
10
(page 37) for the size of the hole needed.
Note:
Beware of concealed wiring and piping when cutting
through the wall.
8. Refer to vent hole size table in previous page.
9. Vent Termination – exhaust gases of this water heater are less
than 140°F (60 C°). 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 in (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 36).
10. Cement the intake-air and/or vent termination to the section(s)
of pipe cut to length in the above step.
11. 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.
12. Working from outside, slide the pipe and termination(s) assembled
in the above steps through the wall. Ensure that the termination(s)
is pointed down towards the ground. See
Figure 39
.
INTERIOR WALL EXTERIOR WALL
FROM
WATER
HEATER
COUPLING
METAL PLATES
INSTALL INSIDE
AND/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 39. Sidewall Termination Installation
39
13. 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.
14. Press the wall plate ush against the outside wall.
15. 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).
16. 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 that the termination(s) is still pointing
down towards the ground. See
Figure 39
.
17. Return to
Power Vent Installation
(page 35) or
Direct Vent Installation
(page 35) to complete the installation of the intake-air and/
or vent piping between the termination(s) and the water heater.
POLYPROPYLENE INSTALLATIONS (RIGID)
The water heaters covered by this manual have been approved to
be installed with Polypropylene vent material as shown in
Table 11
and
Table 12
. 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
,
Table 8
, and
Table
9
(page 32) to determine the maximum pipe length and maximum
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 dierent 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, which allow 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 stien the joints of four-inch and six-inch diameter pipes.
Table 11. 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)
2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90B 2PPS
2PPS-E45B for Exhaust;
2PPS-E45B for Intake (Direct Vent Only)
3” 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90B 3PPS
3PPS-E45B for Exhaust;
3PPS-E45B for Intake (Direct Vent Only)
4” 4PPS-AD PPS-PAC 4PPS-LB 4PPS-E90B 4PPS
4PPS-E45B for Exhaust;
4PPS-E45B for Intake (Direct Vent only)
6” 6PPS-06PVCM-6PPF PPS-PACL 6PPS-LBC 6PPS-E90 6PPS
6PPS-E45 for Exhaust;
6PPS-E45 for Intake (Direct Vent only)
Table 12. 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)
2” ISAGL0202 IAFC02 IANS02 ISELL0287 ISVL02
ISELL0245UV for Exhaust;
ISELL0245UV for Intake (Direct Vent only)
3” ISAGL0303 IAFC03 IANS03 ISELL0387 ISVL03
ISELL0345UV for Exhaust;
ISELL0345UV for Intake (Direct Vent only)
4” ISAGL0404 IAFC04 IANS04 ISEL0487 ISVL04
ISELL0445UV for Exhaust;
ISELL0445UV for Intake (Direct Vent only)
6” ISAGL0606 IAFC06 IANS06 ISEL0687 Polypropylene
ISELL0645UV for Exhaust;
ISELL0645UV for Intake (Direct Vent only)
FLEXIBLE POLYPROPYLENE
All previous notes about polypropylene venting installations apply
to the exible polypropylene.
For use of ex pipe, it is recommended to have the vent material in
32°F (0°C) or higher ambient space before bending at installation.
No bends should be made greater than 45° and ONLY installed in
vertical or near vertical installations. When choosing ex pipe, make
notation of appropriate sizing of ex to any existing B-vent material to
ensure proper t of pipe- i.e. if there exists 4” B-vent material then 2”
or 3” ex would be appropriate for that installation. The approved ex
pipe is intended ONLY for room-air or power-vent conguration and
40
is intended to be a replacement option for those who are replacing
atmospheric or room-air systems.
The approved application of exible polypropylene vent material is
oered by one specic manufacturer (Centrotherm ECO Systems).
These listed products must be installed by following the vent
manufacturer’s instructions. See
Table 15
to determine the maximum
equivalent exible pipe length that can be used (including non-exible
polypropylene). The exible polypropylene MAY only be used with the
appropriate non-exible polypropylene vent system (for Centrotherm
Flexible Polypropylene, Centrotherm InnoFlue SW-
Table 12
.
For approved exible polypropylene venting, refer to
Table 13
and
Table 14
.
Table 13. Centrotherm InnoFlue Flex Vent System Part
Numbers
(other components)
Description Part Number
Universal B-Vent Cap IAUBVC
B-Vent Support Bracket IABVSB
Table 14. Centrotherm InnoFlue Flex Vent System Part Numbers
Nominal
Pipe
Diameter
Vent
Length
SW to Flex
Coupler
Flex to SW
Coupler
Flex to Flex
Coupler B-Vent Kits
B-Vent Compo-
nent Kits
Flex End
Pipe
Base Sup-
ports
2” IFVL02 IFSFC02 IFFSC02 IFFFC02 IFBK02 IFBKC02 IFEP02 ISBS02
3" IFVL03 NA IFFSC03 IFFFC03 IFBK03 IFBKC03 IFEP03 ISBS03
4" IFVL04 NA IFFSC04 IFFFC04 IFBK04 IFBKC04 IFEP04 ISBS04
Table 15. Centrotherm InnoFlue Polypropylene (Flex) Equivalent
Length
Model
Maximum Number of Feet (Meters)
2” Pipe 3” Pipe 4” Pipe
100/120 /145 45 (13.71) 100 (30.48) 150 (45.72)
150 /199 /250 --- 70 (21.33) 200 (60.96)
251/300/400/500 --- --- 100 (30.48)
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 16
and
Table 17
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 32) for the maximum and minimum
equivalent linear vent lengths and number of elbows that may be
used. However, see
Table 16
and
Table 17
below to nd the appropriate
equivalent linear vent lengths for the AL29-4C
®
elbows.
Note: The equivalent lengths of the AL29-4C
®
elbows are dierent
than those from smooth walled plastic vents. See
Table 16
and
Table 17
for the correct equivalent linear vent lengths.
Listed vent systems composed of AL29-4C
®
must not mix parts from
the dierent 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 can be installed using the
approved vent terminations shown in this manual. This means that,
the installer must use the adapter listed in
Table 16
and
Table 17
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 16. HeatFab Saf–T Vent AL29-4C
®
Vent System Parts
Dia.
Flue
Outlet
Adapter
*Straight
Pipe (3’
Section)
45°
Elbow
Equivalent
Linear
Length, 45°
Elbow
90°
Elbow
Equivalent
Linear
length, 90°
Elbow
Adapter to
PVC
3”
9301
PVC
9307 9311
5 ft
(178 cm)
9314
10 ft
(305 cm)
9353CPVC
4"
9401
PVC
9407 9411
5 ft
(178 cm)
9414
10 ft
(305 cm)
9454CPVC
6"
9601
PVC
9607 9611
5 ft
(178 cm)
9614
10 ft
(305 cm)
9656CPVC
*Consult vent manufacturer’s catalog for other available lengths.
Table 17. Duravent FasNSeal AL29-4C® Vent System Parts
Dia.
Flue Outlet
Adapter
*Straight
Pipe
(3’ Section)
45° Elbow
Equivalent
Linear
Length,
45° Elbow
90° elbow
Equivalent
Linear
Length, 90°
Elbow
Adapter to
PVC
3” 810005378 FSVL3603 FSELB4503
5 ft
(178 cm)
FSELB9003
10 ft
(305 cm)
810009530
4" 810005545 FSVL3604 FSELB4504
5 ft
(178 cm)
FSELB9004
10 ft
(305 cm)
810009529
6" 810005225 FSVL3606 FSELB4506
5 ft
(178 cm)
FSELB9006
10 ft
(305 cm)
810005572
*Consult vent manufacturer’s catalog for other available lengths.
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.
41
CONCENTRIC TERMINATION INSTALLATION
Concentric terminations must be ordered separately.
• The 100k - 250k BTU/h models must use the four-inch
concentric termination, Part Number: 100111100, for both
three-inch and four-inch vent diameters or the two-inch
terminal (100112869) for two-inch diameter pipe.
• The 251k-500k BTU/h models must use the six-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.
1. Determine the location for the termination.
Note:
Roof termination is preferred since it is less susceptible
to damage, has reduced risk of intake contaminants,
and vent vapors are less visible.
2. When installing a concentric termination vertically through the
roof, ensure that all exterior vertical clearance requirements for
the concentric termination shown in
Figure 40
and
Figure 43
(page
42) are being maintained. These clearances and those cited
by local and national codes must be maintained.
3. When installing a concentric termination vertically through a at
roof, the termination’s vent cap must be a minimum of 10 ft (3
m) away from any parapet, vertical wall, or structure as shown
in
Figure 40
.
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
36).
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
Figure 40. Concentric Termination - Flat Roof Parapet Clearance
4. When installing a concentric termination through a sidewall,
ensure that all exterior sidewall clearance requirements for the
termination shown in
Figure 66
(page 49) are being maintained.
These clearances and those cited by local and national codes
must be maintained.
5. When installing multiple concentric terminations vertically through
a roof or horizontally through a sidewall, ensure that the required
clearances between terminations and groupings of multiple
terminations are maintained. See
Multiple Concentric Termination
Clearances
(page 42)
for more information.
6. Cut a 7 in (18 cm) diameter hole for six-inch concentric
terminations where they will pass through the wall or roof. Cut a 5
in (13 cm) diameter hole for the four-inch concentric terminal or a
3 in (7.6 cm) hole for the two-inch terminal, where the termination
will pass through the wall or roof.
Note:
Beware of concealed wiring and piping when cutting
through the wall or roof.
7. 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
42).
8. Determine if the concentric termination will need to be shortened
to accommodate required clearances or to ensure that all
vent caps are at the same height when installing multiple
terminations vertically through the roof in the same location.
See
Figure 41
and
Figure 42
for the minimum lengths allowed for
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 o of the smaller (vent) pipe.
Note:
Lengthening of the Concentric Vent Termination is not
permitted.
VENT PIPE
INTAKE AIR CONNECTION
VENT CONNECTION
INTAKE AIR PIPE
Y FITTING ASSEMBLY
VENT CAP
VENT PIPE ASSEMBLY
MINIMUM ALLOWABLE LENGTH 25 INCHES (64 cm)
INTAKE AIR PIPE MAY BE SHORTENED
MINIMUM ALLOWABLE LENGTH 12 INCHES (30 cm)
VENT CAP
INTAKE AIR PIPE
Y FITTING
VENT PIPE MAY BE SHORTENED
Figure 41. Concentric Termination Kit - 60/100 Gallon
9. Assemble and install the concentric termination. See
Figure 42
,
Figure 43,
and
Figure 44
for these instructions.
42
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 42. Concentric Termination Kit - 119 Gallon
10. Cement the Y tting to the larger diameter intake-air pipe.
11. 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.
12. Secure the intake-air Y-tting assembly using eld-supplied metal
strapping or equivalent support materials.
13. On installations installed through the roof, slide a eld-supplied
plumbing boot or roof flashing over the intake-air Y-fitting
assembly and secure it to the roof.
14. Seal around the plumbing boot or roof ashing.
15. Cement the vent cap onto the vent pipe. Alternately a eld-
supplied stainless-steel screw can be used to secure the two
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.
16. Install the vent cap/vent pipe assembly into the intake-air Y-tting
assembly. Ensure that the small-diameter vent pipe is cemented
and bottomed in the Y tting.
17. Connect the intake-air and vent piping from the water heater to
the six-inch concentric termination using eld-supplied reducer
couplings as needed. Cement all ttings and pipe in place. Use
the appropriate method for connecting intake-air and vent piping
to the terminations as follows:
• For two-inch installations, connect the pipe directly to the
two-inch termination.
• For three-inch installations, connect the pipe directly to
the three-inch termination. Do not mix dierent pipe and
termination sizes.
• For four-inch pipe installations, connect the piping to the
concentric termination using eld-supplied 4” x 3” reduc-
er coupling and short sections of three-inch pipe 18 in
(45 cm) or less.
Do not exceed the maximum equivalent vent length in
Table 7
,
Table 8
, and
Table 9
(page 32).
18. Return to
Direct Vent Installation
(page 35) 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
Figure 43. Concentric Termination - Vertical 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 44. Concentric Termination - Sidewall Installation
Multiple Concentric Termination Clearances
When installing multiple concentric terminations vertically through
a roof or horizontally through a sidewall, ensure that 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 45
(page 43)
through
Figure 49
(page 43)
must be maintained.
43
Close Proximity & Standard Clearance
1. The clearance between multiple termination caps must be 0 cm
(0 in) / touching to a maximum of 2 in (5 cm), dimension A -
Figure
45
, when installing concentric terminations in close proximity. See
Figure 45
through
Figure 49
.
2. The clearance between multiple termination caps must be
increased to a minimum of 24 in (61 cm), dimension B -
Figure
45
, 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 45. Two Concentric Terminations
Three Concentric Terminations
1. When installing three concentric terminations through a roof or
through a sidewall, the third termination can be installed in close
proximity as indicated by dimension A in
Figure 46
.
2. If close-proximity installation of the third termination is not
possible, the third termination can be installed as indicated by
dimension B in
Figure 46
.
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 46. Three Concentric Terminations
Four Concentric Terminations
1. When installing four concentric terminations through a roof or
through a sidewall in close proximity, they can be arranged into
stacked rows of two, as shown in
Figure 47,
or lateral rows of two
as shown in
Figure 48
.
2. Four is the maximum number of concentric terminations that
can be installed in a group where all terminations are in close
proximity as shown in
Figure 47.
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 47. 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 48. 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 52
(page 44). Lateral groups of four as shown in
Figure 49
can 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 49. Eight Concentric Terminations
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 42) 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 as measured from the ground.
Two Concentric Terminations
Two concentric terminations can be installed in close proximity as
shown in
Figure 50
or with standard clearances when this arrangement
is not possible. See
Figure 45
(page 43) for detailed information
44
on clearances. See
Figure 46
(page 43) when installing three
concentric terminations.
SIDEWALL
ROOF
Figure 50. Two Concentric Terminations - Sidewall and Roof
Four Concentric Terminations
Four concentric terminations can be installed in close proximity as
shown in
Figure 51
. See
Figure 47
(page 43)
and
Figure 48
(page 43)
for detailed information on clearances and additional arrangement
options.
SIDEWALL
ROOF
Figure 51. Four Concentric Terminations - Sidewall and Roof
Eight Concentric Terminations
Eight concentric terminations can be installed in two stacked groups
of four, in close proximity, as shown in
Figure 43
. See
Figure 43
(page
42) for detailed information on clearances.
Lateral groups of four as shown in
Figure 42
(page 42) can be a more
convenient installation arrangement for multiple groups depending
on available space.
SIDEWALL
ROOF
Figure 52. 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
.
1. Once the proper location has been determined, cut two holes in
the wall large enough to accommodate the pipe. Pipe diameters
and distance between hole centers can be found in
Table 18
(page 45).
2. Slide both the intake and exhaust pipes through the holes. Solvent
cement to 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.
3. To fasten the base to the wall, use the supplied screws and
anchors. A 3/16 in (5 mm) hole, 1-3/16” (30mm) deep, will need
to be drilled for the anchors. Locate the anchor hole using the
base as a template.
4. Screw the Cap to the Base using the supplied screws.
5. 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.
6. All vent pipes and air inlets must terminate at the same height to
avoid possibility of severe personal injury, death, or substantial
property damage.
45
7. Operate heater through one heat cycle to ensure combustion-
air and vent pipes are properly connected to concentric vent
termination.
Figure 53. Inlet and Vent Flow in Low Profile Installation
Figure 54. Inlet and Vent Flow in Low Profile Vent Installation
Figure 55. Multiple Low Prole Vent Clearances
Table 18. Low Prole Termination Kits - Dimensions
Kit Number
IPEX
Part Number Description
Pipe Outside
Diameter
Hole Spacing
(Center to Center)
100086241 196984 2” Flush Mount Vent Kit 2.375 in (6 cm) 5.63 in (14.3 cm)
100187887 196985 3” Flush Mount Vent Kit 3.5 in (8.9 cm) 5.63 in (14.3 cm)
100187888 196986 4" Flush Mount Vent Kit 4.50 in (11.4 cm) 5.63 in (14.3 cm)
100187889 196080 6" Flush Mount Vent Kit 6.61 in (16.8 cm) 7.63 in (19.4 cm)
Table 19. Each Low Prole Termination Kit Contains
Qty Item Description
1 Base (two holes)
1 Cap (one hole)
8 Stainless Steel Screws
4 Plastic Anchors
46
VENTING ARRANGEMENTS
Figure 56. Power Vent Vertical
Figure 57. Power Vent Horizontal
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 58. Direct Vent Vertical
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 59. Direct Vent Horizontal
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 60. Direct Vent Vertical Vent
Horizontal Intake
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
*
Figure 61. 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 36).
47
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 62. Direct Vent Vertical Concentric
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 63. Direct Vent Horizontal Concentric
*
*
Enlarged View of
Direct Vent Air Intake
Moisture Protection
Figure 64. Direct Vent Horizontal Low-Profile
*Direct Vent combustion air intake drains are required in certain situations. See
Direct Vent Air Intake Moisture Protection
(page 36).
48
TERMINATION CLEARANCES SIDEWALL POWER VENT
Fixed
Closed
Operable
Fixed
closed
Operable
B
V
V
V
V
V
V
V
V
C
B
B
X
A
M
K
Regulator vent outlet
In the event no
regulator is present,
H and I can be
disregarded
.
V
Legend:
= Vent terminal
X
= Air supply inlet
= Area where terminal is not permitted
B
B
J
F
X
B
L
E
D
Inside
corner detail
V
A
G
H
15 ft
I
Figure 65. 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 appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW),
• 36 in (91 cm) for appli-
ances > 100,000 Btuh
(30 kW)
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 9 in (23 cm) for appli-
ances >10,000 Btuh (3
kW) and ≤ 50,000 Btuh
(15 kW)
• 12 in (30 cm) for appli-
ances > 50,000 Btuh
(15 kW)
C Clearance to
permanently closed
window
12 inches (30 cm)* 12 inches (30 cm)*
D Vertical clearance
to ventilated sot
located above the
terminal within a
horizontal distance
of 2 feet (61 cm)
from the center line
of the terminal
12 inches (30 cm)* 12 inches (30 cm)*
E Clearance to unven-
tilated sot
12 inches (30 cm)* 12 inches (30 cm)*
F Clearance to out-
side corner
2 feet (60 cm)* 2 feet (60 cm)*
G Clearance to inside
corner
18 inches (45 cm)* 18 inches (45 cm)*
Termination Clearances for Sidewall Power Vent
Type of Clearance Canadian Installations
1
US Installations
2
H Clearance to each
side of center line
extended above
meter/regulator
assembly
3 ft (91 cm) within a
height of 15 ft (4.6 m)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
I
Clearance to service
regulator vent outlet
3 ft (91 cm)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
J
Clearance to a non
mechanical air sup-
ply inlet into building
or combustion air
inlet to any other
appliance
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW)
• 36 in (91 cm) for appli-
ances >100,000 Btuh
(30 kW)
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 9 in (23 cm) for appli-
ances >10,000 Btuh (3
kW) and ≤ 50,000 Btuh
(15 kW)
• 12 in (30 cm) for appli-
ances > 50,000 Btuh
(15 kW)
K Clearance to a me-
chanical air supply
inlet
6 feet (1.83 m)
3 feet (91 cm) above
if within 10 feet (3 m)
horizontally
L
Clearance above
paved sidewalk or
paved driveway
located on public
property
7 feet (2.13 m)†
7 ft (2.13 m) for me-
chanical draft systems
(Category I appliances);
vents for Category II and
IV appliances cannot
be located above public
walkways or other areas
where condensate or va-
por can cause a nuisance
or hazard
M Clearance under
veranda, porch,
deck, or balcony
12 inches (30 cm) ‡ 12 inches (30 cm) ‡
1. In accordance with the current
CSA B149.1, Natural Gas and Propane Installation Code
.
2. In accordance with the current
ANSI Z223.1/NFPA 54, National Fuel Gas Code
.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings where it can cause
hazardous frost o ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions
49
TERMINATION CLEARANCES SIDEWALL DIRECT VENT
Fixed
Closed
Operable
Fixed
closed
Operable
B
V
V
V
V
V
V
V
V
C
B
B
X
A
M
K
Regulator vent outlet
In the event no
regulator is present,
H and I can be
disregarded
.
V
Legend:
= Vent terminal
X
= Air supply inlet
= Area where terminal is not permitted
B
B
J
F
X
B
L
E
D
Inside
corner detail
V
A
G
H
15 ft
I
Figure 66. Sidewall Direct Vent Using Outside Air
Termination Clearances for Sidewall Direct Vent
Type of Clearance
Canadian Installations
1
US Installations
2
A Clearance above
grade, veranda,
porch, deck or
balcony
12 inches (30 cm) 12 inches (30 cm)
B
Clearance to window
or door that may be
opened
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW),
• 36 in (91 cm) for appli-
ances > 100,000 Btuh
(30 kW)
• 4 feet (1.2 m) below or
to side of opening;
• 1 foot (30 cm) above
opening
C Clearance to perma-
nently closed window
6 inches (15 cm)* 6 inches (15 cm)*
D Vertical clearance to
ventilated sot locat-
ed above the terminal
within a horizontal
distance of 2 feet (61
cm) from the center
line of the terminal
12 inches (30 cm) 12 inches (30 cm)
E Clearance to unventi-
lated sot
12 inches (30 cm) 12 inches (30 cm)
F Clearance to outside
corner
2 feet (60 cm)* 2 feet (60 cm)*
G Clearance to inside
corner
18 inches (45 cm)* 18 inches (45 cm)*
Termination Clearances for Sidewall Direct Vent
Type of Clearance
Canadian Installations
1
US Installations
2
I
Clearance to service
regulator vent outlet
3 ft (1.83 m)
Clearance in accordance
with local installation
codes and the require-
ments of the gas supplier
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
• 6 in (15 cm) for appli-
ances ≤ 10,000 Btuh
(3 kW)
• 12 in (30 cm) for appli-
ances > 10,000 Btuh
(3 kW) and ≤ 100,000
Btuh (30 kW)
• 36 in (91 cm) for appli-
ances >100,000 Btuh
(30 kW)
• 4 feet (1.2 m) below or
to side of opening;
• 1 foot (30 cm) above
opening
K Clearance to a
mechanical air supply
inlet
6 feet (1.83 m)
3 feet (91 cm) above
if within 10 feet (3 m)
horizontally
L
Clearance above
paved sidewalk or
paved driveway locat-
ed on public property
7 feet (2.13 m)†
7 ft (2.13 m) for me-
chanical draft systems
(Category I appliances);
vents for Category II and
IV appliances cannot
be located above public
walkways or other areas
where condensate or va-
por can cause a nuisance
or hazard
M Clearance under
veranda, porch, deck,
or balcony
12 inches (30 cm) ‡ 12 inches (30 cm) ‡
1 In accordance with the current
CSA B149.1, Natural Gas and Propane Installation Code.
† 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 oor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
50
INSTALLING THE WATER HEATERINSTALLING THE WATER HEATER
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 standos 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. 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.
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 that 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 67
.
3. Terminate the condensate drain piping near the drain. See
Figure
67
(page 50).
Note:
In cold climates it is recommended the condensate
drain be terminated at a suitable drain inside the
building.
4. Ensure that the condensate drain line is not elevated above the
condensate drain connection on the exhaust/condensate elbow.
See
Figure 67
.
5. Brace the condensate drain line with oor mounted standos at
intervals of 3 ft (1 m).
6. Ensure that the condensate drains freely during start up. See
Start Up
(page 56).
7. Condensate clean out cap must be on and tight when unit is in
operation.
CONDENSATE DRAIN
LINE - FIELD INSTALLED
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 67. Condensate Drain Installation
LEAK DETECTION MODULE INSTALLATION
The water heaters covered by this manual have a water leak
detection feature that senses the buildup of water in the vicinity of
the appliance setting o alarm to alert the end user. Please follow
installation instructions in included kit.
Note: Must be installed prior to start up.
Sensor
(Inside Drain Pan)
Drain Pan
Wire Mounts
Connector
Lower Door
Figure 68. Leak Detection Module Installation
51
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 sucient 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.
• Do not use water heater with any gas other than
the gas shown on the rang label.
• Excessive gas pressure to gas valve can cause
serious injury or death.
• Turn off gas lines during installaon.
• Contact a qualified installer or service agency for
installaon and service.
⚠
WARNING
Fire and Explosion Hazard
Make sure gas supplied is same type listed on the water heater’s
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. (3.49 kPa) for natural
and propane gas supply pressure. See
Table 5
(page 18). 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 replaced.
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 69. Supply Gas Line Installation
Ensure that 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 69
. 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 4 (page 18)
and
Table 5
(page 18). 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 20
(page
51) and
Table 21
(page 52). The values given in
Table 20
and
Table 21
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.
Table 20. Supply Gas Line Sizing U. S. Units
Length in
Feet
Normal Iron Pipe Sizes (Inches)
Input In Thousands Btu/Hr
1/2” 3/4” 1” 1 1/4” 1 1/2” 2”
10 175 360 680 1400 2100 3960
20 120 250 485 950 1460 2750
30 97 200 375 770 1180 2200
40 82 170 320 660 990 1900
50 73 151 285 580 900 1680
60 66 138 260 530 810 1520
70 61 125 240 490 750 1400
80 57 118 220 460 690 1300
90 53 110 205 430 650 1220
100 50 103 195 400 620 1150
125 44 93 175 360 550 1020
150 40 84 160 325 500 950
175 37 77 145 300 460 850
200 35 72 135 280 430 800
52
Table 21. Supply Gas Line Sizing Metric Units
Length In
Meters
Normal Iron Pipe Sizes (inches)
Input in kW
1/2” 3/4” 1” 1 1/4” 1 1/2” 2”
3.0 51 105 199 410 615 1160
6.1 35 73 142 278 428 805
9.1 28 59 110 225 346 644
12.2 24 50 94 193 290 556
15.2 21 44 83 170 264 492
18.3 19 40 76 155 237 445
21.3 18 37 70 143 220 410
24.4 17 35 64 135 202 381
27.4 16 32 60 126 190 357
30.5 15 30 57 117 182 337
38.1 13 27 51 105 161 299
45.7 12 25 47 95 146 278
53.3 11 23 42 88 135 249
61.0 10 21 40 82 126 234
Gas Line Connection
The water heaters covered by this manual are shipped from the
factory with a supply gas connection. See
Table 4
(page 18).
Connect the supply gas line to the water heater’s Gas Valve in
accordance with all applicable local and national code requirements.
See
Figure 70
(page 52).
1. The 60-gallon and 100-gallon gas models require a 3/4” NPT
minimum supply gas line. The 119-gallon natural gas models
require a 1 1/4”NPT minimum supply gas line
Gas Line Sizing
for additional information.
2. Apply thread sealing compounds (pipe dope/ thread-sealer 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 thread-sealer tape marked as being resistant to the action of
liquid petroleum (LP/propane) gases.
3. 3. Use only a smooth jaw adjustable wrench (such as a monkey
wrench) as a back up on the body of the 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.
4. 4. 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 Gas Valve on
water heater from twisting during installation.
5. 5. To prevent damage, care must be taken not to apply too much
torque when connecting the supply gas line to the water heater.
6. 6. Install a sediment trap as shown in
Figure 69
(page 51).
7. Install a Main Gas Shuto valve in the supply gas line as shown
in
Figure 69
(page 51).
Note:
If overheating occurs or the gas supply fails to shut o,
turn o the Main Gas Shuto valve to the water heater.
Gas Valve
Supply Gas Pressure Test Port
Gas
Connection
Venturi
Manifold Gas Pressure
Test Port (Non Adjustable)
Combustion Air Inlet
Figure 70. 60 Gallon PX52 - Supply Gas Line Connection
Gas
Valve
Supply Gas Pressure
Test Port
Gas
Connection
Venturi
Manifold Gas Pressure
Test Port (Non Adjustable)
Combustion Air Inlet
Figure 71. 100 Gallon VK - Supply Gas Line Connection
Gas Connection
Manifold Gas Pressure
Test Port (Non Adjustable)
Figure 72. 119 Gallon - Supply Gas Line Connection
53
GAS LINE LEAK TESTING
• Use joint compound or thread sealer tape compable
with propane gas.
• Leak test gas connecons
before placing the water heater in operaon.
• Disconnect gas piping at main gas shutoff valve before
leak tesng.
• Install sediment trap in accordance
with NFPA 54 or CAN/CSA B149.1.
⚠
WARNING
Fire and Explosion Hazard
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 0.5 psi (3.45 kPa) disconnect the
water heater and its Main Gas Shuto Valve from the gas supply
piping system during testing. See
Figure 50
(page 44). The gas
supply line must be capped when disconnected from the water
heater.
2. For test pressures of 0.5 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 Shuto Valve during testing.
3. Paint all supply gas line joints and connections upstream of the
water heater with a with a chloride-free liquid leak detection
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. Turn o gas supply and 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, replacement harnesses are available through Service
Parts.
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: Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and are
required when installing the water heater
NFPA 70, CSA C22.1
and
UL 943
.
Power Supply Connections
See the requirements for the
Power Supply
(page 21)
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 73
.
Power supply connections must be made as follows:
1. Turn o the enable/disable switch to disable heating operation.
2. Turn o power to the water heater at the breaker that supplies
power to the water heater.
3. Remove the junction box cover. See
Figure 5,
Figure 6
and
Figure
7
(pages 11 through 13) for junction box location.
4. Connect the 120 VAC hot wire from the power supply to the
black jumper wire or the terminal block location marked “L1”
inside of the junction box located on top of the water heater. If
the black jumper wire is used, make the connection inside of the
junction box with a properly sized wire nut and wrap electrical
tape around the wire nut and wire end. See
Figure 73 (page 54)
and wiring diagrams,
Figure 88 (page 102)
,
Figure 89 (page 103)
,
and
Figure 90 (page 104)
.
5. 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
Figure 73 (page 54)
and wiring diagrams,
Figure 88 (page 102)
,
Figure 89 (page 103)
,
and
Figure 90 (page 104)
.
Note:
If electrical connections are made directly to the
terminal block remove the jumper wires before making
connection.
6. 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
Figure 73 (page 54)
and wiring diagrams,
Figure 88 (page 102)
,
Figure 89 (page 103)
, and
Figure 90 (page
104)
.
7. 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.
54
Heater Wiring
(factory installed)
MOV Ground
Ground Terminal
Jumper Wire
L1
Neutral
Figure 73. Power Supply Connections
Note: Ensure that 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.
External Enable-Disable Circuit
The water heaters covered in this manual are equipped with an
enable disable circuit for use with eld-supplied 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 “use External Enable” from the UIM. Field support wiring
is then installed between the water heater’s controls and a set of dry
contacts (no voltage or load) on the eld-supplied external control.
See the wiring diagrams,
Figure 88 (page 102)
,
Figure 89 (page 103)
,
and
Figure 90 (page 104)
.
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 22).
2.
Dish-washing Machines
(page 22).
3.
Temperature-Pressure Relief Valve
(page 22).
4.
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. For multiple water heater installations, see
Water Piping Diagrams
(page 105).
Water Piping Diagrams
This manual provides detailed water piping diagrams for typical
methods of application for the water heaters. See
Water Piping Diagrams
(page 105).
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 105).
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.
Thermometers
Thermometers (not supplied) 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 105).
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 22).
5. These water heaters cannot be used in space heating applications
only.
T&P Valve Discharge Pipe
To avoid this hazard, you must install a properly-
sized temperature-pressure relief valve in opening
provided.
• The temperature-pressure relief valve must
comply with
and ASME
code.
• Do not plug, block, or cap the discharge line.
⚠
WARNING
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 22) for
information on replacement and other requirements.
55
Property Damage Hazard
While the water heater is in roune operaon, it can
release hot water from the temperature-pressure relief
valve discharge pipe in quanes that could cause
damage to the surroundings.
Locate the water heater near an adequate drain and
in an area where water from the temperature-pres-
sure relief valve discharge pipe will not result in
damage to the area of the lower floors of the
structure.
⚠
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.
56
START UPSTART UP
PRIOR TO START UP
Installation and start up of this water heater requires abilities and
skills equivalent to that of a licensed tradesman in the eld involved,
see
Qualifications
(page 8).
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 60.
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 Gas Valve, Main Burner ignition,
and ame sensing. See
Control System Operation
(page 65)
.
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
83).
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. It is recommended to purge air from the furthest
hot water xture preferably at the highest point. 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. Follow the steps in
Start Up
(page 56).
INITIAL START UP AND AIQ™ CALIBRATION
At the initial start up of the water heater, the gas type will be
selected and an initial calibration routine must run. AiQ™ aligns
the combustion system during calibration and veries ame signal
detection. AiQ acts as the water heater’s built-in start-up checklist
that is designed to protect performance and eciency. This initial
calibration may take up to 15 minutes. During this initialization, any
burner heat demand will be blocked.
Initial calibration should be performed if a unit has NEVER completed
a calibration, after installation, or after parts have been changed. If
the Main Menu and/or “uncalibrated” appears on the display, power
cycle the heater to have this initial calibration appear. Calibration is
critical for eciency and overall performance. During calibration, the
Combustion Safety Control (CSC) monitors the system for a proper
ame, which depends on intake air piping, exhaust piping, and the
quality of the supplied fuel.
Calibration Steps
1. Power on the water heater - After installation is complete, power
up the unit.
2. Enable the heater to start calibration. Follow the steps in
Gas Type
Calibration
(page 57).
3. Calibration completion:
• If successful, the heater enters normal operation.
• If unsuccessful after 15 minutes: The heater will lock out
with an error code. The common error codes are: “Cali-
bration Error” and “Ignition Failure.”
If Calibration Does Not Complete:
Common causes of calibration failure and/or ignition failure are:
Component issues
• Dirty burner - caused from new construction debris
• Gas valve assembly
• Igniter gap out of specication
• Flame sensor misaligned
• Loose or disconnected wiring
Installation deciencies
• Insucient gas volume or pressure
• Incorrect exhaust vent pipe
• Incorrect intake air pipe
After calibration, the continuous monitoring function becomes active.
This function can trigger a new calibration in case a gas quality
change is detected or there is a manual intervention by a qualied
service technician.
Troubleshooting Failed Calibration
• Evaluate the installation thoroughly before attempting
another calibration.
• Correct installation deciencies before replacing compo-
nents.
• If “Uncalibrated” appears in the upper left part of the dis-
play, cycle main power to reach the calibration screen.
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; -20.00 to + 20.00”
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.
57
GAS TYPE CALIBRATION
At the initial start up of the heater the gas type selection screen
will appear. Please insure the correct gas type is selected when
starting the calibration process. This initial calibration may take up
to 15 minutes.
During this initialization, any burner heat demand will be blocked.
After calibration, the continuous monitoring function becomes active.
This function can trigger a new calibration in case a gas quality
change is detected or there is a manual intervention by the qualied
service technician.
1. Select the correct gas type upon startup.
SELECT FUEL TYPE
CONFIRM
BACK
NATURAL GAS
PROPANE GAS
1. Click ‘Conrm’ to proceed with the calibration.
Please press confirm to start the calibration.
Calibration
CONFIRM
BACK
2. Set the date and time, then click Conrm to continue with the
calibration.
Calibration will begin and progress screen will display.
DATE/TIME
MONTH DAY YEAR HOURS MINUTES AM/PM
4
28
2025
/ /
12
53
PM
- :
1 2 3
TAB
4 5 6
7 8 9
0
CONFIRM
CANCEL
3. The calibration process will begin and show its progress on the
screen.
Note:
Calibration may take up to 15 minutes.
Calibrating
(May take up to 15 minutes)
Calibration
CONFIRM
BACK
58
4. When the calibration is complete, click BACK to return to the
home screen.
Calibration Complete
Calibration
CONFIRM
BACK
START UP CONDITIONS
Smoke/Odor
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning o of oil from metal
parts, and will disappear in a short while.
THERMAL EXPANSION
CAUTION
Property Damage Hazard
• Fill tank with water before operang.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold water inlet.
• Contact qualified installer or service agency.
Water supply systems may, because of such events as high line
pressure, frequent cut-os, the eects of water hammer among
others, have installed devices such as pressure reducing valves,
check valves, back ow preventers, etc. to control these types of
problems. When these devices are not equipped with an internal
by pass, and no other measures are taken, the devices cause the
water system to be closed. As water is heated, it expands (thermal
expansion) and closed systems do not allow for the expansion of
heated water.
The water within the water tank expands as it is heated and increases
the pressure of the water system. If the relieving point of the water
heater’s temperature-pressure relief valve is reached, the valve will
release excess pressure. The temperature-pressure relief valve is
not intended for the constant relief of thermal expansion. This is an
unacceptable condition and must be corrected. It is recommended
that any devices installed which could create a closed system have
a by-pass and/or the system have an expansion tank or device to
relieve the pressure built by thermal expansion in the water system.
Expansion tanks are available for ordering through a local plumbing
contractor. Contact the local water heater supplier or qualied service
agency for assistance in controlling these situations.
OPERATIONAL CONDITIONS
Do not remove the powered anode rod leaving the tank unprotected.
By doing so, all warranty on the water heater tank is voided.
Having the 120 v power to the water heater turned o for extended
periods of time also leaves the tank unprotected and can void the
warranty.
Air In Hot Water Faucets
Flammable hydrogen gases can form in water pipes.
The hydrogen can explode if it is exposed to flame and
can cause severe injury or death.
Keep all igni�on sources away from faucet when
turning on hot water.
⚠
WARNING
Explosion Hazard
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely ammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances
which are connected to the hot water system are used (such as a
dishwasher or washing machine). If hydrogen gas is present, there
will probably be an unusual sound similar to air escaping through the
pipe as the hot water faucet is opened. There must be no smoking
or open ame near the faucet at the time it is open.
START-UP PROCEDURE
1. Using the control system menus, change the Operating Set
Point to the lowest temperature setting. See
Operating Set Point
and Differential Adjustment
(page 67) .
2. Turn the water heater’s Enable/Disable switch to the “Disable”
position.
3. Close the Main Gas Shut O Valve.
4. Wait ve minutes for any residual gas to clear.
5. Connect manometer to the supply gas pressure port on the gas
valve.
6. 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 (do
not fully remove the needle valve), then 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 74
.
7. Slowly open the supply gas isolation valve.
8. Purge the manometer tubing before taking any readings.
59
9. Measure and record the supply gas pressure, this is a “static”
supply gas pressure reading; while the water heater is not ring.
When applicable, adjust the supply gas pressure at the gas supply
regulator for the water heater See
Supply Gas Pressure Adjustment
(page 61).
Note: The manometer tubing should be purged before taking any
readings.
Gas Valve
Supply Gas Pressure Test Port
Gas
Connection
Venturi
Manifold Gas Pressure
Test Port (Non Adjustable)
Combustion Air Inlet
Figure 74. 60 Gallon_PX52 - Gas Valve Assembly
Gas
Valve
Supply Gas Pressure
Test Port
Gas
Connection
Venturi
Manifold Gas Pressure
Test Port (Non Adjustable)
Combustion Air Inlet
Figure 75. 100 Gallon VK - Gas Valve Assembly
Manifold Pressure
Test Port
(Non Adjustable)
Supply Gas Pressure
Test Port
Figure 76. 119 Gallon - Gas Valve Assembly
60
LIGHTING THE WATER HEATER
The instruction label below is axed to the water heaters that are covered by this manual at the factory and must be followed when lighting
and operating the water heater.
FOR YOUR SAFETY READ BEFOR 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.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED
WITH WATER AND AIR PURGED FROM ALL LINES
This appliance does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
BEFORE OPERATING, smell all around the appliance
area for gas. Be sure to smell next to the floor because
gas is havier than air and will settle to the floor.
A.
B.
“WHAT TO DO IF YOU SMELL GAS”
• Do not try to light the appliance.
• Do no touch any electrical switch; do not use
any telephone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you connot reach your gas supplier, call the
fire department.
Use only your hand to push in the control buttons.
Never use tools. If the control buttons will not push
in, don’t try to repair them, call a qualified service
technician. Force or attempted repair may result in
fire or explosion
C.
Do not use this appliance if any part has been under
water. Immediately contact a qualified inst
aller or
service agency to replace a flooded water heater. Do
not attempt to repair the service unit. It must be
replaced.
D.
STANDBY-HOLD
SYSTEM OK
49°C
49°C
SETPOINT
ENABLE/DISABLE
SWITCH
STOP! Read the safety information above
on this label
Set the Enable/Disable switch on the control
panel to the Enable position.
1.
2.
Set the thermostat to the lowest setting.
3.
Set the Enable/Disable switch on the control
panel to the Disable position.
4.
This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
5.
Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B” in the
safety information above on this label. If you don’t
smell gas, go to the next step.
6.
Turn on all electrical power to the appliance.
7.
Set the Enable/Disable switch on the control panel
to the Enable position.
8.
Set the thermostat to the desired setting.
9.
CAUTION: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature
10.
If the appliance will not operate, follow the instruc-
tions “TO TURN OFF GAS TO APPLIANCE” and
call your technician or gas supplier.
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING.
Set the thermostat to the lowest setting.
1.
Set the Enable/Disable switch on the control
panel to the Disable position.
2.
Turn off all electrical power to the appliance if
service is to be performed.
3.
TO TURN OFF GAS TO APPLIANCE
61
Supply Gas Pressure Adjustment
• Do not use water heater with any gas other than
the gas shown on the rang label.
• Excessive gas pressure to gas valve can cause
serious injury or death.
• Turn off gas lines during installaon.
• Contact a qualified installer or service agency for
installaon and service.
⚠
WARNING
Fire and Explosion Hazard
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 5
(page 18)
adjust the supply gas regulator as necessary. Adjust the supply gas
regulator(s) per the regulator manufacturer’s instructions to achieve
the required “static” supply gas pressure. The dynamic pressure will
be directly proportional to the static pressure. The dynamic pressure
cannot be adjusted directly but is directly proportional to the static
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 5
(page 18) 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 that the supply gas lines and regulator(s) are properly
sized and installed. See the requirements for the supply
gas line in
Table 4 (page 18)
and
Table 5 (page 18)
and the
instructions in
Supply Gas Line Installation
(page 51). See the
requirements for
Supply Gas Regulator
(page 21). Ensure that
all requirements and installation instructions are maintained.
CHECKING THE FIRING RATE
Follow these instructions to determine the actual ring rate of the
water heater:
1. Ensure that 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 O Gas Supply
1. Change the Operating Set Point to the lowest temperature setting.
See
Operating Set Point and Differential Adjustment
(page 67).
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, Control board,
and other electrical components will still be energized and the
display will read “Water Heating Disabled.”
3. 3. Close the Main Gas Shuto Valve. See
Figure 69
(page 51).
62
HIGH ALTITUDE INSTALLATIONS
The water heaters covered by this manual are certied for use without
modication for altitudes up to 10,100 feet.
• Under no circumstances should the input exceed
the rate shown on the water heater’s rang label.
• Over-firing could result in fire or explosion.
• Gas and carbon monoxide detectors are available.
⚠
WARNING
• Under no circumstances should the input exceed
the rate shown on the water heater’s rang label.
• Overfiring could result in damage to the water
heater and soong.
• Gas and carbon monoxide detectors are available.
Breathing carbon monoxide can cause brain damage or death. Always
read and understand instrucon manual.
⚠
WARNING
Breathing Hazard - Carbon Monoxide Gas
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.
63
TEMPERATURE REGULATIONTEMPERATURE REGULATION
HIGH TEMPERATURE LIMIT CONTROL (ECO)
This water heater is equipped with a non adjustable high temperature
limit control.
The high temperature limit control sensors are located inside the
Main Temperature Probe. See
Figure 5 (page 11), Figure 6 (page
12),
and Figure 7 (page 13) for location. The high temperature
limit control activates when the water temperature reaches an unsafe
level and deactivates when the water temperature falls back to a
safe level.
If the high temperature limit control activates due to abnormally
high water temperatures in the storage tank, the control system
immediately deenergizes the gas valve and ends the current
heating cycle. The control system becomes locked out, disabling
further heating operation. The control system displays the “HIGH
TEMP LIMIT EXCEEDED” fault message on the LCD screen. It is
important that you contact a Qualied Service Agent to determine
the reason for the high temperature limit control activation before
resetting the high temperature limit control. Once the reason has
been determined and corrected, the high temperature limit control
can be reset as follows:
If the high temperature limit control activates, the water temperature
must drop below 185°F (85°C) before the control system can be
reset. Once the water temperature has cooled below this point,
turn o the power supply to the water heater, then turn it on again
to reset the control system
THERMOSTAT CONTROL
Because of the increased risk from scalding, if you
set the water heater’s gas control knob higher than
⚠
Burn Hazard
Hot water temperatures required for automatic dishwasher and
laundry use can cause scald burns resulting in serious personal
injury and/or death.
Table 22
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.
The temperature of the water in the water
⚠
WARNING
Burn Hazard
In addition to using the lowest possible temperature setting
that satisfies the demand of the application, a means, such as a
thermostatic point-of-use mixing valve, for example, can be used
at the hot water taps used by these people to reduce the water
temperature.
Check State and/or local codes for thermostatic point-of-use mixing
valve requirements and installation practices.
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 Setpoint at 120°F will reduce risk of scalds.
Some jurisdictions require settings at specic lower temperatures.
Table 22. 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)
The temperature of the water in the water
To reduce the risk of unusually hot water
of use.
⚠
WARNING
Burn Hazard
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 the temperature from
two factory-installed temperature probes: one installed in the top
of the storage tank and the other installed near the bottom. See
Figure 5
(page 11),
Figure 6
(page 12), and
Figure 7
(page
13) for location.
64
The Operating Setpoint 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 user interface module (UIM) located
on the front of the water heater. See
Figure 79
(page 66).
The Operating Setpoint is adjustable from 90°F (32°C) to 180°F
(82°C). The factory setting is 120°F (49°C). See 120°F (49°C). See
Operating Set Point and Differential Adjustment
(page 67) for instructions
on how to adjust the Operating Set Point and other user settings.
Set the Operating Setpoint at the lowest setting which produces
an acceptable hot water supply. This will always provide the most
energy ecient operation.
Firing Rate Modulation
The water heaters covered by this manual are capable of modulating
their ring rate. The controls system monitors the water temperature
in the tank and regulates the firing rate to achieve the target
temperature setpoint. The ring rate is dictated by the hot-water draw,
proximity to the tank temperature and various other temperature
limitations.
High Temperature Applications
Higher operating temperatures cause more wear on all water heaters
and will decrease the life span of the water heater. Consider installing
a small booster water heater for high temperature applications, such
as commercial dishwashers, to raise the outlet temperature from the
larger primary water heater to the desired point of use temperature.
BTH250-NAT
HEATING
118°F
120°F
OFF
GAS
O
N
SETPOINT
Figure 77. Tank Temperature Setpoint
65
CONTROL SYSTEM OPERATIONCONTROL SYSTEM OPERATION
LIMITING THE RISK OF SCALDING
For a variety of reasons, water heaters can produce water that is
much hotter than its temperature setting. Take precautions to prevent
this higher temperature water from reaching the water xtures.
The temperature of the water in the water
To reduce the risk of unusually hot water
of use.
⚠
WARNING
Burn Hazard
According to a national standard,
Performance Requirements for Water
Temperature Limiting Devices (ASSE 1070)
and many local plumbing codes,
the water heater’s gas control valve should not be used as the sole
means to regulate water temperature and avoid scalds.
A properly adjusted thermostatic mixing valve at each point of use
allows you to set the tank temperature to a higher setting without
increasing risk of scalds. A higher temperature setting allows the
tank to provide much more hot water and can help provide proper
water temperatures for appliances such as dishwashers and washing
machines.
WI-FI
The water heaters covered in this manual feature a Wi-Fi functionality
that is enabled at the factory. If Wi-Fi is not required for installation,
you can be disabled it as follows:
1. Go to main menu screen.
2. Select iCOMM icon.
3. Wi-Fi Status should show “AP Mode” (If not scroll down to
“Change to AP Mode” line item and Enable).
4. Enable the Wi-Fi if it is showing as disabled.
5. Using a phone or tablet go to the Wi-Fi settings and search
available networks.
6. In the list of networks, there should be a name that is similar to
“iCOMMNextGenUIM-XXXXXXXX”. This is the website being
broadcast by the display on the water heater. Select this network.
7. After selecting the iCOMM network, a separate message may
appear asking for permission to Stay Connected to the selected
network. Select the option to stay connected. Under the selected
network name, there should be an indication that the Wi-Fi
connected with the above iCOMM network.
8. Open a new Internet browser window on the device.
9. The Internet browser may automatically go to the web address
192.168.0.1. If it doesn’t, type that number into the address bar.
This will bring up a page that looks similar to the following:
10. Find the network name on the left that corresponds to the local
Wi-Fi network, and select the Connect button to the right of it.
11. If the local network is password protected, a new screen will
appear asking for the password. Enter the password for the local
network and click Connect.
12. A conrmation message should appear indicating the Connection
to Wi-Fi was completed.
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. See
page 76 for the procedure.
CONTROL SYSTEM 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 high temperature limit control sensors, ame sensor,
pressure switches, and temperature probes are monitored by the
control system. The combustion blower, spark ignition transformer,
gas valve and anode rods are all powered by the control system.
The main components of the control system are a user interface
module (UIM), Temperature Regulation Control (TRC) and
combustion safety control (CSC). The UIM is located on the top front
side of the water heater. The control boards are 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 10) for location
of these and all water heater components.
TRC
CSC
J13
Figure 78. 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 Home Screen
During normal operation, the control system displays the Home
screen on the LCD Touch Display, which is the default screen. The
control system returns to the Home 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 displays in
the Title Bar at the top of the Home screen.
• The Operating setpoint is shown in the middle of the Home
screen. This is the temperature at which the control system will
maintain the water inside the storage tank.
• Status is shown in the upper left. The status shows the current
66
operational state of the control system in real time.
• The light green band on the temperature dial shows the
temperature oset.
• The three horizontal lines on the Home screen will allow you to
access sub menus.
• The Home screen also displays animated status icons to
convey operational information. See Table 20 for descriptions
of the status icons.
The temperature of the water in the water
⚠
WARNING
Burn Hazard
HEATING
118°F
120°F
SET POINT
OFF
GAS
O
N
Touch Display
Status
Icons
Title Bar
Menu:
(Operational Menus
are Multifunctional.)
Help
Figure 79. User Interface Module (UIM) Home Screen
Status Icons
The Status Icons are displayed on the Home screen and convey
operational and diagnostic information. The icons are described in
the table below. See
Figure 79
(page 66). Ensure that the water
heater is properly grounded. Proper operation requires an adequate
earth ground. If the water heater is not properly grounded it will cause
errors including Ignition Failure.
Table 23. Status Icons
Icon Description
OFF
GAS
O
N
The Combustion Blower is energized.
GAS
OFF
O
N
The gas valve is being energized.
OFF
GAS
O
N
The control system has sensed ame at the
Main Burner from the flame sensor. See
Sequence of Operation
(page 83) and
Figure
2
(page 10).
OFF
GAS
O
N
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 (lockout)
until the condition that caused the fault is
corrected. Power to the water heater must
be cycled o and on at the breaker to reset
the control system.
Note: Cycling power will not reset the control
system if the condition that caused the
fault has not been corrected.
The control system has declared an alert
condition and must be inspected/serviced
by a Qualified Service Agent. The water
heater will continue to operate during an alert
condition.
67
Operating States
The current operational state of the water heater is displayed on the
Home screen as the “Status.” The common operational states are
described in the table below. See
Figure 79
(page 66).
Table 24. Operating States
State Description
Uncalibrated The unit is currently uncalibrated and must go
through calibration before use.
Calibration The unit is currently going through calibration
procedure.
Standby Heater is waiting on a call for heat.
Initializing The unit has begun a burn cycle and is checking
all safety circuits.
Input Verication The unit has begun a burn cycle and is checking
all safety circuits.
Pre-Purge The unit has begun a spark period to ignite the
main burner.
Ignition The unit has begun a burn cycle and is checking
safety circuits.
Inter-Purge After a failure to ignite the burner, the control is at-
tempting to purge any excess gas from the heater
exchanger before another attempt to light.
Heating The water heater has been properly lit, and the
water in the tank is being heated.
Post-Purge Excess gas is being pushed out of the heater
exchanger after a successful heating cycle.
System in Fault The water heater control has detected a fault.
No further heating of the water will be done until
reset.
Blocked A condition is preventing a burn cycle that must
clear before resuming water heating.
Ext Ena External enable/disable switch is active on unit.
BMS BMS is active on unit.
Heater Disabled The heater has been disabled and will not heat
water.
Control System Menus
From the Home 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 25. Control System Menus
Menu Description
Setpoint Manager Most commonly accessed menu. Contains the
Operating Set Point and Dierential user settings.
Heater Status This menu displays the current state of all pres-
sure switches and the ECO. The on/o status of
the Combustion 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 back-light 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 control board 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 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 ex-
plaining how to change user settings, navigate the
control system menus and icon descriptions.
USER SETTINGS & CONTROL SYSTEM MENUS
Operating Set Point and Dierential Adjustment
The Operating Setpoint is adjustable from 90°F (42°C) to 180°F
(82°C). The factory setting is 120°F (49°C). The Dierential is
adjustable from 2°F (1°C) to 20°F (11°C). The factory setting is 8°F
(4°C). 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 (main and lower) Temperature Probes reaches the Operating
Setpoint the control system will end the heating cycle. A heating
cycle will be activated again when the sensed water temperature
drops below the Operating Setpoint minus the Dierential setting.
The temperature of the water in the water
⚠
WARNING
Burn Hazard
Note: Lower Dierential settings may cause excessive heating
cycles (short-cycling) which can cause premature failure of
heater components. Set the Dierential at the highest setting
which produces an acceptable hot water supply. Set the
Operating Setpoint to the lowest setting which produces an
acceptable hot water supply for most ecient use.
68
Setpoint Manager
From the Setpoint Manager, you can adjust the Dierenal Mode,
the Dierenal, and see the current Tank Temperature.
To change the Operang Set-Point and Dierenal, do the following:
1. From the Home screen, press MENU icon. The “Main Menu”
screen will be displayed.
Note:
The dierential is indicated by the light green band on
the temperature dial.
BTH250-NAT
HEATING
118°F
120°F
OFF
GAS
O
N
SETPOINT
The Main Menu is where all control system menus are listed.
See
Table 25 (page 67)
for a complete list and description of
control system menus.
2. Press Heater icon to access the Setpoint Manager.
FAULTS
SETTINGS
MAIN MENU
HEATER
3. Use the arrow Buttons to change the current setting.
Note:
Higher Temperature settings increase wear and
operating costs. Set the Operating Setpoint to the
lowest setting which produces an acceptable hot
water supply. This will always provide the most energy
ecient operation and longer life.
150°F
SETPOINT
SETPOINT MANAGER
MODE:
CANCEL
DIFFERENTIAL
10°F
ENTER
MANUAL
4. Tap “CONFIRM” to save the new setting. Press “CANCEL” to
discard changes and return to the previously saved setting.
150°F
SET POINT
SETPOINT MANAGER
MODE:
CANCEL
DIFFERENTIAL
10°F
ENTER
MANUAL
Setpoint changed:
New Setpoint is 130°F
Please confirm to continue:
CONFIRM CANCEL
69
5. To change the differential setting: change the mode from
automatic to manual, then use the up and down arrows on the
dierential to change setting. Conrm to keep changes or Press
the Cancel button to return to the previously saved settings.
• Dierential Mode - Operating mode with an Intelligent
Demand Response (IDR). This mode allows the water
heater to reduce preset dierential 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.
• Dierential - Adjustable user setting that changes the
tank temperature dierential with a range of 2° to 20°F.
The factory setting is 8°F.
• Tank Temperature - Non adjustable. Control system
sensed temperature (averaged from main and lower tem-
perature probes).
These settings are adjusted in the same way described in
Operating Set Point and Differential Adjustment
(page 67).
150°F
SETPOINT
SETPOINT MANAGER
MODE:
CANCEL
DIFFERENTIAL
10°F
ENTER
MANUAL
iCOMM Menu
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. Press the iCOMM icon to access the iCOMM screen.
FAULTS
SETTINGS
MAIN MENU
HEATER
The iCOMM screen displays the following Wi-Fi information:
• Wi-Fi Status - displays status of Wi-Fi connection.
• Ethernet - displays status of Ethernet connection.
• iCOMM Server - displays status the iCOMM server.
• Wi-Fi MAC - displays the Wi-Fi MAC number.
• Ethernet MAC - displays the Ethernet MAC number.
• DSN - displays the Device Serial Number (DSN). Used
for registration of the heater.
• Wi-Fi Strength - displays Wi-Fi signal strength as a se-
ries of bars.
• Wi-Fi Strength - displays Wi-Fi signal strength dBm
units.
Wi-Fi - Wi-Fi functionality is enabled at the factory. In the bottom
portion of the menu, the Wi-Fi can be disabled by selecting the
Enabled>
marker and selecting the
Disable
option. This is the
only item on this screen that can be adjusted. The other items
are for view and information purposes only.
Top of menu
iCOMM
Wi-Fi Status Connected
Ethernet Not Connected
Registration Registered
iCOMM Server Connected
Bottom of Menu
DSN
AC000W006323619
Wi-Fi Strength
0Bars
Enabled
Wi-Fi
-128dBm
Wi-Fi Strength
iCOMM
70
Heater Information Menu
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the Heater icon to access the
Heater menu.
FAULTS
SETTINGS
MAIN MENU
HEATER
3. Press the Heater Information icon from the Heater menu to enter
the Heater Information screen.
HEATER
INFORMATION
HEATER
STATUS
SETPOINT
MANAGER
HEATER MENU
This screen contains non adjustable operational information.
• Elapsed Time - Total accumulated time the control sys-
tem (water heater) has been energized.
• Total Heat Time - Total accumulated time the control
system has been in the heating operating state; burner
run time.
• Total Cycle Counter - Total accumulated count of heat-
ing cycles.
• Ignition Failure Count – Total accumulated count of ig-
nition failures.
• Flame Loss Count - Total accumulated count of ame
losses.
• TRC Version - Software version for TRC board.
• UIM Version - Software version for user interface mod-
ule.
• Serial Number - Serial number of the water heater.
• Model Number - Model number of the water heater
• CSC Version - Software version for CSC board.
• CPAM1 Version - Software version for CPAM1.
• CPAM2 Version - Software version for CPAM2.
• Building Management Version - Software version for
Building Management System.
• Water Valve Control Version - Software version for the
water valve control.
• NANODE Version - Software version for NANODE.
Historical data is stored in the Flex Memory Module (FMM). If the
FMM is removed or damaged during servicing, the historical data will
be lost and heater may no longer operate. The FMM should never
be replaced unless directed by Technical Support.
The Elapsed Time, Burner On Time and Cycle Count indicate age,
usage and wear.
If the Cycle Count per day is high (divide cycle count by days to
determine cycles per day) or the cycle duration is short (determine
burner on time total minutes, divide burner on time total minutes by
cycle count) consider raising the Dierential setting to avoid short
cycling and excessive component wear. See Operating Set-Point and
Differential Adjustment (page 64).
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.
Elapsed Time 0 Days 0 Hrs 31 Mins 37
Total Heat Time
0 Days 0 Hrs 10 Mins 0 Secs
Yes
External Enable Status
YesUse External Enable
HEATER INFO
71
Heater Status Menu
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the
Heater Information
icon to access
the Heater Information screen.
HEATER
INFORMATION
HEATER
STATUS
SETPOINT
MANAGER
HEATER MENU
The Heater Status menu displays the following information:
• Status - Indicates whether the heater is Enabled or Disabled.
• Blocked Inlet PS - Indicates if the Inlet is blocked.
• Blocked Outlet PS - Indicates if the Outlet is blocked.
• Igniter On - Indicates if the Igniter is operational
• Gas Valve On - Indicates if the gas valve is on.
• Flame Detected - Indicates if ame is detected.
• Blower RPM - Indicates the blower RPMs
• Main Temperature - Temperature reading of the main
temperature probe.
• Lower Temperature - Temperature reading of the lower
temperature probe.
• Anode Current – Current reading of anode
• Anode Tank Voltage – Voltage of anode tank
• Anode Drive Voltage – Voltage of anode drive
• Water Valve 1 Status – Current status of Water Valve 1
• Water Valve 1 Error – Error in Water Valve 1
• Water Valve 2 Status - Current status of Water Valve 2
• Water Valve 2 Error - Error in Water Valve 2
• Water Valve 3 Status - Current status of Water Valve 3
• Water Valve 3 Error - Error in Water Valve 3
Top of Menu
HEATER STATUS
Status: HEATER DISABLED
Blocked Inlet PS Open
Blocked Outlet PS Open
Igniter Yes
HEATER STATUS
Water Valve 2 Status Yes
Water Valve 2 Error 3 Tries
Water Valve 3 Error 15rpm
Water Valve 3 Status 500rpm
FAULTS
SETTINGS
MAIN MENU
HEATER
Bottom Of Menu
HEATER STATUS
Status: HEATER DISABLED
Blocked Inlet PS Open
Blocked Outlet PS Open
Igniter Yes
HEATER STATUS
Water Valve 2 Status Yes
Water Valve 2 Error 3 Tries
Water Valve 3 Error 15rpm
Water Valve 3 Status 500rpm
FAULTS
SETTINGS
MAIN MENU
HEATER
72
Display Settings Menu
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the Heater Information icon to access
the Heater Information screen.
HEATER STATUS
Status: HEATER DISABLED
Blocked Inlet PS Open
Blocked Outlet PS Open
Igniter Yes
HEATER STATUS
Water Valve 2 Status Yes
Water Valve 2 Error 3 Tries
Water Valve 3 Error 15rpm
Water Valve 3 Status 500rpm
FAULTS
SETTINGS
MAIN MENU
HEATER
The Settings screen contains adjustable display options for viewing
information on the LCD screen.
• Temperature Units - Adjustable user setting that changes
temperature units display to Celsius °C or Fahrenheit °F.
• Back-light Delay - Adjustable user setting that determines
how long the LCD back light remains illuminated after a key
has been pressed. Available settings are; Always O, 10, 30 or
60 seconds and Always On.
• Brightness - Adjustable user setting to adjust the LCD screen
contrast between text and background.
• These settings are adjusted in the same way as described
Operating Set-Point and Dierential Adjustment (page 64).
• Lock Setpoint manager
• Current Date/Time
Temp Units °F
Display Brightness 8
09/09/2020 12:34 AMDate/Time
30 secBacklight
SETTINGS
FAULTS
SETTINGS
MAIN MENU
HEATER
FAULT MENU
FAULT
OCCURRENCE
FAULT
HISTORY
CURRENT
FAULT (NONE)
73
Current Fault
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the Faults icon to access the Fault
Menu.
Temp Units °F
Display Brightness 8
09/09/2020 12:34 AMDate/Time
30 secBacklight
SETTINGS
FAULTS
SETTINGS
MAIN MENU
HEATER
FAULT MENU
FAULT
OCCURRENCE
FAULT
HISTORY
CURRENT
FAULT (NONE)
3. From the Fault Menu, press the Current Fault or Current Alert
icon to access the Current Fault screen.
Temp Units °F
Display Brightness 8
09/09/2020 12:34 AMDate/Time
30 secBacklight
SETTINGS
FAULTS
SETTINGS
MAIN MENU
HEATER
FAULT MENU
FAULT
OCCURRENCE
FAULT
HISTORY
CURRENT
FAULT (NONE)
The Current Fault screen 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.
Press the MORE button for more detailed service information and a
list of possible causes for the Fault or Alert condition.
See
Troubleshooting
(page 83) 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
Fault menu.
MORE
!
!
CURRENT FAULT
CURRENT FAULT NAME
Occurred:
09/08/2020 12:34 AM
This will be a brief description of the fault. It
wil be described in one or two sentences.
74
Fault History Menu
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the Faults icon to access the
Fault Menu.
FAULTS
SETTINGS
MAIN MENU
HEATER
Hardware Fault 1
Software Failure 7
0
Software and FMM Key Incompatible
4
Missing Module
Fault Occurrence
3. From the Fault Menu, press the Fault History icon to access the
Fault History screen.
The Fault History screen contains non adjustable operational
information.
CURRENT FAULT
CURRENT FAULT NAME
Occurred:
09/08/2020 12:34 AM
This will be a brief description of the fault. It will be
described in one or two sentences.
MORE
FAULTS
SETTINGS
MAIN MENU
HEATER
FAULT MENU
FAULT
OCCURRENCE
FAULT
HISTORY
CURRENT
FAULT (NONE)
FAULT HISTORY
1: High Temp Limit Exceeded (2)
07/13/2020 03:30 AM
2: Upper Temperature Probe Sensing Failure (3)
06/08/2020 04:06 AM
The Fault History screen 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.
CURRENT FAULT
CURRENT FAULT NAME
Occurred:
09/08/2020 12:34 AM
This will be a brief description of the fault. It will be
described in one or two sentences.
MORE
FAULTS
SETTINGS
MAIN MENU
HEATER
FAULT MENU
FAULT
OCCURRENCE
FAULT
HISTORY
CURRENT
FAULT (NONE)
FAULT HISTORY
1: High Temp Limit Exceeded (2)
07/13/2020 03:30 AM
2: Upper Temperature Probe Sensing Failure (3)
06/08/2020 04:06 AM
75
Fault Occurrence Menu
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the Faults icon to access the
Fault Menu.
FAULTS
SETTINGS
MAIN MENU
HEATER
Hardware Fault 1
Software Failure 7
0
Software and FMM Key Incompatible
4
Missing Module
Fault Occurrence
3. From the Fault Menu, press the Fault Occurrence icon to access
the Fault Occurrence screen.
The Fault Occurrence screen contains a running total of how
many times each Fault condition has occurred since the water
heater was rst installed.
Hardware Fault 1
Software Failure 7
0
Software and FMM Key Incompatible
4
Missing Module
Fault Occurrence
76
Lockout Function
1. From the Home screen, press MENU icon.
The “Main Menu” screen will be displayed.
2. From the Main Menu, press the Settings icon to access the
Settings screen.
3. Use the arrow buttons to scroll through the list to the Lock item.
4. Click on the arrow to the right to access the Lock dialog box.
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
30 secBacklight
SETTINGS
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
SETTINGS
30 secBacklight
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
Lock
No
CONFIRM
CANCEL
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
30 secBacklight
SETTINGS
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
SETTINGS
30 secBacklight
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
Lock
No
CONFIRM
CANCEL
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
5. Use the arrows in the Lock dialog box to toggle Yes to enable the
lock or No to disable the lock.
Note:
The lock is disabled by default from the factory.
Click Conrm to implement your selection.
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
30 secBacklight
SETTINGS
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
SETTINGS
30 secBacklight
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
Lock
No
CONFIRM
CANCEL
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
6. Press and hold on the lock icon on the Home screen to unlock
the Setpoint settings.
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
30 secBacklight
SETTINGS
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
SETTINGS
30 secBacklight
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
Lock
No
CONFIRM
CANCEL
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
77
Restore Factory Defaults Function
1. Press and hold on the A. O. Smith logo on the Home screen.
The Service Information screen displays.
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
30 secBacklight
SETTINGS
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
SETTINGS
30 secBacklight
Temp Units °F
04/28/2025 12:34 AMDate/Time
Brightness
8
Lock
No
CONFIRM
CANCEL
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
2. Select Restore User Defaults on the Service Information screen.
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
SERVICE INFORMATION
Restore User Defaults Display
Access Code
SERVICE INFORMATION
Restore User Defaults Display
Access Code
Restore User Defaults
TRC
CONFIRM
CANCEL
3. Ensure TRC is selected in the list menu, then press the Conrm
buttons.
The original factory settings of the water heater are restored.
BTH250-NAT
HEATING
118°F
120°F
SETPOINT
OFF
GAS
O
N
SERVICE INFORMATION
Restore User Defaults Display
Access Code
SERVICE INFORMATION
Restore User Defaults Display
Access Code
Restore User Defaults
TRC
CONFIRM
CANCEL
78
Service Contact Information
The control system has a menu that Installing contractors and/or
service agents can access to enter their contact information for
customers. This contact information will be displayed with all Fault
and Alert messages.
1. From the Home screen, press the Main Menu icon. The Main
Menu screen displays.
2. From the Main Menu screen, press the Settings icon.
BTH250-NAT
HEATING
118°F
120°F
OFF
GAS
O
N
SETPOINT
3. Scroll down to the Settings Menu and select the Current Contact
Info item. The Contact Information screen displays.
BTH250-NAT
HEATING
118°F
120°F
OFF
GAS
O
N
SETPOINT
Temp Units °F
Display Brightness 8
09/09/2020 12:34 AMDate/Time
30 secBacklight
SETTINGS
CONTACT INFORMATION
John Doe
Widgits LLC
123-456-7890
www.widgitsllc.com
CONTACT INFORMATION
John Doe
Q W R T YE I O PU
A S F G HD K L ‘J
C V BX MNZ
.,123
SAVE EXIT
BTH250-NAT
HEATING
118°F
120°F
OFF
GAS
O
N
SETPOINT
Temp Units °F
Display Brightness 8
09/09/2020 12:34 AMDate/Time
30 secBacklight
SETTINGS
CONTACT INFORMATION
John Doe
Widgits LLC
123-456-7890
www.widgitsllc.com
CONTACT INFORMATION
John Doe
Q W R T YE I O PU
A S F G HD K L ‘J
C V BX MNZ
.,123
SAVE EXIT
4. To edit a contact information item, select it and press the Pencil
icon.
5. Edit the item using the keyboard. Press the Save Key to save
your data after each entry.
Note:
You can enable or disable the display of Contact info by
editing the “Show Contact” item on the Settings Menu.
BTH250-NAT
HEATING
118°F
120°F
OFF
GAS
O
N
SETPOINT
Temp Units °F
Display Brightness 8
09/09/2020 12:34 AMDate/Time
30 secBacklight
SETTINGS
CONTACT INFORMATION
John Doe
Widgits LLC
123-456-7890
www.widgitsllc.com
CONTACT INFORMATION
John Doe
Q W R T YE I O PU
A S F G HD K L ‘J
C V BX MNZ
.,123
SAVE EXIT
79
MAINTENANCEMAINTENANCE
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 56). 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.
MAINTENANCE SCHEDULE
Table 26. Maintenance Schedule
Component Operation Interval Reference
Tank Drain and Flush Every 6 Months See
Maintenance
(page 79)
.
Tank
Lime Scale Removal
(Water Less Than
25 Grains Hard)
Not Required N/A
Tank
Lime Scale Removal
(Water Greater Than
25 Grains Hard)
Annually
See
Lime Scale Removal
(page
80).
Burner Flames Inspection Every 3 Months
See
Burner Flame Inspection
(page 81).
Burner Inspection/Cleaning As Needed
Contact qualied agency or
professional.
Moving Parts Lubrication Not Required N/A
Powered
Anodes
Inspection/Cleaning Annually
See
Anode Rod Maintenance
(page 81).
T&P Valve Test Operation Semi Annually
See
Temperature-Pressure Relief
Valve Test
(page 82).
Vent System Inspection Annually
See
Vent System Maintenance
(page 82).
Condensate
Neutralization
Inspection Annually
See manual for the conden-
sate neutralization kit.
Condensate
Collection
Cleaning Annually
See
Vent System Maintenance
(page 82).
Precautions
⚠
CAUTION
Safety Hazard
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.
• Soong.
Do not operate the water heater unl all correcve steps
have been made by a qualified service technician.
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 22).
• Overheated water can cause water tank explosion.
• A properly sized temperature and pressure relief
valve must be installed in the opening provided.
⚠
WARNING
Explosion Hazard
If overheating occurs or the gas supply fails to shut o, turn o the
Main Gas Shuto valve. See
Figure 69
(page 51).
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 10) for the location of the water
heater components described below.
⚠
DANGER
Burn Hazard
The discharge water from the drain valve is hot enough
to cause burns.
Keep your hands clear of the drain valve discharge
outlet.
Draining the Water Heater Storage Tank
1. Turn the Enable/Disable switch located on the front of the heater
to the Disabled position.
2. Turn o the electrical supply to the water heater.
3. Turn o the gas supply at the Main Gas Shuto Valve if the water
heater is going to be shut down for an extended period.
4. Ensure that 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.
Flushing the Water Heater Storage Tank
1. Turn the Enable/Disable switch located on the front of the heater
to the Disabled position.
2. Turn o the electrical supply to the water heater.
3. Ensure that 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 that 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.
80
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 56).
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 aects 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 eciency 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 clean-out
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 clean-out opening furnished on the water heater. See
Figure 80
.
TANK
CLEANOUT
OPENING
CLEANOUT
COVER
CLEANOUT
GASKET
CLEANOUT
ACCESS PANEL
Figure 80. Clean-out Access
Manual Lime Scale Removal
Note: Contact Technical Support for assistance in ordering a new
clean-out gasket. See the contact information label on the
water heater. Have the new gasket available before removing
the clean-out cover.
The cleanout opening is shown in
Figure 80
. To remove lime scale
manually through the clean-out opening proceed as follows:
1. Turn o the electrical supply to the water heater.
2. The water heater must be drained. See
(page 79). Follow
the instructions on how to drain the water heater.
3. Remove outer clean-out access panel from lower side of the
water heater jacket.
4. Remove the clean-out cover from clean-out opening.
5. Remove lime, scale and/or sediment using care not to damage
the glass-lining.
6. Install a new clean-out gasket if required.
7. Reinstall the clean-out 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 56).
10. Turn on the electrical supply to place the water heater back in
operation. See
Start Up
(page 56).
11. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
12. Check for water leakage.
13. Reinstall the clean-out access panel.
Chemical Lime Scale Removal
To dissolve and remove more stubborn lime scale deposits, white
vinegar should be used. Hydrochloric base acids must not be used
to delime the water heaters covered in this manual.
81
BURNER FLAME INSPECTION
Check main burner every three months for proper flame
characteristics. You can see the burner ame through the sight
glass on top of the burner plate. To access the sight glass, you must
remove the plastic cover.
Sight
Glass
Air Intake Connection
Figure 81. Location of Sight Glass
The main burner should display the following characteristics:
• Provide complete combustion of gas.
• Cause rapid ignition and carry over of ame across entire
burner.
• Give reasonably quiet operation during initial ignition,
operation and extinction.
• Cause no excessive lifting of ame from burner ports. See
Figure 82
.
Figure 82. Normal and Abnormal Burner Flames
If the preceding burner characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or blocks
the air intake tting or air intake terminal.
To ensure continued good performance, keep the area around the
water heater clean and free from lint and debris. Sweep the oor
around the water heater regularly. This will reduce the dust and dirt
which can enter the burner and heat exchanger, causing improper
combustion and sooting.
If the air intake tting and air intake terminal are clear and the burner
continues to exhibit abnormal ames, contact a qualied service
agency or have a qualied service professional inspect and clean
the burner.
ANODE ROD MAINTENANCE
CAUTION
Property Damage Hazard
Operating the water heater with depleted or
malfunctioning anodes can damage the water
heater.
Annual inspection and replacement of the anode
rod is required.
The water heaters covered in this manual are factory equipped
with powered anode rods mounted in the top of the unit. The anode
rods are of a permanent design and do not need replacing unless
damaged, however, inspection and cleaning should be performed
once a year.
To inspect the powered anode, do the following:
1. Turn o electrical supply and gas supply to the water heater.
2. Shut o the water supply and open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons of water from tank. See
(page
79)
for proper procedures. Close drain valve.
4. Remove the wiring connection on the top of the powered anode.
5. Remove the powered anode by loosening the 3/4” NPT bushing
that forms the top of the anodes.
6. Remove the entire anode rod from the water heater for inspection.
• If undamaged and in working order, clean the anode rod
with a soft cloth and reinstall.
• If the anode needs to be replaced, obtain a new anode
rod. Apply thread-sealer
®
tape or an approved pipe seal-
ant on the threads before installing the new powered an-
ode rod.
Whether re-installing or replacing the powered anode rod, check
for any leaks and immediately correct if found.
7. Turn on water supply and open nearby hot water faucet to purge
air from water system.
8. Rell the water heater following the instructions for
Filling The
Water Heater
(page 56).
9. Restart the water heater as directed in this manual.
DRAIN VALVE AND ACCESS PANELS
The water heaters covered in this manual are equipped with a
drain valve. See
Features and Components
(page 10) for location.
The water heaters covered in this manual are also equipped with a
clean-out opening for sediment and lime scale removal. See
Figure
80
(page 80).
82
TEMPERATURE-PRESSURE RELIEF VALVE TEST
⚠
DANGER
Burn Hazard
The discharge water from the temperature-pressure
relief valve is hot enough to cause burns.
Keep clear of the 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 83
. 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 79). Replace the Temperature-Pressure Relief
Valve with a properly rated/sized new one. See
Temperature-Pressure
Relief Valve
(page 22) for instructions on replacement.
Figure 83. 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 22)
and
Thermal Expansion
(page 22). 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.
D
o not plug the Temperature-Pressure Relief Valve opening. This
can cause property damage, serious injury or death.
To avoid this hazard, you must install a properly-
sized temperature-pressure relief valve in opening
provided.
• The temperature-pressure relief valve must
comply with
and ASME
code.
• Do not plug, block, or cap the discharge line.
⚠
WARNING
Explosion Hazard
VENT SYSTEM MAINTENANCE
Examine the vent system once a year. Points of inspection are as
follows:
1. Check for obstructions and/or deterioration of the intake-air and/
or vent piping and the intake-air and vent terminations. Replace
immediately where needed.
2. The debris screens in the intake-air and vent terminations should
be should be cleaned of foreign material and soot. See
Figure 38
(page 38).
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.
83
TROUBLESHOOTINGTROUBLESHOOTING
INSTALLATION CHECKLIST
The list below represents some of the most critical installation
requirements that, when overlooked, often result in operational
problems, down time and needless parts replacement. This is not
a complete list. Before performing any troubleshooting procedures
use the list below to check for installation errors.
Note: Costs to correct installation errors are not covered under the
limited warranty. Ensure that 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 sucient room to service the water heater. See
Clearance
to Combustible Materials
(page 19).
2. Ensure that the area is free of corrosive elements and ammable
materials. See the instructions in
Contaminated Air
(page 25).
Venting
3. Ensure that the intake-air and/or vent (exhaust) piping is the
correct size for the installed length. See
(page 31).
4. Ensure that the maximum equivalent length of pipe has not been
exceeded for the intake-air and/or vent pipe. See
Table 7
(page
32).
5. Ensure that the maximum number of elbows has not been
exceeded in the intake-air and/or vent pipe. See
(page 31).
6. Ensure that 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 34
(page 36).
7. Ensure that all exterior clearances for the intake-air, vent,
concentric, and low prole terminations are maintained. See
Vertical Termination Installation
(page 36),
Sidewall Termination
Installation
(page 38),
Low Profile Vent Installation
(page 44).
These clearances and those cited by local and national codes
must be maintained.
Gas Supply And Piping
8. Ensure a supply gas regulator has been installed for each water
heater.
9. Ensure that 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
(page 18) and
Table 5
(page
18) and the instructions in
Supply Gas Line Installation
(page
51).
Condensate Drain
10. Ensure that 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 15
(page 24)
and
Condensate Drain Installation
(page 50).
Electrical Connections
11. Ensure that the power supply is on a dedicated circuit and
connections to the water heater are polarity correct. See the
requirements for the
Power Supply
(page 21) and
Electrical Wiring
(page 53).
12. Ensure that the water heater is properly grounded. Flame sensing
requires an adequate earth ground. If the water heater is not
properly grounded it will cause Ignition Failure.
SEQUENCE OF OPERATION
Read the Sequence of Operation before attempting to correct any
operational problems. See
Features and Components
(page 10) for
the location of various water heater components described below.
See
Sequence of Operation
(page 84).
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 user
interface module (UIM) will display the default screen known as
the Home screen.
2. If the control system determines that the actual water temperature
inside the tank is below the programmed Operating Setpoint
minus the Dierential setting, a heating cycle is activated.
3. The control system then performs selected diagnostic system
checks. This includes conrming the blocked exhaust, blocked
intake and high temperature limit control sensors are not
activated.
4. If all diagnostic checks are successfully passed, the control
system energizes the Combustion Blower for prepurge.
5. The control system energizes the spark ignition control.
6. The control system energizes the 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 lockout and display the “Ignition
Failure” fault message.
8. If a ame is veried, the control system will deenergize the Spark
Ignition Control and enter the heating mode where it will continue
heating the water until the Operating Setpoint is reached. At this
point, the control system will deenergize the Gas Valve and enter
the post-purge cycle.
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 deenergized 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 Setpoint minus the Dierential setting, the control
will automatically return to Step 2 and repeat the operating cycle.
84
SEQUENCE OF OPERATION
YES NO
Water is heated to
set point
Gas Valve
de-energized
Inter-Purge cycle
Gas Valve
de-energized
Retries up to
two more times
Post-Purge cycle
Control System
Locks Out
“Ignition Failure”
Fault Message
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.
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 Messages
NO
Combustion Blower is energized
Pre-Purge cycle
Control System performs diagnostic checks
• Normal State of all pressure switches and high-tempera-
ture limit control are checked
• Pressure switches and high-temperature limit control are
verified inactive
Sequence is shown with Enable/Disable Switch in the Enable position
Figure 84. Sequence of Operation
85
OPERATIONAL PROBLEMS
Failure to follow these instrucons and safety
messages could result in death or serious injury.
Read and understand this instrucon manual and the
safety messages herein before installing, operang or
servicing this water heater.
This manual must remain with the water heater.
⚠
WARNING
Safety Hazard
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 defined in
Qualifications
(page 8), 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. 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 that all installation requirements and
instructions have been maintained and followed. See
Installation
Checklist
(page 83).
Note: Costs to correct installation errors are not covered under the
limited warranty.
Rough Starting, Rough Operation
• Do not use water heater with any gas other than
the gas shown on the rang label.
• Excessive gas pressure to gas valve can cause
serious injury or death.
• Turn off gas lines during installaon.
• Contact a qualified installer or service agency for
installaon and service.
⚠
WARNING
Fire and Explosion Hazard
• Undersized supply gas line (low volume of supply gas). See
the requirements for the supply gas line in
Table 4
(page 18)
and
Table 5
(page 18) and the instructions in
Supply Gas Line
Installation
(page 51).
• Supply gas regulator is not installed per installation
requirements (erratic gas supply volume/pressures). See
Supply Gas Regulator
(page 21).
• Excessive supply gas pressure. See
Table 5
(page 18) and
Supply Gas Regulator
(page 21).
• Vent (exhaust) gas recirculation at the vent and intake-air
pipe terminations on direct vent installations. See
Direct Vent
Installation
(page 35).
• Excessive equivalent lengths of intake-air and/or vent
(exhaust) piping installed. See
(page 31).
• Debris clogging/blocking the intake-air screen(s). See
Figure 33
(page 36) and
Figure 38
(page 38).
• Debris clogging/blocking the Main Burner. See
Figure 2
(page
10).
Momentary Ignition
Burn Hazard
• The combustion chamber and burner
sleeve and housing become very hot
during operation.
• 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.
⚠
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
(page 18)
and
Table 5
(page 18) and the instructions in
Supply Gas Line
Installation
(page 51).
• Supply gas regulator is not installed per installation
requirements (erratic gas supply volume/pressures). See
Supply Gas Regulator
(page 21).
• See the list of possible causes and things to check and repair
for the Ignition Failure Fault message in
Fault and Alert Messages
(page 87).
• Debris clogging/blocking the intake-air screen(s). See
Figure 33
(page 36) and
Figure 38
(page 38).
• Debris clogging/blocking the Main Burner
Figure 2
(page 10).
86
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, Dierential setting is set too
high. See
Control System Operation
(page 65).
• Tank Probe Oset is causing the heating cycles to terminate
prematurely. See
Setpoint Manager
(page 68).
• 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 aecting water
heater operation. See
Maintenance
(page 79) for sediment
and lime scale removal procedures.
• Water heater not ring at full input rating. See
Checking the Firing
Rate
(page 61).
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 67).
• If installed check Thermostatic Mixing Valve settings.
• Tank Probe Oset setting improperly set. See
Setpoint Manager
(page 68).
• Lime build-up on temperature probes. Inspect and clean.
• Improper water piping. See
Water Piping Diagrams
(page 105).
Noisy Operation
• Sediment or lime scale accumulations can cause rumbling and
pounding noises during heating cycles. See
Maintenance
(page
79)
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 that the water heater drain valve is tightly closed.
• Check cleanout opening for leaks. See
Figure 8
(page 14)
Figure 9
(page 14).
• 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 22)
and
Thermal Expansion
(page 22). 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 axed 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 o 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
Servicing this water heater exposes you to
electrified components that can cause severe
injury or death if you touch them.
• Turn off power at the branch circuit breaker
serving the water heater before performing any
service.
• Label all wires prior to disconnecng when
performing service. Wiring errors can cause
improper and dangerous operaon.
• Verify proper operaon aer servicing.
⚠
WARNING
Electrical Shock Hazard
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.
87
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 alteraon of the water heater
controls and/or wiring will result in voiding the
appl
iance warranty.
⚠
WARNING
Safety Hazard
FAULT AND ALERT CONDITIONS
Fault Conditions
When the control system shows a Fault condition it will display a Fault
message on the control system’s UIM with an exclamation “!” mark.
The control system will lockout and disable heating operation. To
reset the current fault, toggle the Enable/Disable switch on the front
of the heater from enable to disable, and then back to enable. If the
condition that caused the fault has not been resolved the fault will
reappear. 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.
Verify the power to the water heater is turned off before
performing any service procedures. The Enable/Disable
switch on front panel disables the gas valve. Electrical
supply must be turned off at circuit breaker serving water
heater.
Fault and Alert Messages
Contact Technical Support for further assistance or to locate a qualied service agent in your area. See the contact-information label on
the water heater.
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
2
Data Error Code: (3,
30) NTC A short
(3, 31) NTC A open
(3, 32) NTC B short
(3, 33) NTC B open
(3,1001) NTC C open
(3,1002) NTC C short
(3,1018) NTC drift
High Temp Limit Exceeded
The water heater is shut down due to high tank temperature.
The water temperature in the tank has exceeded the high
temperature limit.
1. Use a thermometer at a hot water xture to conrm the
actual water temperature. If temperature is below 180˚
reset water heater.
2. If problem continues, contact technical support or refer
to the service handbook for further instructions.
CURRENT FAULT
High Temp Limit Exceeded
Occurred:
09/08/2020 12:34 AM
The water heater is shut down due to high
tank temperature.
MORE
3
Data Error Code:
30;31;
32;33
Main Temperature Probe Failure
The indicated temperature probe might be shorted or open.
The control system has detected an issue with the main
temperature probe.
1. Ensure the wire connections for the main temp probe
are clean and secure.
2. Ensure the wire harness for the main temp probe is
free from damages.
3. If the problem continues, contact technical support or
refer to the service handbook for further instructions.
Note: If there are both main and lower temperature probes,
the Main Temperature probe is the main temperature
probe.
CURRENT FAULT
Main Temperature Probe Failure
Occurred:
09/08/2020 12:34 AM
The indicated temperature probe might be
shorted or open.
MORE
88
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
4
Data Error Code:
(4,1006) NTC open
(4,1007) NTC short
Lower Temperature Probe Failure
The indicated temperature probe might be shorted or open.
The control system has detected an issue with the main
temperature probe.
1. Ensure the wire connections for the lower temp probe
are clean and secure.
2. Ensure the wire harness for the lower temp probe is
free from damages.
3. If the problem continues, contact technical support or
refer to the service handbook for further instructions.
CURRENT FAULT
Lower Temperature Probe Failure
Occurred:
09/08/2020 12:34 AM
The indicated temperature probe might be
shorted or open.
MORE
5
Data Error Code:
(3,10xx) where xx =
5,9,13 or 17
Software Failure
Internal control failures are detected on TRC. Cycle power
to the water heater.
The controls system has detected a software issue.
1. Cycle the main power supply to the water heater
by turning o the breaker/disconnect, then wait
approximately 30 seconds and turn main power supply
back on.
2. If problem continues, contact Technical Support or
refer to the service handbook for further instructions.
CURRENT FAULT
Software Failure
Occurred:
09/08/2020 12:34 AM
Internal control failures are detected on
TRC. Cycle power to the water heater.
MORE
6
(6,10xx) where xx =
4, 8, 12 or 16
OR
(6,80xx) where xx
= 1-10
Hardware Failure
Internal control failures are detected on the TRC. Cycle
power to the water heater.
The controls system has detected a hardware issue.
1. Cycle the main power supply to the water heater
by turning o the breaker/disconnect, then wait
approximately 30 seconds and turn main power supply
back on.
2. If problem continues, contact Technical Support or
refer to the service handbook for further instructions.
CURRENT FAULT
Hardware Failure
Occurred:
09/08/2020 12:34 AM
Internal control failures are detected on the
TRC. Cycle power to the water heater.
MORE
9
Data Error Code: 22
Power Supply Fault
The Control System is detecting a problem with the incoming
power supply.
1. Cycle the main power supply to the heater by turning
o the breaker/disconnect, then wait approximately 30
seconds and turn main power supply back on.
2. If problem continues, contact technical support or refer
to the service handbook for further instructions.
CURRENT FAULT
Power Supply Fault
Occurred:
09/08/2020 12:34 AM
The Control System is detecting a problem
with the incoming power supply.
MORE
89
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
20
Data Error Code:
(20,0)
Communication Failure
Communications between the display and the TRC is lost.
The control system has lost communications with UIM.
1. Cycle the main power supply to the heater by turning
o the breaker/disconnect, then wait approximately 30
seconds and turn main power supply back on.
2. Inspect the communication cable between the UIM
and the TRC to ensure the cable is not damaged and
the connections are clean and secure.
3. If problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULT
Communication Failure
Occurred:
04/28/2025 12:34 AM
Communications between the display and
the TRC is lost.
MORE
25
Data Error Code:
(4,1010) NTC open
(4,1011) NTC short
Flue Gas Temperature Probe Failure
The ue gas temperature probe might be shorted or open.
The control system has detected an issue with the ue gas
temperature probe.
1. Cycle the main power supply to the heater by turning
o the breaker/disconnect, then wait approximately 30
seconds and turn main power supply back on.
2. If problem continues, contact technical support for
further instructions.
CURRENT FAULT
Flue Gas Temperature
Probe Failure
Occurred:
04/28/2025 12:34 AM
The flue gas temperature probe might be
shorted or open.
MORE
26
Data Error Code:
(4,1014) NTC open
(4,1015) NTC short
Recirc Temperature Probe Failure
The recirculation temperature probe might be shorted or
open.
The control system has detected an issue with the recirc
temperature probe.
1. Cycle the main power supply to the heater by turning
o the breaker/disconnect, then wait approximately 30
seconds and turn main power supply back on.
2. If problem continues, contact technical support for
further instructions.
CURRENT FAULT
Recirc Temperature
Probe Failure
Occurred:
04/28/2025 12:34 AM
AMThe recirculation temperature probe might be
shorted or open.
MORE
90
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
31
Data Error Code:
(31,7002) or
(31, 7003) or
(31, 7004)
Water Leak Detected
A water leak or other water-present condition is being
detected. Check for a leak or other water problem at the
water sensor.
The control system has detected a leak near the heater.
1. Inspect the area around the heater for signs of
moisture.
2. Inspect all threaded ttings connected to the water
heater for signs of moisture.
3. Inspect the exhaust elbow connection to the heater for
signs of moisture.
4. Inspect the cleanout cover for signs of moisture.
5. Using litmus strips for pH testing to identify if the
moisture is condensate or water from the tank.
6. Condensation from the exhaust will be highly acidic.
7. If problem continues, contact technical support for
further instructions.
CURRENT FAULT
Water Leak Detected
Occurred:
09/08/2020 12:34 AM
A water leak or other water-present
condition is being detected. Check for a leak
or other water problem at the water sensor.
MORE
32
Data Error Code:
(32, 7001))
Leak Sensor Disconnected
The leak sensor is no longer being detected by the controller.
The control system has detected that the leak detector has
been disconnected.
1. Ensure the leak detector is securely connected to the
water heater.
2. Ensure the leak detector harness is securely
connected to the TRC at terminal J6 pins 1 and 11.
3. If problem continues, contact technical support for
further instructions.
CURRENT FAULT
Leak Sensor Disconnected
Occurred:
09/08/2020 12:34 AM
The leak sensor is no longer being detected
by the controller.
MORE
33
Data Error Code:
(33, 60x7) where
x = 0 is on TRC-1000
board anode circuit
x = 1 is CPAM 1,
x = 2 is CPAM 2 etc.
Anode Shorted
The powered anode is shorted to earth ground or to the tank.
The Control System has detected that the anode rod has
shortage to the tank.
1. Inspect anode wire connection for corrosion, moisture,
or other contaminates.
2. Ensure wire connection on both ends is secure.
3. Ensure anode wire harness is not damaged.
4. If problem continues, contact technical support for
further instructions.
CURRENT FAULT
Anode Shorted
Occurred:
09/08/2020 12:34 AM
The powered anode is shorted to earth
ground or to the tank.
MORE
91
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
34
Data Error Code:
(34, 60x4) where
x = 0 is on TRC-1000
board anode circuit.
x = 1 is CPAM 1,
x = 2 is CPAM 2 etc.
No Water
No water is detected by the powered anode.
The Control System is not detecting water in the tank.
1. Ensure there is water in the tank by following Fill the
Tank Instructions found in the installation manual.
2. Inspect anode wire connection for corrosion, moisture,
or other contaminates.
3. Ensure wire connection on both ends is secure.
4. Ensure anode wire harness is not damaged.
5. If problem continues, contact technical support for
further instructions.
CURRENT FAULT
No Water
Occurred:
09/08/2020 12:34 AM
No water is detected by the powered anode.
MORE
36
Data Error Code:
244
(36, 2440x)
x = 1 to 9 are
reason codes.
Weak Flame Signal
The Combustion Safety Control (CSC) is detecting low-ame
generated current.
The control system has detected a weak ame signal
1. Ensure that the ame sensor wire harness is free of
damages
2. Ensure that the ame sensor wire connection on both
ends is secure and free of contaminates
3. Remove ame sensor and inspect for contaminates or
damages in ceramic insulator
4. Clean ame sensor rod with steel wool
5. If the problem continues, contact technical support, or
refer to the service handbook for further instructions
CURRENT FAULT
Weak Flame Signal
Occurred:
09/08/2020 12:34 AM
The Combustion Safety Control (CSC) is
detecting low-flame generated current.
MORE
37
Data Error Code:
2, 130
(37, 2)
Or
(37, 130)
Flame Sensor Error
The control system has detected a ame sensor error.
The ame-sense rod is detecting a ame signal when the
gas valve is supposed to be o.
The control system has detected a ame sensor error.
1. Ensure that the ame sensor wire harness is free of
damages.
2. Ensure that the ame sensor wire connection on both
ends is secure and free of contaminates.
3. Remove ame sensor and inspect for contaminates or
damages in ceramic insulator.
4. Clean ame sensor rod with steel wool.
5. If the problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULT
Flame Sensor Sensing Error
Occurred:
09/08/2020 12:34 AM
The control system has detected a flame
sensor error.
MORE
92
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
38
(Resideo 129, 147,
241)
or 38
Data Error Code:
(38, 129) or
(38, 147) or
(38, 241) or
(38, 38)
Ignition Failure
The control system failed to sense a ame signal during the
ignition sequence.
The control system failed to sense a ame signal during the
ignition sequence
1. Verify that the gas supply, venting, and intake air
pipes are installed according to the instruction manual
provided with the water heater.
2. If the problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULTCURRENT FAULT
CURRENT FAULT
Ignition Failure
Occurred:
09/08/2020 12:34 AM
The control system failed to sense a flame
signal during the ignition sequence.
MORE
41
Data Error Code:
(41, 1003)
High Temperature Warning
The main temperature probe exceeds 190°F.
The water temperature in the tank has exceeded the high
temperature warning temperature. The warning will reset
when tank temperature drops below 180°F.
1. Reset the water heater by toggling the Enable/Disable
switch to disable and back to enable.
2. If the problem continues, use a thermometer at a hot
water xture to conrm the water temperature.
3. If the problem continues, contact technical support or
refer to the service handbook for further instructions.
CURRENT FAULT
CURRENT FAULT
CURRENT FAULT
Temp High Limit
Occurred:
09/08/2020 12:34 AM
The primary temperature exceeds the
high-limit setpoint.
MORE
42
Clock Not Set
Clock (time and date) are not set.
Check the iComm connection (if equipped) and reconnect
for automatic calendar updates.
The control system recognized that the clock is not set.
1. Refer to the installation manual for instructions on how
to set the clock.
2. If the problem continues, contact technical support for
further instructions.
CURRENT FAULT
CURRENT FAULT
CURRENT FAULT
Clock Not Set
Occurred:
09/08/2020 12:34 AM
Clock (time and date) are not set.
MORE
93
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
201
Data Error Code: 71
(201, 71)
Blocked Air Intake
There is a restriction in the air intake. Check the intake pipe
and termination for blockage.
The control system has detected a blockage in the intake
air pipe.
1. Ensure that the intake air pipe installed according to
the manufacturer’s installation manual.
2. Ensure that all horizontal pipe runs are properly sloped
to prevent moisture from accumulating and restricting
air ow.
3. Inspect the inside of the intake air pipe from the
connection at the blower, all the way to the outside
termination for restrictions.
4. Inspect the plastic sensing tube to the blocked intake
air pressure switch to ensure there are no restrictions.
5. Ensure the blocked intake air pressure switch wires
are free from damages and contaminates.
6. Ensure wire connections are secure and free from
contaminates.
7. If problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULTCURRENT FAULT
CURRENT FAULT
Blocked Air Intake
Occurred:
09/08/2020 12:34 AM
There is a restriction in the air intake. Check
the intake pipe and termination for
blockage.
MORE
202
Data Error Code: 70
(202, 70)
Blocked Exhaust
There is a restriction in exhaust pipe. Check exhaust pipe
and termination for blockage.
The control system has detected a blockage in the exhaust
vent pipe.
1. Ensure that the exhaust vent pipe installed according
to the manufacturer’s installation manual.
2. Ensure that all horizontal pipe runs are properly sloped
to prevent moisture from accumulating and restricting
air ow.
3. Inspect the inside of the exhaust vent pipe from the
water heater connection all the way to the outside
termination for restrictions.
4. Inspect the plastic sensing tube to the blocked exhaust
pressure switch to ensure there are no restrictions.
5. Ensure the blocked exhaust pressure switch wires are
free from damages and contaminates.
6. Ensure wire connections are secure and free from
contaminates.
7. If problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULT
Blocked Exhaust
Occurred:
09/08/2020 12:34 AM
There is a restriction in exhaust pipe. Check
exhaust pipe and termination for blockage.
MORE
94
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
205
Data Error Code:
(205,200x)
Where:
x =2 if the key is
uninitialized
x=3 if key
conguration is
corrupt.
Software and FMM Incompatible
The TRC version is older than the TRC version stored in key.
The control system has detected a device that is incompatible.
1. Contact Technical Support for further instructions.
CURRENT FAULT
Software and FMM Key Incompatible
Occurred:
09/08/2020 12:34 AM
The TRC version is older than the TRC
version stored in key.
MORE
206
Data Error Code:
(206, 2011)
CPAM Disconnected
Communication with the anode module has been lost.
The control system has detected that the CPAM is
disconnected.
1. Ensure CPAM is powered
2. Ensure wire connections are secure and free of
contaminates
3. Ensure wire harness is free of damages
4. If problem continues, contact technical support or refer
to the service handbook for further instructions
CURRENT FAULT
CPAM Disconnected
Occurred:
09/08/2020 12:34 AM
Communication with the anode module has
been lost.
MORE
207
Data Error Code:
(207, 35)
CSC Disconnected
Communication with the Combustion Safety control (CSC)
has been lost.
The CSC is disconnected.
1. Ensure the communication cable is securely
connected between the TRC on terminal J4 and the
CSC on terminal X10.
2. If problem continues, contact technical support or refer
to the service handbook for further instructions.
CURRENT FAULT
CSC Disconnected
Occurred:
09/08/2020 12:34 AM
Communication with the anode module has
been lost.
MORE
209
Data Error Code:
(209, 2013)
Water Valve Module Disconnected
Communication with the water valve module has been lost.
The control system has detected that the Valve Module is
disconnected.
1. Ensure Valve module is powered.
2. Ensure wire connections are secure and free of
contaminates.
3. Ensure wire harness is free of damages.
4. If problem continues, contact technical support or refer
to the service handbook for further instructions.
CURRENT FAULT
Water Valve Module Disconnected
Occurred:
04/28/2024 12:34 AM
Communication with the water valve module
has been lost.
MORE
95
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
210
Data Error Code:
(210, 35)
Auto Test Complete
Cycle Main Power to water heater. If problem continues,
contact technical support for further instructions.
CURRENT FAULT
Auto Test Complete/Passed
Occurred:
09/08/2020 12:34 AM
No action required.
MORE
211
Data Error Code:
(211, 133)
No Blower Speed Feedback
The control system has not detected the correct feedback
from the blower when a command was sent to the blower
to operate.
1. Ensure both wire connections to the blower and to the
control system is secure and free of contaminates.
2. Ensure the wire harnesses are free from damages.
3. If problem continue, contact technical support, or refer
to the service handbook for further instructions.
CURRENT FAULT
No Blower Speed Feedback
Occurred:
09/08/2020 12:34 AM
The control system has detected an issue
with the main temperature probe.
MORE
212
Data Error Code:
(212, xxx) where xxx
142, 143,
144 or 146
Main Temperature Probe Failure
The control system has detected an issue with the main
temperature probe.
The control system has detected an issue with the main
temperature probe.
1. Ensure the wire connections for the main temp probe
are clean and secure.
2. Ensure the wire harness for the main temp probe is
free from damages.
3. If the problem continues, contact technical support or
refer to the service handbook for further instructions.
CURRENT FAULT
Main Temperature Probe Failure
Occurred:
09/08/2020 12:34 AM
The control system has detected an issue
with the main temperature probe.
MORE
213
Data Error Code:
(213, 136) or
(213, 243)
Hardware Failure
The control system has detected a ame sensor error.
1. Ensure that the ame sensor wire harness is free of
damages.
2. Ensure that the ame sensor wire connection on both
ends is secure and free of contaminates.
3. Remove ame sensor and inspect for contaminates or
damages in ceramic insulator.
4. Clean ame sensor rod with steel wool.
5. If the problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULT
Hardware Failure
Occurred:
09/08/2020 12:34 AM
The control system has detected a flame
sensor error.
MORE
96
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
214
Data Error Code:
(215, 2400x) where
x is the failed
calibration reason
described in the
service handbook.
Software Failure
The CSC has detected a software issue.
1. Cycle the main power supply to the water heater
by turning o the breaker/disconnect, then wait
approximately 30 seconds and turn main power supply
back on.
2. If problem continues, contact Technical Support or
refer to the service handbook for further instructions.
CURRENT FAULT
Software Failure
Occurred:
09/08/2020 12:34 AM
The CSC has detected a software issue.
MORE
215
Data Error Code:
(215, 2400x) where
x is the failed
calibration reason
described in the
service handbook.
Calibration Error
The CSC has detected a calibration error.
1. The CSC has detected a software issue.
2. Cycle the main power supply to the water heater
by turning o the breaker/disconnect, then wait
approximately 30 seconds and turn main power supply
back on.
3. If problem continues, contact Technical Support or
refer to the service handbook for further instructions.
CURRENT FAULT
Calibration Error
Occurred:
09/08/2020 12:34 AM
The CSC has detected a calibration error.
MORE
216
Data Error Code:
(216, 137)
Gas Valve Circuit Fault
The control system has detected a fault with the Gas Valve
Circuit.
1. Ensure wire connections on both ends are secure and
free of contaminates.
2. Ensure wire harness is not damaged.
3. If problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULT
Gas Valve Circuit Fault
Occurred:
09/08/2020 12:34 AM
The control system has detected a fault with
the Gas Valve Circuit.
MORE
217
Data Error Code:
(217, 242)
MDT Fault
The control system has detected a fault with the Motor Driven
Throttle (MDT).
1. Ensure wire connections on both ends are secure and
free of contaminates.
2. Ensure wire harness is not damaged.
3. If problem continues, contact technical support, or
refer to the service handbook for further instructions.
CURRENT FAULT
MDT Fault
Occurred:
09/08/2020 12:34 AM
The control system has detected a fault with
the Motor Driven Throttle (MDT).
MORE
218
Data Error Code:
(209, 2014)
BMS Module Disconnected
Communication with the BMS module has been lost.
The control system has detected that the BMS is
disconnected.
1. Ensure BMS module is powered.
2. Ensure wire connections are secure and free of
contaminates.
3. Ensure wire harness is free of damages.
4. If problem continues, contact technical support or refer
to the service handbook for further instructions.
CURRENT FAULT
BMS Module Disconnected
Occurred:
09/08/2020 12:34 AM
Communication with the BMS module has
been lost.
MORE
98
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
224
Data Error Code:
(224, 2005)
TRC Software or Hardware Is Old
The control system has detected that the Software or
Hardware Version on the TRC is outdated.
The control system has detected that the Software or
Hardware Version on the TRC is outdated.
1. Typically caused by replacing control system
components with an older revision software.
2. Contact technical support for further instructions.
CURRENT FAULT
TRC Software or Hardware is old.
Occurred:
09/08/2020 12:34 AM
The control system has detected that the
Software or Hardware Version on the TRC is
outdated.
MORE
225
(225, 2007)
Display software or hardware is old
The control system has detected that the Software Hardware
Version on the UIM is outdated.
1. Typically caused by replacing control system
components with an older revision software.
2. Contact technical support for further instructions.
CURRENT FAULT
Display software or hardware is old.
Occurred:
09/08/2020 12:34 AM
The control system has detected that the
Software Hardware Version on the UIM is
outdated
MORE
226
(226, 60xy)
where
x = 0 is on TRC-1000
board anode circuit.
x = 1 is CPAM 1,
x = 2 is CPAM 2 etc.
y = 1, 2, 3, 5, 6 or 8)
Powered Anode Circuit Failure
The control system has detected a failure with the Powered
Anode Circuit.
1. Cycle main power to the water heater.
2. Contact technical support for further instructions.
CURRENT FAULT
Powered Anode Circuit Failure.
Occurred:
09/08/2020 12:34
The control system has detected a failure
with the Powered Anode Circuit.
MORE
99
Fault and Alert Messages
FAULT CODE Possible Causes - Check/Repair
Displayed Fault/Alert Message
227
(227, 4001)
FMM Incompatible
The control system has detected that the Software Version
on the Flex Memory Module (FMM) is outdated.
1. Typically caused by replacing control system
components with an older revision software.
2. Contact technical support for further instructions.
CURRENT FAULT
FMM Incompatible
Occurred:
04/28/2025 12:34 AM
The control system has detected that the
Software Version on the Flex Memory
Module (FMM) is outdated.
MORE
228
(228, 2015)
User Setpoints Error Detected
Data corruption of user adjustable setpoints led to factory
reset of default values.
Toggle the Enable/Disable switch to Disable, wait 30
seconds and toggle back to Enable to clear fault and readjust
setpoints
CURRENT FAULT
User Setpoints Error Detected
Occurred:
04/28/2025 12:34 AM
Data corruption of user adjustable setpoints
led to factory reset of default values.
MORE
100
CHECKING FOR LEAKS
1
2
3
4
7
10
6
5
8
9
11
Figure 85. Leakage Checkpoints
Failure to follow these instrucons and safety
messages could result in death or serious injury.
Read and understand this instrucon manual and the
safety messages herein before installing or. operang
or servicing this water heater.
This manual must remain with the water heater.
⚠
WARNING
Safety Hazard
Never use this water heater unless it is completely lled with water.
To prevent damage to the tank, the tank must be lled with water.
Water must ow from the hot water faucet before turning “ON” gas
to the water heater.
1. *The anode rod ttings may be leaking.
2. *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
3. Condensate from the exhaust connection.
4. Leakage from recirculation plug or pipe connection.
5. *The drain valve may be leaking at the tank tting.
6. Water from a drain valve may be due to the valve being slightly
opened.
7. Leakage from the plug under the clean-out cover.
8. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
9. Leakage from the temperature probe connection (Not shown
in gure).
10. *The temperature probe tting may be leaking.
11. *The temperature-pressure relief valve may be leaking at the
tank tting.
CHECKING THE THREADED FITTINGS
Leakage from other water heaters, water lines, or ground seepage
should also be checked.
1. * To check where threaded portion enters tank, do the following:
2. Insert cotton swab between jacket opening and tting.
3. If cotton is wet, follow drain the tank and then remove tting. See
Draining the Water Heater Storage Tank
(page 79).
4. Put pipe dope or thread-sealer tape on the threads and replace.
5. Then follow the instructions in
Filling The Water Heater
(page
56).
101
DIAGRAMSDIAGRAMS
WIRING DIAGRAMS
Circulation Pump Wiring Diagrams
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 86. Recirculating Loop with Storage Tank or Building Recirculation
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 87. Recirculating Loop with Dish Washer and Toggle Switch
102
Control Circuit Diagrams
J7
J13
12
4 3
1 2
3
4
76
5
8 9 10
1
2 3
4
109
65
11
12 13 14
123
45
6
123
67
8
45
9
10
87
15 16
X5
X7
X1
X3
X10
FF2
FF1
Blower Power
Hall Sensor
PWM
GND
24Vdc
L1
N
PE/GND
Gas Valves
Motor Driven
N
L1
Connected to
heater jacket
PE/GND
NTC1
NTC2
Main Temperature Probe
Flame Sensor Rod
Spark XFMR
NTC3
NTC Lower
Connected to
tank
1(L1)
2(N)
3(PE)
1
23
4
10
6 5
11121314
8
7
1516
J6
9
18 17
123
4
6 5
8
7
J8
1
23
45
1
23
45
1
23
4 15
23
J2
J3
J9
J4
9876
1
J5
J10
Enable/Disable Switch
(LDM)
Display 2.0
FMM
Key
Powered Anode 1 & 2
Field Wiring
L1 PE/GNDN
+5V
D+
D-
DGND
+5V
D+
D-
DGND
+5V
D+
D-
DGND
D+
D-
DGND
Outlet Air
Inlet Air
Spark Rod
Connected to
tank PE/GND
Pressure SW
Pressure SW
TEMPERATURE
REGULATION CONTROL
(TRC)
COMBUSTION & SAFETY
CONTROL
(CSC)
NO FACTORY
CONNECTIONS
NO FACTORY
CONNECTIONS
AC Power
120 Vac/60Hz
Junction Box
PE/GND
P1
P2
P3
P4
P5
P6
P7
P8
OPEN
OPEN
OPEN
OPEN
CPAM N
CPAM L1
L1
N
L1
N
PE/GND
(OAPS)
(IAPS)
PE/GND
PE/GND
L1
N
Leak Detection Module
Connected to tank
PE/GND
Throttle (MDT)
Blower Command
NO FACTORY
CONNECTIONS
123456
NO FACTORY
CONNECTIONS
NO FACTORY
CONNECTIONS
123
S4962VX1018
Field Wiring
WHITE
BLACK
GREEN
GREEN
BLACK
WHITE
WHITE
WHITE
GREEN
GREEN
GREEN
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
GREEN
WHITE
GREEN
GREEN
WHITE
GREEN
BLUEBLUE
ORANGE
ORANGE
BROWN
BROWN
BLUE
BLUE
WHITE
WHITE
BLACK
BLACK
GREY
GREY
VIOLET
VIOLET
BLACK
YELLOW
123
4
6 5
8
7
123
4
6 5
8
7
ORANGE
ORANGE
INNER EXT
BLACK
GREEN
BLUE
BLACK
WHITE
WHITE
GREEN
RED
BLUE
YELLOW
GREEN
RED
YELLOW
BLUE
BLACK
GREY
VIOLET
RED
YELLOW
GREEN
RED
BLACK
BLUE
WHITE
12
4 3
12
4 3
2A
2
1A
1
WHITE
BLACK
GREEN
RED
1234
1234
RED
YELLOW
BLUE
BLACK
NO FACTORY
CONNECTIONS
P1, P2, P3, P4, P5, and P6 ARE NOT USED
GREEN
5
4
3
2
8765
2
1
3
4
EXTERNAL ENABLE
DISABLE SWITCH
Alarm
Louvre
Figure 88. 60 Gallon Models Temperature Regulation and Combustion and Safety Control Wiring Diagram
103
J7
J13
12
4 3
1 2
3
4
76
5
8 9 10
1
2 3
4
109
65
11
12 13 14
123
45
6
123
67
8
45
9
10
87
15 16
X5
X7
X1
X3
X10
FF2
FF1
Blower Power
Hall Sensor
PWM
GND
24Vdc
L1
N
PE/GND
Gas Valves
Motor Driven
N
L1
Connected to
heater jacket
PE/GND
NTC1
NTC2
Main Temperature Probe
Flame Sensor Rod
Spark XFMR
NTC3
NTC Lower
Connected to
tank
1(L1)
2(N)
3(PE)
1
23
4
10
6 5
11121314
8
7
1516
J6
9
18 17
123
4
6 5
8
7
J8
1
23
45
1
23
45
1
23
4 15
23
J2
J3
J9
J4
9876
1
J5
J10
Enable/Disable Switch
(LDM)
Display 2.0
FMM
Key
Powered Anode 1 & 2
Field Wiring
L1 PE/GNDN
+5V
D+
D-
DGND
+5V
D+
D-
DGND
+5V
D+
D-
DGND
D+
D-
DGND
Outlet Air
Inlet Air
Spark Rod
Connected to
tank PE/GND
Pressure SW
Pressure SW
TEMPERATURE
REGULATION CONTROL
(TRC)
COMBUSTION & SAFETY
CONTROL
(CSC)
NO FACTORY
CONNECTIONS
NO FACTORY
CONNECTIONS
AC Power
120 Vac/60Hz
Junction Box
PE/GND
P1
P2
P3
P4
P5
P6
P7
P8
OPEN
OPEN
OPEN
OPEN
CPAM N
CPAM L1
L1
N
L1
N
PE/GND
(OAPS)
(IAPS)
PE/GND
PE/GND
L1
N
Leak Detection Module
Connected to tank
PE/GND
Throttle (MDT)
Blower Command
NO FACTORY
CONNECTIONS
123456
NO FACTORY
CONNECTIONS
NO FACTORY
CONNECTIONS
123
S4962VX1018
Field Wiring
WHITE
BLACK
GREEN
GREEN
BLACK
WHITE
WHITE
WHITE
GREEN
GREEN
GREEN
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
GREEN
WHITE
GREEN
GREEN
WHITE
GREEN
BLUEBLUE
ORANGE
ORANGE
BROWN
BROWN
BLUE
BLUE
WHITE
WHITE
BLACK
BLACK
GREY
GREY
VIOLET
VIOLET
BLACK
YELLOW
123
4
6 5
8
7
123
4
6 5
8
7
ORANGE
ORANGE
INNER EXT
BLACK
GREEN
BLUE
BLACK
WHITE
WHITE
GREEN
RED
BLUE
YELLOW
GREEN
RED
YELLOW
BLUE
BLACK
GREY
VIOLET
RED
YELLOW
GREEN
RED
BLACK
BLUE
WHITE
12
4 3
12
4 3
2A
2
1A
1
WHITE
BLACK
GREEN
RED
1234
1234
RED
YELLOW
BLUE
BLACK
NO FACTORY
CONNECTIONS
P1, P2, P3, P4, P5, and P6 ARE NOT USED
GREEN
5
4
3
2
8765
2
1
3
4
EXTERNAL ENABLE
DISABLE SWITCH
Alarm
Louvre
Figure 89. 100 Gallon Models - Temperature Regulation and Combustion and Safety Control Wiring Diagram
104
J13
J7
4 3
1 2
3
4
76
5
8 9 10
1
2 3
4
109
65
11
12 13 14
123
45
6
123
67
8
45
9
10
87
15 16
X5
X7
X1
X3
X10
FF2
FF1
Blower Power
Hall Sensor
PWM
GND
24Vdc
L1
N
PE/GND
Gas Valves
Motor Driven
N
L1
Connected to
heater jacket
PE/GND
NTC1
NTC2
Main Temperature Probe
Flame Sensor Rod
Spark XFMR
NTC3
NTC Lower
Connected to
tank
1(L1)
2(N)
3(PE)
1
23
4
10
6 5
11121314
8
7
1516
J6
9
18 17
123
4
6 5
8
7
J8
1
23
45
1
23
45
1
23
45 1
23
1
2
J2
J3
J9
J4
98764 52 31
J5
J10
Enable/Disable Switch
(LDM)
Display 2.0
FMM
KEY
Powered Anode 1 & 2
Alarm
Field Wiring
L1 PE/GNDN
+5V
D+
D-
DGND
+5V
D+
D-
DGND
+5V
D+
D-
DGND
D+
D-
DGND
Outlet Air
Inlet Air
Spark Rod
Connected to
tank PE/GND
Pressure SW
Pressure SW
CPAM
TEMPERATURE
REGULATION CONTROL
(TRC)
COMBUSTION & SAFETY
CONTROL
(CSC)
CPAM
Power Supply
12VDC
NO FACTORY
CONNECTIONS
NO FACTORY
CONNECTIONS
AC Power
120 Vac/60Hz
Junction Box
PE/GND
P1, P2, P3, and P4 ARE NOT USED
P1
P2
P3
P4
P5
P6
P7
P8
OPEN
OPEN
OPEN
OPEN
CPAM N
CPAM L1
L1
N
L1
N
PE/GND
(OAPS)
(IAPS)
PE/GND
PE/GND
L1
N
Leak Detection Module
Powered Anode 3
Connected to tank
PE/GND
Connected to tank
PE/GND
Throttle (MDT)
Blower Command
NO FACTORY
CONNECTIONS
123456
NO FACTORY
CONNECTIONS
NO FACTORY
CONNECTIONS
123
S4962VX1018
Field Wiring
WHITE
BLACK
GREEN
GREEN
GREEN
BLACK
BLACK
WHITE
WHITE
WHITE
WHITE
GREEN
GREEN
GREEN
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
GREEN
WHITE
GREEN
GREEN
WHITE
GREEN
BLUEB
LUE
ORANGE
ORANGE
BROWN
BROWN
BLUE
BLUE
WHITE
WHITE
BLACK
BLACK
GREY
GREY
VIOLET
VIOLET
BLACK
YELLOW
123
4
6 5
8
7
123
4
6 5
8
7
ORANGE
ORANGE
INNER EXT
BLACK
GREEN
BLUE
BLACK
WHITE
WHITE
GREEN
RED
GREEN
BLACK
BLUE
YELLOW
GREEN
WHT/OR
WHT/BR
BLUE
WHT/BL
RED
YELLOW
BLUE
BLACK
BLACK
GREY
VIOLET
RED
YELLOW
GREEN
RED
BLACK
BLUE
WHITE
12
4 3
12
4 3
2A
2
1A
1
WHITE
BLACK
GREEN
RED
1234
1234
RED
YELLOW
BLUE
BLACK
Louvre
8765
2
1
3
4
EXTERNAL ENABLE
DISABLE SWITCH
Figure 90. 119 Gallon Models Temperature Regulation and Combustion and Safety Control Circuit Diagram
105
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
Expansion Tank
Cold Water
Supply
Finished Floor
Hot Water to Fixtures
Pipe T&P Valve
to Open Drain
Floor Drain
Hot Water
Return
M
M
M
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
WATER PIPING DIAGRAMS
One Water Heater, Single Temperature with Building Recirculation
106
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
M
M
M
Pipe T&P to
Open Drain
Hot Water
Return
Tempered
Water Outlet
Outlet
Tempered
Water Return
Cold Water
Supply
Expansion
Tank
Cold
Hot
Finished Floor
Floor Drain
12” to 15”
Mixing Valve
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
107
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
STORAGE TANK
Pipe T&P to
Open Drain
Hot
Water
Return
Hot Water to Fixtures
Alternate Cold
Cold Water
Supply
Expansion
Tank
Finished Floor
Floor Drain
M
M
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang 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 operang thermostat should be set 5 degrees F higher than the tank temperature control.
6. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
108
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
STORAGE TANK
Pipe T&P to
Open Drain
Hot
Water
Return
Hot Water to Fixtures
Alternate Cold
Cold Water
Supply
Expansion
Tank
Finished Floor
Floor Drain
M
M
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang 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 operang thermostat should be set 5 degrees F higher than the tank temperature control.
6. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
109
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
M
M
M
M
M
M
Hot
Water
Return
Cold Water
Supply
Expansion
Tank
Pipe T&P to
Open Drain
Hot Water to Fixtures
Finished Floor
Floor Drain
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
110
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
M
M
M
M
M
M
M
M
M
Hot Water
Return
Pump
Tank
Temperature
Control
Cold Water
Supply
Expansion
Tank
Floor Drain
Pipe T&P to
Open Drain
Hot Water to Fixtures
Finished Floor
Pipe T&P to
Open Drain
Pipe T&P to
Open Drain
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
111
Before installation of water piping review the following:
1. See
Mixing Valves
(page 22).
2. See
Dish-washing Machines
(page 22).
3. See
Temperature-Pressure Relief Valve
(page 22).
4. See
Closed Water Systems
(page 22)
and
Thermal Expansion
(page
22).
5. See
Water Line Connections
(page 54).
6. If a pump is being installed between a water heater and storage
tank or on a building recirculation loop wire according to
Figure
86 (page 101)
.
7. If a pump is being installed in a recirculation loop between the
water heater and a commercial dishwasher wire according to
Figure 87 (page 101)
.
WARNING: THIS DRAWING SHOWS A
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.
LEGEND
Temperature & Pressure Relief Valve
Pressure Relief Valve
Tank Temperature Control
Drain Valve
Full-Port Ball Valve
Check Valve
Temperature Gage
Water Flow Switch
Mixing Valve
M
Shut-Off Valve
M
M
M
M
M
M
M
M
M
M
M
M
Hot
Water
Return
Pump
Tank
Temperature
Control
Hot Water to Fixtures
Pipe T&P to
Open Drain
Cold Water
Supply
Expansion
Tank
Finished Floor
Floor Drain
Pipe T&P to
Open Drain
Pipe T&P to
Open Drain
Pipe T&P to
Open Drain
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve seng shall not exceed pressure rang of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. Ensure that any installed recirculaon system does not bypass or interfere in any way with shut-off valves.
112
NOTESNOTES
113
NOTESNOTES
114
NOTESNOTES
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