commercial gas water heaters
instruction manual
PRINTED 0914 318230-004
place these instructions adjacent to heater and notify owner to keep for future reference.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
models Btr 500
series 120/121
installation - operation - serVice
- maintenance - limited warranty
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
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.
•
•
•
•
LOW LEAD
CONTENT
500 Tennessee Waltz Parkway
Ashland City, TN 37015
2
Outdoor Air Through Two Horizontal Ducts ................................... 16
Outdoor Air Through Two Vertical Ducts ........................................ 17
Air From Other Indoor Spaces ....................................................... 17
Technical Data Venting ..................................................................18
WATer HeATer INSTAllATION ...................................................... 19
Water line Connections ................................................................ 19
Thermometers (not Supplied) ........................................................ 19
Water Piping Diagrams .................................................................. 19
T&P Valve Discharge Pipe ............................................................. 19
Installation Diagrams - Top Inlet/Outlet Usage .............................. 20
Heater Wiring ................................................................................. 21
Gas Piping ..................................................................................... 22
Gas line leak Testing ................................................................... 22
Purging .......................................................................................... 22
STArT UP .......................................................................................... 23
Prior to Start Up ............................................................................. 23
Initial Start Up ................................................................................ 23
Checking Venting ........................................................................... 24
Gas Valves ..................................................................................... 24
Checking the Input .........................................................................24
Water Temperature Adjustment .....................................................24
SeQUeNCe OF OPerATION ...........................................................25
lighting & Operation label ............................................................ 25
Sequence of Operation Flow Chart ............................................... 26
MAINTeNANCe .................................................................................27
Check the Igniter Assembly and Main Burners .............................. 27
Igniter Assembly ............................................................................ 27
Main Burner ................................................................................... 27
Venting System .............................................................................. 27
remote Storage Tank Temperature Control ..................................27
Temperature-Pressure relief Valve Test .......................................27
Anode rod Inspection ................................................................... 28
Draining and Flushing .................................................................... 28
recommended Procedure for Periodic removal of lime Deposits
from Tank Type Commercial Water Heaters ................................. 28
Deliming Solvents .......................................................................... 29
Tank Cleanout Procedure .............................................................. 29
Deliming Using FlO-JUG Method ................................................. 29
SerVICe ............................................................................................ 31
Checklist ........................................................................................ 31
System Diagnostics ....................................................................... 31
electrical Servicing ........................................................................ 31
FOR yOUR INFORmATION ............................................................... 32
Start Up Conditions .......................................................................32
Operational Conditions .................................................................. 32
TrOUBleSHOOTING .......................................................................33
WATer PIPING DIAGrAMS ..............................................................34
MANIFOlD KITS ................................................................................ 49
lIMITeD WArrANTy ........................................................................ 50
NOTeS ...............................................................................................51
2
taBle of contents
SAFe INSTAllATION, USe AND SerVICe........................................3
APPrOVAlS ........................................................................................ 3
GeNerAl SAFeTy INFOrMATION .................................................... 4
Precautions ......................................................................................5
Grounding Instructions ....................................................................5
Hydrogen Gas Flammable ............................................................... 5
INTrODUCTION .................................................................................. 6
Abbreviations Used .........................................................................6
Qualications ................................................................................... 6
Preparing For The Installation ......................................................... 6
FeATUreS AND COMPONeNTS .......................................................7
The eliminator (self-cleaning system) .............................................7
High limit Switch ............................................................................. 7
electronic Ignition Control ................................................................ 7
exhaust Inducer (blower assy.)........................................................ 7
Uncrating ......................................................................................... 7
INSTAllATION CONSIDerATIONS ................................................... 8
Rough In Dimensions ...................................................................... 8
recovery Capacities ........................................................................ 8
Gas and electrical Characteristics ................................................... 8
locating the Water Heater ............................................................... 9
Clearances ......................................................................................9
Installation On Combustible Flooring ............................................. 10
Insulation Blanket .......................................................................... 10
Hard Water ....................................................................................10
Circulation Pumps .........................................................................10
High Altitude Installations .............................................................. 11
Propane Installations ..................................................................... 11
Natural Gas Installations ............................................................... 11
INSTAllATION reQUIreMeNTS ....................................................12
Gas Supply Systems ..................................................................... 12
Gas Pressure requirements ......................................................... 12
Supply Gas regulator ...................................................................12
Power Supply ................................................................................12
Water Temperature Control and Mixing Valves.............................. 12
Dishwashing Machines .................................................................. 13
Closed Water Systems .................................................................. 13
Thermal Expansion ........................................................................ 13
Temperature-Pressure relief Valve ...............................................13
Contaminated Air ........................................................................... 14
Air requirements ........................................................................... 14
Unconned Space ......................................................................... 15
Conned Space ............................................................................. 15
Vent Adapter ..................................................................................15
VeNTING INSTAllATION .................................................................15
Venting ........................................................................................... 15
Multiple Heater Manifold ................................................................ 16
Fresh Air Openings For Conned Spaces ..................................... 16
Outdoor Air Through Two Openings .............................................. 16
Outdoor Air Through One Opening ................................................ 16
3
safe installation, use and serVice
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive
harm. This appliance can cause low level exposure to some of the substances listed in the Act.
DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
approVals
4
general safety information
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
Fire and Explosion Hazard
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Use joint compound or Teflon tape
compatible with propane gas.
Turn off power to the water heater
before performing any service.
Electrical Shock Hazard
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
Verify proper operation after servicing.
•
Failure to follow these instructions can
result in personal injury or death.
•
Fire Hazard
For continued protection against
risk of fire:
•
Do not install water heater on
carpeted floor.
•
Do not operate water heater if
any part has been exposed to
flooding or water damage.
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Jumping out control circuits or components can
result in property damage, personal injury or death.
Service should only be performed by a qualified service
technician using proper test equipment.
•
Altering the water heater controls and/or wiring in any way
could result in permanent damage to the controls or water
heater and is not covered under the limited warranty.
•
Any bypass or alteration of the water
heater controls and/or wiring will result
in voiding the water heater warranty.
Altering the water heater controls and/or wiring in any way
could result in altering the ignition sequence allowing gas to
flow to the main burner before the hot surface igniter is at
ignition temperature causing delayed ignition which can
cause a fire or explosion.
•
5
precautions
DO NOT USe THIS WATer HeATer IF ANy PArT HAS
BeeN eXPOSeD TO FlOODING Or WATer DAMAGe.
Immediately call a qualified service technician to inspect
the water heater and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualified
service technician.
1. external re.
2. Damage.
3. Firing without water.
grounding instructions
This water heater must be grounded in accordance with the
National electrical Code and/or local codes. These must be
followed in all cases.
This water heater must be connected to a grounded 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,
see Figure 20.
hydrogen gas flammaBle
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Hydrogen gas can be produced in a hot water system served
by this 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 appliance be
opened for several minutes before using any electrical appliance
connected to the hot water system. If hydrogen is present there
will probably be an unusual sound such as air escaping through
the pipe as the water begins to ow. THere SHOUlD Be NO
SMOKING Or OPeN FlAMe NeAr THe FAUCeT AT THe
TIMe IT IS OPeN.
general safety information
Verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
general safety information
Improper installation, use and service may result
in property damage.
•
Do not operate water heater if any part has been exposed
to flooding or water damage.
•
Inspect anode rods regularly, replace if damaged.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
CAUTION
6
Thank you for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
aBBreViations used
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASMe - American Society of Mechanical engineers
• AHrI - Air-Conditioning, Heating and refrigeration Institute
• NeC - National electrical Code
• NFPA - National Fire Protection Association
• Ul - Underwriters laboratory
• CSA - Canadian Standards Association
Qualifications
Qualified installer or serVice agency
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI
below) in the eld involved. Installation skills such as plumbing,
air supply, venting, gas supply and electrical supply are required
in addition to electrical testing skills when performing service.
ansi Z223.1 2006 sec. 3.3.83: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person
or through a representative is engaged in and is responsible
for (a) the installation, testing or replacement of gas piping
or (b) the connection, installation, testing, repair or servicing
of appliances and equipment; that is experienced in such
work; that is familiar with all precautions required; and that
has complied with all the requirements of the authority having
jurisdiction.”
If you are not qualied (as dened by ANSI above) and licensed
or certied as required by the authority having jurisdiction
to perform a given task do not attempt to perform any of the
procedures described in this manual. If you do not understand
the instructions given in this manual do not attempt to perform
any procedures outlined in this manual.
preparing for the installation
1. read the entire manual before attempting to install or
operate the water heater. Pay close attention to the General
Safety Information on pages 4 and 5. If you don’t follow the
safety rules, the water heater may not operate safely. It
could cause property damage, injury and/or death.
This manual contains instructions for the installation,
operation, and maintenance of the water heater. It also
contains warnings throughout the manual that you must
read and be aware of. All warnings and all instructions are
essential to the proper operation of the water heater and
your safety.
Detailed installation diagrams are also found in this manual.
These diagrams will serve to provide the installer with a
reference. It is essential that all venting, water piping, gas
piping and wiring be installed as shown.
introduction
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" on page in this manual. Use
this reference to locate and identify various components on
the water heater.
See Troubleshooting on page 33. By using this information
the user may be able to make minor operational adjustments
and avoid unnecessary service calls. However, service
and diagnostic procedures should only be performed by a
Qualied Service Agency.
Note: Costs to correct installation errors are not covered
under the limited warranty.
2. Be sure to turn off power when working on or near the
electrical system of the water heater. Never touch electrical
components with wet hands or when standing in water.
3. The installation must conform to all instructions contained in
this manual and the local code authority having jurisdiction.
These shall be carefully followed in all cases. Authorities
having jurisdiction should be consulted before installation
begins if there are any questions regarding compliance with
local, state or national codes.
In the absence of local codes, the installation must comply
with the current editions of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and the National electrical Code,
NFPA 70 or CAN/CSA-B149.1, the Natural Gas and
Propane Installation Code and CSA C22.1, the Canadian
electrical Code. All documents are available from the
Canadian Standards Association, 8501 east Pleasant Valley
road, Cleveland, OH 44131. NFPA documents are also
available from the National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
4. If after reading this manual you have any questions or do
not understand any portion of the instructions, call the toll
free number on the back cover of this manual for technical
assistance. In order to expedite your request, please have
the full Model, Serial and Series number of the water heater
you are working with available for the technician. This
information is located on the water heater’s rating label.
5. Carefully plan the placement of the water heater. examine
the location to ensure that it complies with the requirements
in locating The Water Heater on page 9 and the rough In
Dimensions on page 8.
6. For installation in California this water heater must be braced
or anchored to avoid falling or moving during an earthquake.
See instructions for correct installation procedures.
Instructions may be obtained from California Ofce of the
State Architect, 1102 Q Street, Suite 5100, Sacramento, CA
95811.
7
the eliminator (self-cleaning system)
These units include The eliminator (Self-Cleaning System)
installed in the front water inlet, See Figure 1. The eliminator inlet
tube can only be used in the front water inlet connection. Do not
install the eliminator inlet tube in either the top or back inlet water
connection. The eliminator must be oriented correctly for proper
function. There is a marked range on the pipe nipple portion of
the eliminator, that must be aligned with the top of the inlet spud.
A label above the jacket hole has an arrow that will point to the
marked portion of the pipe nipple if the orientation is correct. If
the arrow does not point within the marked range on the pipe
nipple, adjust the pipe nipple to correct. A pipe union is supplied
with the eliminator to reduce the probability of misaligning the
eliminator accidentally while tightening the connection to the
inlet water supply line. Improper orientation of the eliminator
can cause poor performance of the heater and can signicantly
reduce outlet water temperatures during heavy draws.
note: the eliminator may have 1, 3 or 7 cross tubes.
figure 1
high limit switch
The digital thermostat (Figure 2) contains the high limit (energy
cutout) switch. The high limit switch interrupts main burner gas
ow should the water temperature reach 203°F (95°C).
In the event of high limit switch operation, the water heater
cannot be restarted unless the water temperature is reduced to
approximately 120°F (49°C). The high limit reset button on the
front of the control then needs to be depressed.
Continued manual resetting of high limit control, preceded by
higher than usual water temperature is evidence of high limit
switch operation. The following is a possible reason for high limit
switch operation:
• A malfunction in the thermostatic controls would allow the gas
valve to remain open causing water temperature to exceed the
thermostat setting. The water temperature would continue to
rise until high limit switch operation.
Contact your dealer or qualied service agency if continued high
limit switch operation occurs.
digital thermostat
figure 2
electronic ignition control
each heater is equipped with an ignition control. The solid state
ignition control (Figure 3), ignites the main burner by utilizing a
silicon nitride igniter. The silicon nitride igniter shuts off during
the heating cycle and the main burner ame is sensed through
a remote ame sensor integral to the silicon nitride igniter
assembly.
The ignition control will try to ignite the main burner three times
before lockout. Then it waits one hour before tr ying again to ignite
the main burners. This is a continuous cycle.
ignition control Board
figure 3
exhaust inducer (Blower assy.)
All models are equipped with an exhaust inducer. The inducer
assists in drawing in fresh air to the unit for combustion and then
assists in dispensing the combustion by-products into the venting
leading outside.
The exhaust inducer is equipped with a gravity controlled damper
to reduce the amount of heat loss through the ue, improving
efciency.
exhaust inducer
figure 4
uncrating
The heater is shipped with the inducer already installed. The
wiring conduit runs from the thermostat to the inducer. Before
turning unit on, check to make sure the wiring conduit is securely
plugged into the inducer.
features and components
8
rough in dimensions
recoVery capacities
gas and electrical characteristics
front View
top View
Back View
TABLE 2. RECOVERY CAPACITIES, based on 80% thermal efciency
f
top
outlet
1 1/2” npt
top
inlet
1 1/2” npt
taBle 3. gas and electrical characteristics
taBle 1. rough-in-dimensions
Model
Input Rate
Btu/Hr
Kw/Hr
Approximate
Tank Cap
G/l
Dimensions in Inches/cm
Connections
Approx. Ship Weight
Inlet (NPT) Outlet (NPT)
A B C D E F
Gas
Inlet
G H
Vent
Dia
I J
Top Front Back Top Front Back Std.
lbs/
Kgs.
ASMe
lbs/
Kgs.
BTr 500 500,000 85 81.50 17.50 77.25 67.50 27.13 21.00 1.00 67.50 8.00 27.75 1.50 1.50 1.50 1.50 1.50 1.50 812 857
BTr500 147 322 207 44 196 171 69 53 3 171 20 70 1.50 1.50 1.50 1.50 1.50 1.50 368 389
Model
Input Rate
Btu/Hr
Kw/Hr
Approximate
Tank Cap
G/l
recovery rating Capacities (GPH and lPH) at temperature rise indicated
30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F
17°C 22°C 28°C 33°C 39°C 44°C 50°C 56°C 61°C 67°C 72°C 78°C
BTr 500 500,000 85 1616 1212 970 808 693 606 539 485 441 404 373 346
BTr 500 147 322 6118 4588 3671 3059 2622 2294 2039 1835 1668 1529 1412 1311
Model Gas Type
Gas Supply Pressure
Gas Manifold Pressure Volts / Hz Amperes
minimum maximum
BTr-500 Natural 4.5" W.C. (1.12 kPa) 14" W.C. (3.48 kPa) 3.5" W.C. (0.87 kPa) 120/60 <5
BTr-500 Propane 11" W.C. (2.74 kPa) 14" W.C. (3.48 kPa) 10" W.C. (2.49 kPa) 120/60 <5
installation considerations
figure 5
9
IS NOT SUBJeCT TO PHySICAl DAMAGe By A MOVING
VeHICle.
flammaBle items, PreSSUrIZeD CONTAINerS Or ANy
OTHer POTeNTIAl FIre HAZArDOUS ArTICleS MUST
NeVer Be PlACeD ON Or ADJACeNT TO THe HeATer.
OPeN CONTAINerS Or FlAMMABle MATerIAl SHOUlD
NOT Be STOreD Or USeD IN THe SAMe rOOM WITH THe
HeATer.
THe HeATer MUST NOT Be lOCATeD IN AN AreA WHere
IT WIll Be SUBJeCT TO FreeZING.
lOCATe IT NeAr A FlOOr DrAIN. THe HeATer SHOUlD
Be lOCATeD IN AN AreA WHere leAKAGe FrOM THe
HeATer Or CONNeCTIONS WIll NOT reSUlT IN DAMAGe
TO THe ADJACeNT AreA Or TO lOWer FlOOrS OF THe
STrUCTUre.
WHeN SUCH lOCATIONS CANNOT Be AVOIDeD, A SUITABle
DrAIN PAN SHOUlD Be INSTAlleD UNDer THe HeATer.
Such pans should be fabricated with sides at least 2” (5.1 cm)
deep, with length and width at least 2” (5.1 cm) greater than the
diameter of the heater and must be piped to an adequate drain.
The pan must not restrict combustion air ow.
clearances
This water heater is approved for installation on combustible
ooring (with NSF leg Kit #9003425205) in an alcove when the
minimum clearance from any combustible construction is as
indicated in Figure 6 and Table 4.
In all installations the minimum combustible clearances from
vent piping shall be 6” (15.2 cm). Vent piping passing through a
combustible wall or ceiling must be a continuous run (no joints)
and retain the 6” (15.2 cm) clearance unless an approved reducing
thimble is used.
A service clearance of at least 24” (61 cm) should be maintained
from serviceable parts.
The units are approved for installation with side, rear and ceiling
clearances as indicated below:
taBle 4
minimum clearances to comBustiBles in inches (mm)
model
"a"
right
side
"B"
left
side
"c"
Back
"d"
ceiling
BTr 500
5"
(12.7 cm)
5"
(12.7 cm)
5"
(12.7 cm)
20"
(50.8 cm)
taBle 5
minimum clearances to noncomBustiBle construction
model
"a"
right
side
"B"
left
side
"c"
Back
"d"
ceiling
BTr 500 0 0 0
12"
(30.5 cm)
locating the water heater
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
When installing the heater, consideration must be given to
proper location. location selected should be as close to the
stack or chimney as practicable, with adequate air supply and as
centralized with the piping system as possible.
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
THere IS A rISK IN USING FUel BUrNING APPlIANCeS
SUCH AS GAS WATer HeATerS IN rOOMS, GArAGeS Or
OTHer AreAS WHere GASOlINe, OTHer FlAMMABle
lIQUIDS Or eNGINe DrIVeN eQUIPMeNT Or VeHICleS Are
STOreD, OPerATeD Or rePAIreD. FlAMMABle VAPOrS
Are HeAVy AND TrAVel AlONG THe FlOOr AND MAy Be
IGNITeD By THe HeATer’S PIlOT Or MAIN BUrNer FlAMeS
CAUSING FIre Or eXPlOSION. SOMe lOCAl CODeS
PerMIT OPerATION OF GAS APPlIANCeS IN SUCH AreAS
IF THey Are INSTAlleD 18” (45.7 cm) Or MOre ABOVe THe
FlOOr. THIS MAy reDUCe THe rISK IF lOCATION IN SUCH
AN AreA CANNOT Be AVOIDeD.
DO NOT INSTAll THIS WATer HeATer DIreCTly ON A
CArPeTeD FlOOr. A FIre HAZArD MAy reSUlT. Instead the
water heater must be placed on a metal or wood panel extending
beyond the full width and depth by at least 3 inches (7.6 cm) in
any direction. If the heater is installed in a carpeted alcove, the
entire oor shall be covered by the panel. Also, see the DrAINING
requirements in MAINTeNANCe Section.
THe HeATer SHAll Be lOCATeD Or PrOTeCTeD SO IT
installation considerations
10
insulation Blanket
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Insulation blankets are available to the general public for external
use on gas water heaters but are not necessary with these
products. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. The
water heaters covered by this manual meet or exceed the energy
Policy Act standards with respect to insulation and standby heat
loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this
heater, you should follow these instructions. See the Features
and Components section of this manual for identication of
components mentioned below. Failure to follow these instructions
can restrict the air ow required for proper combustion, potentially
resulting in re, 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 exhaust inducer.
• do not cover the gas valve, thermostat or the Temperature-
Pressure relief Valve.
• do not allow insulation to come within 2” (5 cm) of the burners,
to prevent blockage of combustion air ow to the burners.
• do not allow insulation to come within 9 inches (23 cm)
of oor, (within 2 inches (5 cm) of bottom cover) to prevent
blockage of combustion air ow to the burners..
• 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.
hard water
Where hard water conditions exist, water softening or the
threshold type of water treatment is recommended. This will
protect the dishwashers, coffee urns, water heaters, water piping
and other equipment.
See the Maintenance Section in this manual for sediment and
lime scale removal procedures.
circulation pumps
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the water
heater. See Water Piping Diagrams in this manual for installation
location of circulating pumps.
figure 6
installation on comBustiBle flooring
The BTr 500 is approved for installations on combustible ooring
when installed with NSF leg Kit number 9003425205. The installed
height of the water heater will increase by 3" (7.6 cm) when the leg
kit is installed.
figure 7
1. Unit needs to be lifted in a way not to damage unit or laid
on it’s side to access the bottom of the legs.
2. Slide leg extension under leg and the bolt up through the
bottom hole located in the bottom of the leg.
3. Once in place, screw nut down and secure.
4. Front of leg should line up with front of leg extension as
shown in Figure 7 to make sure weight of unit is distributed
through the leg extension.
11
Breathing Hazard - Carbon Monoxide Gas
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Under no circumstances should
the input exceed the rate shown
on the water heater’s rating label.
Overfiring could result in damage to
the water heater and sooting.
Gas and carbon monoxide detectors
are available.
propane installations
INSTAllATIONS ABOVe 2000 FeeT (610 MeTerS) reQUIre
rePlACeMeNT OF BUrNer OrIFICeS IN ACCOrDANCe
WITH CUrreNT eDITION OF THe NATIONAl FUel GAS CODe
(ANSI Z223.1). FOr CANADIAN INSTAllATIONS CONSUlT
CANADIAN INSTAllATIONS CODe CAN/CSA B149.1. FAIlUre
TO rePlACe OrIFICeS WIll reSUlT IN IMPrOPer
AND INeFFICIeNT OPerATION OF THe WATer HeATer
reSUlTING IN THe PrODUCTION OF INCreASeD leVelS OF
CArBON MONOXIDe GAS IN eXCeSS OF SAFe lIMITS WHICH
COUlD reSUlT IN SerIOUS PerSONAl INJUry Or DeATH.
you should contact your gas supplier for any specic changes
which may be required in your area.
As elevation above sea level is increased, there is less oxygen
per cubic foot of air. Therefore, the heater input rate should
be reduced at high altitudes for satisfactory operation with the
reduced oxygen supply. Failure to make this reduction would
result in an over ring of the heater causing sooting, poor
combustion and/or unsatisfactory heater performance.
ratings specied by manufacturers for most appliances apply for
elevations up to 2000 feet (610m). For elevations above 2000 feet
(610), ratings must be reduced at the rate of 4% for each 1000
feet (305m) above sea level. For example, if a heater is rated at
78,000 Btuh (22.9 Kwh) at sea level, to rate the heater at 4000 feet
(1219m), you subtract 4 (once for each thousand feet) x.04 (4%
input reduction) x 78,000 (original rating) from the original rating.
Therefore, to calculate the input rating at 4,000 feet (1219m): 4 x
.04 x 78,000 = 12,480 Btuh (3.7 Kwh), 78,000 (22.9 Kwh) - 12,480
(3.7 Kwh) = 65,520 Btuh (19.2 Kwh). At 6000 feet (1829m) the
correct input rating should be 59,280 Btuh (17.4 Kwh).
natural gas installations
The natural gas red version of the water heater covered by this
manual is certied for use without modication for altitudes up to
10,100 feet.
For installations above 10,100 feet call the technical support
phone number listed on the back cover of this manual for further
technical assistance. Call the local gas or utility company to verify
Btu per cubic foot content before calling for technical assistance
and have that information available.
Note: The actual ring rate of the water heater must not exceed
the input rating on the water heater's rating label under any
circumstances.
Note: Due to the input rating reduction at high altitudes, the
output rating of the water heater is also reduced and should be
compensated for in the sizing of the equipment for applications.
See the Circulation Pump Wiring Diagrams (Figure 8, Figure
9) in this manual for electrical hookup information. Install in
accordance with the current edition of the National electrical
Code, NFPA 70 or the Canadian electrical Code, CSA C22.1.
All-bronze or stainless steel circulating pumps are recommended
for use with commercial water heaters.
Some circulating pumps are manufactured with sealed bearings
and do not require further lubrication. Some circulating pumps
must be periodically oiled. refer to the pump manufacturer’s
instructions for lubrication requirements.
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
figure 8.
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
DISHWASHER
TOGGLE
SWITCH
CIRC
PUMP
MOTOR
L1 HOT
L2 NEUTRAL
120 VAC
POWER
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
figure 9.
high altitude installations
Fire and Explosion Hazard
Gas and carbon monoxide detectors are
available.
Overfiring could result in fire or
explosion.
Under no circumstances should the
input exceed the rate shown on the
water heater’s rating label.
12
5. 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 from the supply
gas connection on the water heater.
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.
water temperature control and mixing ValVes
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes
washing, dish washing, and other sanitizing needs can scald
and cause permanent injury upon contact. Short repeated
heating cycles caused by small hot water uses can cause
temperatures at the point of use to exceed the water heater’s
temperature setting by up to 20°F (11°C).
Some people are more likely to be permanently injured by
hot water than others. These include the elderly, children, the
inrm and the physically/mentally disabled. Table 6 shows the
approximate time-to-burn relationship for normal adult skin. If
anyone using hot water provided by the water heater being
installed ts into one of these groups or if there is a local code
or state law requiring a certain water temperature at the point
of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting
that satises the demand of the application a Mixing Valve
should be installed at the water heater (see Figure 10) or at
the hot water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores.
Consult a Qualied Installer or Service Agency. Follow mixing
valve manufacturer’s instructions for installation of the valves.
taBle 6.
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)
gas supply systems
low pressure building gas supply systems are dened as those
systems that cannot under any circumstances exceed 14” W.C.
(3.48 kPa) (1/2 PSI Gauge). These systems do not require pressure
regulation. Measurements should be taken to insure that gas pressures
are stable and fall within the requirements stated on the water heater
rating plate. readings should be taken with all gas burning equipment
off (static pressure) and with all gas burning equipment running at
maximum rate (dynamic pressure). The gas supply pressure must be
stable within 1.5” W.C. (0.37 kPa) from static to dynamic pressure
to provide good performance. Pressure drops that exceed 1.5” W.C.
(0.37 kPa) may cause rough starting, noisy combustion or nuisance
outages. Increases or spikes in static pressure during off cycles may
cause failure to ignite or in severe cases damage to water heater
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. (3.48 kPa) (1/2 PSI Gauge). These systems must use
eld supplied regulators to lower the gas pressure to less than
14” W.C. (3.48 kPa) (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 (34.5 kPa) often require multiple
regulators to achieve desired pressures. Systems in excess of 5
PSI (34.5 kPa) building pressure should be designed by gas delivery
professionals for best performance. Water heaters connected
to gas supply systems that exceed 14” W.C. (3.48 kPa) (1/2 PSI
Gauge) at any time must be equipped with a gas supply regulator.
gas pressure reQuirements
Natural gas models require a minimum gas supply pressure of
4.5” W.C. (1.12 kPa). Propane gas models require a minimum
gas supply pressure of 11" W.C. (2.74 kPa). The minimum supply
pressure is measured while gas is owing (dynamic pressure).
The supply pressure (dynamic) should never fall below the
specied minimum supply pressure. 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. (0.37 kPa) as gas begins to ow to the water
heater then the supply gas system including the gas line and/or
the gas regulator may be restricted or undersized. See Supply
Gas regulator section and Gas Piping section of this manual.
The gas valve on all models has a maximum gas supply pressure
limit of 14" W.C. (3.48 kPa) The maximum supply pressure is
measured while gas is not owing (static pressure).
supply gas regulator
The maximum allowable gas supply pressure for this water
heater is 14.0 inches W.C. (3.48 kPa). Install a positive lock-up
gas pressure regulator in the gas supply line if inlet gas pressure
can exceed 14.0 inches W.C. (3.48 kPa) at any time. regulators
must be sized/used according to manufacturer's specications.
If a positive lock-up regulator is required follow these instructions:
1. Positive lock-up gas pressure regulators must be rated at or
above the input Btu/hr rating of the water heater they supply.
2. 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 8, page 22.
3. 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)
of equivalent length from the water heater’s inlet gas connection.
4. After installing the positive lock-up gas pressure regulator(s) an
initial nominal supply pressure setting of 7.0” W.C. (1.74 kPa) while
the water heater is operating is recommended and will generally
provide good water heater operation. Some addition adjustment
maybe required later to maintain a steady gas supply pressure.
installation reQuirements
13
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 10.
dishwashing machines
All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water
ow pressures between 15 and 25 pounds per square inch (103
kPa and 173 kPa). Flow pressures above 25 pounds per square
inch (173 kPa), or below 15 pounds per square inch (103 kPa),
will result in improperly sanitized dishes. Where pressures are
high, a water pressure reducing or ow regulating control valve
should be used in the 180°F (82°C) line to the dishwashing
machine and should be adjusted to deliver water pressure
between these limits.
The National Sanitation Foundation also recommends circulation
of 180°F (82°C) water. The circulation ow rate should be just
enough to provide 180°F (82°C) water at the point of take-off to
the dishwashing 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 in
this manual.
note: This water heater meets the NSF Standard 5 for sanitary
installations when used with leg kit, Part Number 9003425205.
closed water systems
Water supply systems may, because of code requirements
or such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back ow preventers. Devices such as these cause
the water system to be a closed system.
thermal expansion
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase
in water pressure due to thermal expansion. Thermal expansion
can cause premature tank failure (leakage). This type of failure
is not covered under the limited warranty. Thermal expansion
can also cause intermittent Temperature-Pressure relief Valve
operation: water discharged from the valve due to excessive
pressure build up. This condition is not covered under the limited
warranty. The Temperature-Pressure relief Valve is not intended
for the constant relief of thermal expansion.
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service technician to have a
thermal expansion tank installed.
See Water line Connections on page 19 and the Water Piping
Diagrams beginning on page 34.
temperature-pressure relief ValVe
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and
certied combination Temperature-Pressure relief Valve (T&P
valve) by the manufacturer. The valve is certied by a nationally
recognized testing laboratory that maintains periodic inspection
of production of listed equipment of materials as meeting the
requirements for relief Valves for Hot Water Supply Systems,
ANSI Z21.22 • CSA 4.4, and the code requirements of ASMe.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination Temperature-
Pressure relief Valve rated/sized and certied as indicated in
the above paragraph. The new valve must be marked with a
maximum set pressure not to exceed the marked hydrostatic
working pressure of the water heater (150 psi = 1,035 kPa) and
a discharge capacity not less than the water heater Btu/hr or kW
input rate as shown on the water heater’s model rating label.
NOTe: In addition to the factory installed Temperature-Pressure
relief Valve on the water heater, each remote storage tank that
may be installed and piped to a water heating appliance must also
have its own properly sized, rated and approved Temperature-
Pressure relief Valve installed. Call the toll free technical
support phone number listed on the back cover of this manual
for technical assistance in sizing a Temperature-Pressure relief
Valve for remote storage tanks.
For safe operation of the water heater, the Temperature-Pressure
relief Valve must not be removed from its designated opening
nor plugged. The Temperature-Pressure relief Valve must be
installed directly into the tting of the water heater designed for the
relief valve. Install discharge piping so that any discharge will exit
the pipe within 6 inches (15.2 cm) above an adequate oor drain,
or external to the building. In cold climates it is recommended
that it be terminated at an adequate drain inside the building. Be
certain that no contact is made with any live electrical part. The
discharge opening must not be blocked or reduced in size under
any circumstances. excessive length, over 30 feet (9.14 m), or
use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve.
14
No valve or other obstruction is to be placed between the
Temperature-Pressure relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm)
air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge
water in adequate quantities should circumstances demand. If
the discharge pipe is not connected to a drain or other suitable
means, the water ow may cause property damage.
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
t&p Valve discharge pipe requirements:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
the Temperature-Pressure relief Valve and the discharge
pipe.
• Must terminate a maximum of six inches above a oor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
relief valve and the drain.
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
The Temperature-Pressure relief Valve must be manually
operated at least twice a year. Caution should be taken to ensure
that (1) no one is in front of or around the outlet of the Temperature-
Pressure relief Valve discharge line, and (2) the water manually
discharged will not cause any bodily injury or property damage
because the water may be extremely hot. If after manually
operating the valve, it fails to completely reset and continues to
release water, immediately close the cold water inlet to the water
heater, follow the draining instructions in this manual, and replace
the Temperature-Pressure relief Valve with a properly rated/sized
new one.
note: The purpose of a Temperature-Pressure relief Valve is
to prevent excessive temperatures and pressures in the storage
tank. The T&P valve is not intended for the constant relief of
thermal expansion. A properly sized thermal expansion tank must
be installed on all closed systems to control thermal expansion,
see Closed Water Systems and Thermal expansion on page 13.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure relief Valve call the toll free
number listed on the back cover of this manual for technical
assistance.
contaminated air
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Corrosion of the ue ways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion
may result in failure and risk of asphyxiation.
Combustion air that is contaminated can greatly diminish the life
span of the water heater and water heater components such as
hot surface igniters and burners. Propellants of aerosol sprays,
beauty shop supplies, water softener chemicals and chemicals
used in dry cleaning processes that are present in the combustion,
ventilation or ambient air can cause such damage.
Do not store products of this sort near the water heater. Air which
is brought in contact with the water heater should not contain any
of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outdoor sources. The limited warranty is
voided when failure of water heater is due to a corrosive atmosphere.
(See limited warranty for complete terms and conditions).
air reQuirements
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
An insufcient supply of air can cause recirculation of combustion
products resulting in contamination that may be hazardous to
life. Such a condition often will result in a yellow, luminous burner
ame, causing sooting of the combustion chamber, burners and
ue tubes and creates a risk of asphyxiation.
Do not install the water heater in a conned space unless an
adequate supply of air for combustion and ventilation is brought
in to that space using the methods described in the Conned
Space section that follows.
15
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 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.
Vent adapter
The BTr 500 model is shipped with a 6" to 8" diameter
vent adapter (Fig. 11). The vent adapter fits on top of the
installed blower exhaust. Use only vent adapters supplied
with the unit. The venting must comply with the NATIONAl
FUel GAS CODe, ANSI Z223.1/NFPA 54 and for Canadian
installations consult the Canadian Installation Code CAN/
CSA B149.1-00.
figure 11
Never obstruct the ow of ventilation air. If you have any doubts
or questions at all, call your gas supplier. Failure to provide the
proper amount of combustion air can result in a re or explosion
and cause property damage, serious bodily injury or death.
unconfined space
An Unconned Space is one whose volume IS NOT leSS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconned space.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and replaces shall
also be considered in determining the adequacy of a space to
provide combustion, ventilation and dilution air.
unusually tight construction
In unconned spaces in buildings, inltration may be adequate
to provide air for combustion, ventilation and dilution of ue
gases. However, in buildings of unusually tight construction (for
example, weather stripping, heavily insulated, caulked, vapor
barrier, etc.) additional air must be provided using the methods
described in the Conned Space section that follows.
confined space
A Conned Space is one whose volume IS leSS THAN 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters 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.
exhaust fans
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed
in the same space with a water heater, sufcient openings to
provide fresh air must be provided that accommodate the
requirements for all appliances in the room and the exhaust fan.
Undersized openings will cause air to be drawn into the room
Venting installation
Venting
THe INSTrUCTIONS IN THIS SeCTION ON VeNTING MUST
Be FOllOWeD TO AVOID CHOKeD COMBUSTION Or
reCIrCUlATION OF FlUe GASeS. SUCH CONDITIONS
CAUSe SOOTING Or rISKS OF FIre AND ASPHyXIATION.
Heater must be protected from freezing downdrafts.
remove all soot or other obstructions from the chimney that will
retard a free draft.
Type B venting is recommended with these heaters. For
typical venting application see TeCHNICAl DATA VeNTING
on page 18.
This water heater must be vented in compliance with all local
codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.
If any part of the vent system is exposed to ambient temperatures
below 40°F (4.4°C) it must be insulated to prevent condensation.
• Do not connect the heater to a common vent or chimney
with solid fuel burning equipment. This practice is
prohibited by many local building codes as is the
practice of venting gas fired equipment to the duct work
of ventilation systems.
figure 12
• Where a separate vent connection is not available and the
vent pipe from the heater must be connected to a common
16
vent with an oil burning furnace, the vent pipe should enter
the smaller common vent or chimney at a point above the
large vent pipe.
multiple heater manifold
Figure 13 and Table 7 should be used for horizontally manifolding
two or more heaters.
figure 13
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 on page 15 for complete
venting installation instructions.
outdoor air through two openings
figure 14
The conned space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 14.
each opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. each opening shall
not be less than 100 square inches (645 cm2).
outdoor air through one opening
figure 15
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 15. The water heater shall have clearances of at least
1 inch (25 mm) from the sides and back and 6 inches (150 mm)
from the front. The opening shall directly communicate with the
outdoors or shall communicate through a vertical or horizontal
duct to the outdoors or spaces that freely communicate with the
outdoors and shall have a minimum free area of the following:
1. 1 square inch per 3000 Btu/hr (733 mm
2
per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in
the space.
outdoor air through two horiZontal ducts
figure 16
The conned space shall be provided with two permanent
horizontal ducts, one commencing within 12 inches (300 mm) of
the top and one commencing within 12 inches (300 mm) of the
bottom of the enclosure. The horizontal ducts shall communicate
directly with the outdoors. See Figure 16.
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 (7.6 cm).
17
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 (7.6 cm).
air from other indoor spaces
figure 18
The conned space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 18.
each opening shall communicate directly with an additional
room(s) of sufcient volume so that the combined volume of all
spaces meets the criteria for an Unconned Space.
each opening shall have a minimum free area of 1 square inch
per 1,000 Btu/hr (2200 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
).
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 on page 15 for complete
venting installation instructions.
figure 17
The conned space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See Figure 17.
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.
18
technical data Venting
type B gas Vent
multiple gas fired tank-type heaters
When venting multiple tank type heaters using Type B vent
pipe, follow the installation diagram (gure 13) and tables
below which give sizing and data based upon NFPA 54/ANSI
Z223. 2006.
taBle 7. technical data Venting
model 500
input: 500,000 btu/hr
Total Vent Height (Feet)
Vent connector size: 8 inches 6 8 10 15 20 30 50 100
Input (btu/hr) Rise Vent Connector Diameter (Inches)
500,000 1 Ft. - 10 10 10 9 8 8 7
500,000 2 Ft. 10 10 10 9 9 8 8 7
500,000 3 Ft. 10 10 9 9 9 8 7 7
multiple fan assisted water heaters
Total Vent Height (Feet)
Number of 500
Heaters
Combined
Input (btu/hr)
6 8 10 15 20 30 50 100
Manifold and Common Vent Diameter (Inches)
2 1,000,000 14 14 14 12 12 10 9 9
3 1,500,000 16 16 16 14 14 14 12 10
4 2,000,000 18 18 18 16 16 14 14 12
combination of multiple fan assisted and natural draft water heaters
Total Vent Height (Feet)
Number of 500
Heaters
Combined
Input (btu/hr)
6 8 10 15 20 30 50 100
Manifold and Common Vent Diameter (Inches)
2 1,000,000 16 16 14 14 12 12 10 9
3 1,500,000 18 18 18 16 16 14 14 12
4 2,000,000 22 20 20 18 18 16 14 14
19
water heater installation
t&p ValVe discharge pipe
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and
certied combination temperature - pressure (T&P) relief valve by
the manufacturer. See Temperature-Pressure relief Valve on pages
13-14 for information on replacement and other requirements.
Water Damage Hazard
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
•
CAUTION
Install a discharge pipe between the T&P valve discharge opening and
a suitable oor drain. Do not connect discharge piping directly to the
drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury,
hazard to life, or property damage, the relief valve must be allowed
to discharge water in adequate quantities should circumstances
demand. If the discharge pipe is not connected to a drain or other
suitable means, the water ow may cause property damage.
t&p Valve discharge pipe requirements:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
Temperature-Pressure relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a oor drain
or external to the building. In cold climates, it is recommended
that the discharge pipe be terminated at an adequate drain
inside the building.
• Shall not have any valve or other obstruction between the
relief valve and the drain.
The type, size and location of the relief valves must be in
accordance with local codes. The locations of the relief valves
shown in the installation diagrams are typical. See pages 34-48.
The heater has a factory installed high temperature limit switch
and temperature and pressure relief valve.
Cold water lines to heater should be installed as shown in order to
minimize gravity circulation of hot water to building cold water lines.
A listed temperature and pressure relief valve of adequate capacity
is installed on the heater. The locations shown in the installation
diagrams on pages 34-48 are typical.
The discharge opening of the temperature and pressure relief
valve must be piped to an open drain and should not be subject
to freezing temperatures.
Install in accordance with all local codes.
water line connections
The water piping installation must conform to these instructions
and to all local 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. Water Temperature Control and Mixing Valves on page 12.
2. Dishwashing Machines on page 13.
3. Closed Systems and Thermal expansion on page 13.
4. Temperature-Pressure relief Valve on page 13.
5. For multiple water heater installations see Water Piping
Diagrams beginning on page 34.
This manual provides detailed installation diagrams (see pages
34-48 of this manual) for typical methods of application for the
water heater(s).
water (potaBle) heating and space heating
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment, shall
NeVer be introduced into this system.
3. This unit may NeVer be connected to any existing heating
system or component(s) previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a tempering valve must be installed. Please refer
to installation diagrams on pages 34-48 of this manual for
suggested piping arrangements.
5. These water heaters cannot be used in space heating
applications only.
thermometers (not supplied)
Thermometers should be obtained and eld installed as shown in
the installation diagrams.
Thermometers are installed in the system as a means of detecting
the temperature of the outlet water supply.
water piping diagrams
This manual provides detailed water piping diagrams for
typical methods of application for the water heaters, see
Water Piping Diagrams beginning on page 34. The water
heater may be installed by itself, or with a separate storage
tank, on both single and two-temperature systems. When
used with a separate storage tank, the circulation may
be either by gravity or by means of a circulating pump.
Adjust flow by throttling a full port ball valve installed in the
circulating line on the outlet side of the pump. Never throttle
flow on the suction side of a pump. See the Water Piping
Diagrams beginning on page 34.
note: In addition to the factory installed Temperature-
Pressure relief Valve (T&P valve) on the water heater, each
remote storage tank that may be installed and piped to a
water heating appliance must also have its own properly
sized, rated and approved Temperature-Pressure relief
Valve installed. Call the toll free technical support phone
number listed on the back cover of this manual for further
assistance in sizing a T&P valve for remote storage tanks.
20
installation diagrams - top inlet/outlet usage
Use of the top inlet water connection requires an inlet dip tube
(refer to gure 19). The tube is supplied in the heater. Follow
caution labels if applying heat to this tting. Do not allow pipe
dope to contact the plastic tube during installation.
tuBe inlet installation
figure 19
temperature setting should not exceed safe use
temperature at fixtures. see water temperature
control and mixing ValVe warning on page 12. if
higher preheat temperatures are necessary to
oBtain adeQuate Booster output, add an anti-
scald ValVe for hot water supplied to fixtures.
21
heater wiring
All electrical work must be installed in accordance with the latest version of the National electrical Code ANSI/NFPA No. 70 and
must conform to all local code authority having jurisdiction. AN eleCTrICAl GrOUND IS reQUIreD TO reDUCe rISK OF
eleCTrICAl SHOCK Or POSSIBle eleCTrOCUTION.
If any of the original wire as supplied with the water heater must be replaced, use only type 105°C thermoplastic or equivalent and
250
0
C type F must be used for the ame sensor and igniter leads.
The controls of this water heater are polarity sensitive. Be certain to properly wire the hot and neutral connections.
figure 20
22
gas piping
Contact your local gas service company to ensure that adequate
gas service is available and to review applicable installation
codes for your area.
Size the main gas line in accordance with Table 8. The gures
shown are for straight lengths of pipe at 0.5 in. W.C. pressure
drop, which is considered normal for low pressure systems.
Note: Fittings such as elbows, tees and line regulators will add
to the pipe pressure drop. Also refer to the latest version of the
National Fuel Gas Code.
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.
The heater is not intended for operation at higher than 14.0" W.C.
(3.49 kPa) (1/2 pound per square inch gage) supply gas pressure.
exposure to higher supply pressure may cause damage to the
gas valve which could result in re or explosion. If overpressure
has occurred such as through improper testing of gas lines or
emergency malfunction of the supply system, the gas valve must
be checked for safe operation. Make sure that the outside vents
on the supply regulators and the safety vent valves are protected
against blockage. These are parts of the gas supply system, not
the heater. Vent blockage may occur during ice storms.
taBle 8 - gas supply pipe length (feet)
Schedule 40 metallic
pipe nominal dia.
500,000 btu/hr input rate
MAXIMUM eQUIVAleNT PIPe leNGTH (FeeT)
Natural Gas Propane
3/4" - 10
1" 10 40
1 1/4" 60 150
1 1/2" 150 350
2" 200 400
2 1/2" 200 400
Natural Gas: 0.60 Specic Gravity, 0.50"W.C. pressure drop
Propane Gas: 1.50 Specic Gravity, 0.50"W.C. pressure drop
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. Before attaching the gas line, be sure that
all gas pipe is clean on the inside.
To trap any dirt or foreign material in the gas supply line, a sediment
trap must be incorporated in the piping, see Figure 21. The
sediment trap must be readily accessible and not subject to freezing
conditions. Install in accordance with recommendations of serving
gas suppliers. refer to the current editions of the National Fuel
Gas Code or B149.1 Natural Gas and Propane installation code.
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve inlet.
Apply joint compounds (pipe dope) sparingly and only to the
male threads of pipe joints. Do not apply compounds to the rst
two threads. Use compounds resistant to the action of liqueed
petroleum gases.
gas meter siZe – natural gases only
Be sure the gas meter has sufcient capacity to supply the full
rated gas input of the water heater as well as the requirements of
all other gas red equipment supplied by the meter. If gas meter
is too small, ask the gas company to install a larger meter having
adequate capacity.
gas piping and sediment trap installation
figure 21
gas line leak testing
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the wateheater
in operation.
Disconnect gas piping and main gas
shutoff valve before leak testing.
Install sediment trap in accordance
with NFPA 54.
Any time work is done on the gas supply system perform a leak
test to avoid the possibility of re or explosion.
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect
the water heater and its Main Gas Shutoff Valve from the
gas supply piping system during testing, see Figure 21. The
gas supply line must be capped when disconnected from the
water heater.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water
heater need not be disconnected, but must be isolated from
the supply gas line by closing the Main Gas Shutoff Valve
during testing.
3. Coat all supply gas line joints and connections upstream of
the water heater with a non-corrosive soap and water solution
to test for leaks. Bubbles indicate a gas leak. Do not use
matches, candles, ame or other sources of ignition for this
purpose.
4. repair any leaks before placing the water heater in operation.
purging
Gas line purging is required with new piping or systems in which
air has entered.
Purging should be performed per the current edition of NFPA
54, the National Fuel Gas Code.
23
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 Qualications on page 6.
Do not place the water heater in operation if any part has been
under water. Immediately call a qualied service technician to
inspect the water heater and to replace any part of the control
system and any gas control which has been under water.
light the water heater in accordance with the lighting and
Operation Instruction label on the water heater and in this manual
on page 25.
The water heaters covered by this manual are equipped with
an electronic control system that automatically sequences the
Blower, the Igniter, the 24 VAC Gas Valve, Burner ignition,
and ame sensing. The control system will lock out after three
unsuccessful ignition attempts.
Before attempting start up, thoroughly study and familiarize
yourself with the exact Sequence Of Operation, see the written
Sequence Of Operation on page 25 and the Sequence Of
Operation Flow Chart on page 26.
Be certain that the water heater is full of water, that air is purged
from the gas and water lines and that there are no leaks in the
gas and water lines. ensure all inlet water valves are open.
filling the water heater
Follow these steps to 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.
supply gas line purging
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
To avoid risk of fire or explosion purge discharge must not
enter into confined areas or spaces where ignition can occur.
The area must be well ventilated and all sources of ignition
must be deactivated or removed.
Gas line purging is required with new piping or systems in
which air has entered.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
1. Close the Main Gas Shutoff Valve, see Figure 21.
2. Purge all air from the supply gas line up to the water heater’s
Main Gas Shutoff Valve.
3. When all air has been purged from the supply gas line, tighten
all supply gas line connections.
4. Check for gas leaks, see Gas line leak Testing on page 22
and repair any leaks found.
start up
initial start up
required test equipment
U-tube manometer, pressure gauge, or digital manometer.
recommended range: 20” W.C. (5 kPa).
note: All test equipment must be acclimated to ambient
temperature before calibration and use.
preparation
1. Adjust the thermostat to the lowest temperature setting.
2. Turn the water heater’s on/off switch to the “off” position.
3. Close the Main Gas Shut Off Valve, see Figure 21.
4. Wait ve (5) minutes for any residual gas to clear.
5. Connect the manometer to the supply gas pressure test port.
6. Open the Main Gas Shutoff Valve.
7. Measure and record the supply gas pressure, this is a “static”
supply gas pressure reading; while the water heater is not ring.
lighting the water heater
1. Turn the water heater’s on/off switch to the “on” position.
2. Adjust the thermostat to the desired water temperature.
3. record the supply gas pressure when the 24 VAC Gas Valve is
energized and the Burner is operating. This is a “dynamic” gas
pressure reading; while the water heater is ring.
4. Compare the actual supply gas pressure reading recorded
above to the required minimum/maximum values given in
Table 3 on page 8. Adjust supply gas pressure as necessary,
see the instructions that follow.
5. After the supply gas pressure adjustments are complete, turn
off the water heater and close the Main Gas Supply Shut Off
Valve. Disconnect the manometer and install the pipe plug in
the Supply Gas Pressure Port.
supply gas pressure adjustment
Fire and Explosion Hazard
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
Excessive gas pressure to gas valve can
cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
label.
Supply gas pressure shall be measured while the water heater
is not ring (static pressure) and while the water heater is ring
at full capacity (dynamic pressure).
If the supply gas pressure to the water heater is not between
the required minimum and maximum values given in Table 3
on page 8 adjust the supply gas regulator as necessary. Adjust
the supply gas regulator(s) per the regulator manufacturer’s
instructions to achieve the required “static” and “dynamic”
supply gas pressure.
multiple appliance installations:
In multiple water heater installations or in installations where
the installed water heater(s) share a common gas supply main
with other gas red appliances; the supply gas pressures shall
be measured at each water heater with all gas red appliances
connected to a common main ring at full capacity.
24
checking the input
For installation locations with elevations above 2000 feet, refer
to HIGH AlTITUDe INSTAllATIONS section of this manual for
input reduction procedure.
1. Attach a pressure gauge or a manometer to the manifold
pressure tap on the gas valve and refer to Table 3, for correct
manifold pressure.
2. Use this formula to “clock” the meter. Be sure that other gas
consuming appliances are not operating during this interval.
(3600/T) x H = Btuh
T = Time in seconds to burn one cubic foot of gas.
H = Btu’s per cubic foot of gas.
Btuh = Actual heater input.
example: (Using BTr-500 heater)
T = 7.56 seconds
H = 1050 Btu
Btuh = (3600/7.56) x 1050 = 500,000
Should it be necessary to adjust the gas pressure to the burners
to obtain the full input rate, the steps below should be followed:
3. remove the regulator adjustment sealing cap and adjust the pressure
by turning the adjusting screw with a screwdriver. See Figure 22.
Clockwise to increase gas pressure and input rate.
Counterclockwise to decrease gas pressure and input rate.
4. “Clock” the meter as in step 2 above.
5. repeat steps 3 and 4 until the specied input rate is achieved.
6. Turn the gas control knob to PIlOT. remove the pressure
gauge and replace the sealing cap and the Allen wrench set
screw in the pressure tap opening.
UNDer NO CIrCUMSTANCeS SHOUlD THe GAS INPUT eXCeeD
THe INPUT SHOWN ON THe HeATer MODel AND rATING PlATe.
OVerFIrING COUlD reSUlT IN DAMAGe Or SOOTING OF THe
HeATer.
water temperature adjustment
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
The water temperature is controlled by a thermostat, Fig. 2,
which has two sensing elements. One sensor is located near the
top of the tank and the other is near the center. The thermostat
is set in the lowest position before the heater leaves the factory.
The thermostat temperature dial, Fig. 2, is accessible by removing
the control box cover. The dial is adjustable and may be set for
120°F (49°C) to 180°F (82°C) water temperature, but 120°F
(49°C) is the recommended starting point. It is suggested the dial
be placed on the lowest setting which produces an acceptable
hot water supply. This will always give the most energy efcient
operation. The temperature control has a 4°F xed differential.
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 3 on page 8 with all gas red appliances connected
to a common gas main ring at full capacity.
note: A pressure drop of more than 1.5” W. C. (0.37 kPa) when
the Main Burner ignites is an indication of an inadequate supply
of gas and can lead to ignition failure, rough starts and/or rough
operation. If a drop of more than 1.5” W. C. (0.37 kPa) in supply
gas pressure occurs when the Main Burner ignites, ensure the
supply gas lines and regulator(s) are properly sized and installed.
See the requirements for Supply Gas regulator on page 12 and
Gas Piping on page 22. ensure all requirements and installation
instructions are maintained.
checking Venting
The following steps shall be followed with each appliance connected
to the venting system placed in operation, while any other
appliances connected to the venting system are not in operation.
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch,
as required in the National Fuel Gas Code, ANSI Z223.1or
the CAN/CGA B149 Installation Codes and these instructions.
Determine that there is no blockage or restriction, leakage,
corrosion and other deciencies which could cause an unsafe
condition.
3. So far as is practical, close all building doors and windows
and all doors between the space in which the water heater(s)
connected to the venting system are located and other spaces of
the building. Turn on all appliances not connected to the venting
system. Turn on all exhaust fans, such as range hoods and
bathroom exhausts, so they shall operate at maximum speed.
Close replace dampers.
4. Follow the lighting instruction. Place the water heater being
inspected in operation. Adjust thermostat so the water heater
operates continuously.
5. Test for spillage at the burner level after 5 minutes of main
burner operation.
6. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, replace dampers
and any other gas burning appliance to their previous conditions
of use.
7. If improper venting is observed during any of the above tests,
the venting system must be corrected.
FAIlUre TO COrreCT BACK DrAFTS MAy CAUSe AIr
CONTAMINATION AND UNSAFe CONDITIONS.
gas ValVes
Figure 22 shows the type of combination manual gas control valve
and regulator used on these heaters.
If the gas valve becomes defective, repairs should not be attempted.
A new valve should be installed in place of the defective one.
figure 22.
25
seQuence of operation
The following information will describe the Sequence of Operation
for this water heater.
1. Switch power on to unit.
2. Thermostat calls for heat.
3. Ignition Control Board performs diagnostic check on system
components.
4. On completion of diagnostics check, the Ignition Control Board
sends signal to exhaust Inducer.
5. exhaust Inducer begins drawing air through the water heater
closing the Prover Switch.
6. On completion of Prover Switch engagement, the Ignition
Control Board begins the ignition cycle.
7. The Ignition Control Board provides power to the Silicon
Nitride Igniter.
8. The Silicon Nitride Igniter heats up for approximately 17 to
20 seconds.
9. At the end of Silicon Nitride Igniter’s warm-up, the Ignition
Control Board opens the Gas Valve.
10. From the time the Gas Valve opens, the Ignition Control Board waits
3 seconds and then shuts off power to the Silicon Nitride Igniter.
11. From the time the Silicon Nitride Igniter’s power is shut off,
the Ignition Control Board waits 3 more seconds to monitor
the Flame Sensor.
12. If the Flame Sensor does not detect a strong enough ame,
the Ignition Control Board shuts off the Gas Valve and allows
the exhaust Inducer to purge the unit for 20 seconds. At that
time, the Ignition Control Board restarts with step 7. It will try
and ignite the main burners 2 more times. If the unit does not
light, the Ignition Control Board will wait one hour and then
restart at step 3. This cycle will continue until the unit lights or
the power is shutoff to the unit.
13. If the Flame Sensor detects a strong ame, the Ignition Control
Board will allow the unit to operate until the thermostat is satised.
14. Once the unit is satised, the Ignition Control Board will shut
off the Gas Valve and the unit will be in standby mode until
another call for heat is initiated by the thermostat.
See the ow chart on page 26 for more information.
lighting & operation laBel
FLAMMABLE
If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury, or loss of life.
WARNING
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
A.
1.
6.
2.
C.
D.
B.
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.
"WHAT TO DO IF YOU SMELL GAS"
BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell
next to the floor because some gas is heavier than air and will settle on the floor.
Do not try to light any appliance.
If you cannot reach your gas supplier, call the fire department.
Use only your hand to push in or turn the gas control knob. Never use tools. If
the knob will not push in or turn by hand, don't try to repair it. Call a qualified
service technician. Force or attempted repair may result in a fire or explosion.
Do not use this appliance if any part has been under water. Immediately call a
qualified service technician to inspect the appliance and to replace any part of
the control system and any gas control which has been under water.
Do not touch any electric switch; do not use any telephone in your building.
Immediately call your gas supplier from a neighbor's telephone. Follow the
gas suppliers instructions.
FOR YOUR SAFETY READ BEFORE OPERATING
STOP! Read the safety information above on this label.
Set thermostat to lowest setting.
5.
1. 3.
3.
4.
Turn off all electric power to the appliance.
This appliance is equipped with an ignition device which automatically lights
the burner. Do not try to light the burner by hand.
GAS
CONTROL
KNOBS
Push in gas control knobs slightly and turn clockwise to off.
7.
8.
9.
10.
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 on to next step.
Turn gas control knobs counterclockwise to "ON".
Turn on all electric power to the appliance.
Set thermostat to desired setting.
If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance"
and call your service technician or gas supplier.
Set the thermostat to lowest setting.
Push in gas control knobs slightly and turn clockwise to "OFF". Do not force.
2.
Turn off all electric power to appliance if service is to be performed.
OFF
IN
PSI
IN
PSI
OFF
ON
ON
figure 23.
26
seQuence of operation flow chart
Description of this ow chart can be found in the “SeQUeNCe OF OPerATION” section found on page 25.
figure 24.
27
maintenance
check the igniter assemBly and main Burners
At least once a year, check the igniter assembly, Figure 25, and
the main burner, Figure 26, for proper operation. refer to the
following igniter assembly and main burner sections.
igniter assemBly
For access to igniter assembly, unfasten two screws to burner
cover and remove. locate the burner with the igniter assembly
and remove screw holding burner to manifold. Slide burner out
to access igniter assembly.
Servicing of the igniter assembly includes keeping the igniter free
of lint, scale or any other foreign debris.
figure 25. igniter
main Burner
The main burner, Figure 26, should display the following
characteristics:
• Cause rapid ignition and carry across entire burner.
• Give reasonably quiet operation during ignition, burning, and
extinction.
• Cause no excessive lifting of ame from burner ports.
figure 26.
If the preceding burner characteristics are not evident, check for
accumulation of lint, scale or other foreign debris that restricts or
blocks the air openings to the burner or heater.
NOTe:
1. remove main burners from unit.
2. Check that burner venturi and ports are free of foreign debris.
3. Clean burners with bristle brush and/or vacuum cleaner - DO
NOT distort burner ports or pilot location.
4. reinstall burners in unit. Make sure front and rear of burners
are installed correctly in burner support brackets.
Also check for good ow of combustion and ventilating air to the
unit. Maintain a clear area around the heater at all times.
Venting system
examine the venting system every six months for obstructions
and/or deterioration of the vent piping.
remove all soot or other obstructions from chimney which will
retard free draft.
remote storage tank temperature control
The water temperature in the remote storage tank (if used) is
controlled by the storage tank temperature control. The sensing
element is mounted in the hot water storage tank, see Water
Piping Diagram section.
A change in water temperature in the storage tank lower than the
tank temperature control setting will cause the sensor to activate the
circulating pump. The pump then circulates the water through the
heater where the thermostat senses the drop in water temperature
and activates main burner operation of the water heater.
If the storage tank temperature control is out of calibration, replace
with new control.
SHOUlD OVerHeATING OCCUr Or THe GAS SUPPly FAIl
TO SHUT OFF, TUrN OFF THe MANUAl GAS CONTrOl VAlVe
TO THe WATer HeATer.
temperature-pressure relief ValVe test
Burn hazard.
Hot water discharge.
Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
It is recommended that the Temperature-Pressure relief Valve should
be checked to ensure that it is in operating condition every 6 months.
When checking the Temperature-Pressure relief Valve operation,
make sure that (1) no one is in front of or around the outlet of the
Temperature-Pressure relief Valve discharge line, and (2) that the
water discharge will not cause any property damage, as the water
may be extremely hot. Use care when operating valve as the valve
may be hot.
To check the relief valve, lift the lever at the end of the valve several
times, see Figure 27. 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 on page 28. replace the Temperature-Pressure relief
Valve with a properly rated/sized new one, see Temperature-Pressure
relief Valve on pages 12-13 for instructions on replacement.
figure 27.
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 and Thermal
expansion on page 12. The Temperature-Pressure relief Valve is
not intended for the constant relief of thermal expansion.
Temperature-Pressure relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
DO NOT PlUG THe TeMPerATUre-PreSSUre relIeF
VAlVe OPeNING. THIS CAN CAUSe PrOPerTy DAMAGe,
SerIOUS INJUry Or DeATH.
28
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
anode rod inspection
Property Damage Hazard
Avoid water heater damage.
•
Inspection and replacement of anode rod required.
•
CAUTION
The anode rod is used to protect the tank from corrosion. Most hot
water tanks are equipped with an anode rod. The submerged rod
sacrices itself to protect the tank. Instead of corroding the tank,
the anode rod deteriorates. This does not affect water’s taste or
color. The rod must be maintained to keep the tank in operating
condition.
Anode deterioration depends on water conductivity, not necessarily
water condition. A corroded or pitted anode rod indicates high
water conductivity and should be checked and/or replaced more
often than an anode rod that appears to be intact. replacement
of a depleted anode rod can extend the life of your water heater.
Inspection should be conducted by a qualied service agency, and
at a minimum should be checked annually after the warranty period.
Articially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions.
The use of a water softener may decrease the life of the water
heater tank.
The anode rod should be inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates
its replacement. Anode replacement is not covered by warranty.
note: Articially softened water requires the anode rod to be
inspected annually.
draining and flushing
Burn harzard.
Hot water discharge.
Keep hands clear of drain
valve discharge.
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
in this manual for the location of the water heater components
described below.
to drain the water heater storage tank:
1. Turn off the gas and electrical supply to the water heater.
2. Turn off the gas supply at the Main Gas Shutoff Valve if the
water heater is going to be shut down for an extended period.
3. ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until
the water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
7. Open the water heater drain valve and allow all the water to
drain from the storage tank.
8. Close the water heater drain valve when all water in the
storage tank has drained.
9. Close the hot water faucet opened in Step 4.
10. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
to flush the water heater storage tank:
1. Turn off the electrical supply to the water heater.
2. ensure the cold water inlet valve is open.
3. Open a nearby hot water faucet and let the water run until
the water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an
adequate drain.
5. ensure the drain hose is secured before and during the
entire ushing procedure. Flushing is performed with system
water pressure applied to the water heater.
6. Open the water heater drain valve to ush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to ow until it runs clean.
8. Close the water heater drain valve when ushing is
completed.
9. remove the drain hose.
10. Fill the water heater - see Filling The Water Heater in this
manual.
11. Turn on the electrical supply to place the water heater back
in operation.
12. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
recommended procedure for periodic
remoVal of lime deposits from tank type
commercial water heaters
The amount of calcium carbonate (lime) released from water is
in direct proportion to water temperature and usage, see chart.
The higher the water temperature or water usage, the more
lime deposits are dropped out of the water. This is the lime
scale which forms in pipes, heaters and on cooking utensils.
29
lime accumulation not only reduces the life of equipment but also
reduces efciency of the heater and increases fuel consumption.
The usage of water softening equipment greatly reduces the
hardness of the water. However, this equipment does not always
remove all of the hardness (lime). For this reason it is recommended
that a regular schedule for deliming be maintained.
The time between cleaning will vary from weeks to months
depending upon water conditions and usage.
The depth of lime buildup should be measured periodically. Heaters
equipped with cleanouts will have about 2" of lime buildup when
the level of lime has reached the bottom of the cleanout opening. A
schedule for deliming should then be set up,based on the amount
of time it would take for a 1" buildup of lime. It is recommended that
the water heater initially be inspected after 6 months.
example 1:
Initial inspection after 6 months shows 1/2" of lime accumulation.
Therefore, the heater should be delimed once a year.
example 2:
Initial inspection after 6 months shows 2" of lime accumulation.
Therefore, the heater should be delimed every 3 months.
figure 28.
deliming solVents
UN•lIMe is recommended for deliming. UN•lIMe is a patented
food grade acid which is safe to handle and does not create the
harmful fumes which are associated with other products.
UN•lIMe may be obtained from your dealer, distributor or water heater
manufacturer. Order Part Number 9005416105, 1 gallon, packed 4
gallons per case or Part Number 9005417105, 5 gallon container.
NOTe: Un•lime is not available for use in Canada.
Hydrochloric base acids are not recommended for use on glass
lined tanks.
Observe handling instructions on label of product being used.
tank cleanout procedure
The following practices will ensure longer life and enable the
unit to operate at its designed efciency:
1. Once a month the heater should be ushed. Open the drain
valve and allow two gallons of water to drain from the heater.
Inlet water valve should remain open to maintain pressure in
tank.
2. A cleanout opening is provided for periodic cleaning of the
tank. Gas must be shut off and heater drained before opening
cleanout.
To clean heater through cleanout opening, proceed as follows:
3. Drain heater.
4. remove outer cover plate from lower side of heater jacket.
5. remove six (6) hex head screws securing tank cleanout plate
and remove plate.
6. remove lime, scale, or sediment using care not to damage
the glass lining.
7. Inspect cleanout plate gasket, if new gasket is required,
replace with part no. 9004099215.
8. Install cleanout plate. Be sure to draw plate up tight by
tightening screws securely.
9. replace outer jacket cover plate.
In some water areas the sediment might not be removed
by this method and may result in the water heater making
rumbling or boiling noises. To dissolve and remove these
more stubborn mineral deposits, UN•lIMe Professional
Delimer should be used.
deliming using flo-jug method
UN•lIMe in the 5 gallon size is recommended for deliming of all
models. Contact your local dealer, distributor or, water heater
manufacturer.
Prepare the Water Heater
To delime the water heater using the Flo-Jug method, rst
prepare the heater for deliming.
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
Do not smoke or have open ame or sparks in vicinity of heater.
Do not mix UN•lIMe with other chemicals. Do not allow contact
with magnesium, aluminum or galvanized metals.
30
threads. Tighten rmly by hand and use wrench or adjustable
pliers to check for secure connection. Do not over tighten to
avoid damage to threads and ttings.
Prepare the Up-N-Down Transfer Kit
The next step is the preparation on the Up-N-Down Transfer Kit,
if you have not already done so:
1. With the 5 gallon Up-N-Down container in the vertical position,
unscrew the plastic vent cap in the handle and pierce the
plastic membrane over the vent boss under the cap to allow
the container to vent.
note: If your container does not have the vent cap and vent
boss, drill a 3/16” hole in the handle. When you have nished
deliming you will be able to plug this drilled vent with the
stainless steel screw that is supplied with the kit.
2. remove the container’s cap and cut the plastic membrane
located in the 3/4” IPT opening in the cap. Take care to not
damage the threads.
3. Find the 3/4” male adapter, apply teon tape to the threaded
end and screw it into the 3/4” IPT opening in the cap.
4. Put cap with male adapter back on the container and slide
3/4” hose over end of male adapter and fasten in place using
hose clamp provided.
Delime using Flo-Jug Method
5. Slide the hose clamp over end of hose and slide hose over the
male adapter in the water heater drain opening and secure in
place using hose clamp.
6. lift container to the “Pour” Position, see Figure 29, being
careful to keep the vent in the handle above the liquid level
and pour the UN•lIMe into the heater.
7. lower container, you may have to place the container on its
empty carton to prevent the UN•lIMe from owing back into
the container.
8. let UN•lIMe remain in the heater for 5 minutes and then
lower the container to the “Drain” Position, see Figure 29.
9. Deliming activity is indicated by foaming on the surface of the
UN•lIMe. If there is deliming activity, repeat steps 6 thru 8.
Normally, lime removal will be completed within one hour. Severe
build-up of lime may take longer than an hour to complete descaling.
Note: To check UN•lIMe for continued use, place some scale
or white chalk in a glass with a small amount of UN•lIMe. If
the material is vigorously dissolved by the UN•lIMe, it can be
reused; if not, the UN•lIMe should be replaced.
figure 29.
Chemical Hazard
• Product contains phosphoric acid.
• Keep out of reach of children.
• Use rubber or neoprene gloves.
Contains phosphoric acid. In case of external contact, ush
with cool water. If irritation persists, get medical attention. If
swallowed, give 1 or 2 glasses of water or milk and call physician.
Get immediate medical attention for eyes. Keep out of reach of
children.
note: the use of ruBBer or neoprene gloVes is
recommended, especially if you haVe any open sores
or cuts to aVoid unnecessary irritation or discomfort.
1. Turn off fuel and/or power supply to heater. Also, turn off power
to any electrical device or equipment, which is attached, or
part of the system.
2. Open hot water side of faucet closest to heater and allow
water to run until it is cool enough to handle safely.
3. Close cold water inlet valve to heater.
4. Connect hose to drain valve at bottom of heater and start
draining heater into suitable oor drain area.
5. remove relief valve while heater is draining. NOTe: Do not
replace relief valve until deliming is completed. relief valve
opening will also act as a vent in case of possible contact
between the delimer and the anode rod(s), which may
produce ammable hydrogen-air mixtures.
6. If relief valve appears to be limed-up, place it in a clean glass or
plastic container adequate in size so that you can pour enough
UN•lIMe® into the container to cover the valve and allow
space for foaming. When foaming stops, run fresh cool water
into the container and rinse the relief valve for a few minutes.
7. If heater does not drain completely after a reasonable length
of time, turn off the main water supply valve to stop water from
entering the tank due to a by-pass problem or defective cold
water inlet valve. Also, check for clogged drain valve opening.
Heater must be completely drained before introducing
UN•lIMe.
8. remove the cleanout cover and place a clean plastic bucket
next to the cleanout opening.
Partially open the cold water inlet valve to allow time to
accomplish the following and then close the valve.
While the water is being run through the tank, insert a stiff
wire, copper tube attened at one end or an opened wire coat
hanger through the cleanout opening and scrape out any
loose deposits of scale or sediment. This is an economical
way to avoid unnecessary usage of the deliming solution.
repeat the opening and closing of the cold water inlet valve
as necessary but be sure the heater is completely drained
when ready to introduce the UN•lIMe.
Upon completion, reinstall the cleanout cover and use a new
cleanout cover gasket (part number 9004099215).
remove the drain valve.
9. Install the long plastic male adapter insert tting into the drain
valve opening of heater after applying Teon tape or paste to
31
serVice
The installer may be able to observe and correct certain
problems which may arise when the unit is put into operation.
HOWeVer, it is recommended that only qualied service
agents, using appropriate test equipment, be allowed to service
the heater.
As preliminary step, check wiring against diagram, check for
grounded, broken or loose wires. Check all wire ends to be sure
that they are making good contact.
checklist
Before calling your service agent, the following checklist should
be examined to eliminate obvious problems from those requiring
replacement or servicing.
• Check that “main manual gas shutoff valve” is fully open and
that gas service has not been interrupted.
• Check that after following the OPerATING INSTrUCTIONS,
the “Top Knob” of the gas valve is in “ON” position.
• Check electrical supply to the water heater for possible
blown (or tripped) fusing or power interruption. Also check
the 3 amp fuse on the front of the digital thermostat (Fig. 2).
• Is the water temperature in tank below the thermostat dial
setting on the thermostat (calling for heat)?
• It is possible that the high limit (e.C.O.) has functioned to
shut off the water heater. See High limit page 7 - High limit
Switch for reset procedure. Contact your service agent if
limit continues to function to shut off the water heater.
system diagnostics
your water heater is equipped with an ignition control that
incorporates a diagnostic system to assist in troubleshooting. The
indicator codes on the ignition control are as follows:
TABle 9:
1 FlASH System lockout (retries or cycles exceeded)
2 FlASHeS Pressure switch stuck close
3 FlASHeS Pressure switch stuck open
4 FlASHeS Open on high temperature limit switch (eco)
6 FlASHeS 115 volt AC power reversed (check polarity)
7 FlASHeS
low ame sense signal (make sure ame
sensor is in burner ame)
8 FlASHeS Check igniter
Continuous ash: Continuous ame sensed for greater than 5 seconds
without the gas valve energized. Check gas valve for malfunction.
Continuous on: Internal control failure. replace the ignition control.
Use this diagnostic system in conjunction with the table
titled “TrOUBleSHOOTING” and the “SeQUeNCe OF
OPerATION” to troubleshoot the appliance.
electrical serVicing
lABel All WIreS PrIOr TO DISCONNeCTION WHeN
SerVICING CONTrOlS. WIrING errOrS CAN CAUSe
IMPrOPer AND DANGerOUS OPerATION.
VerIFy PrOPer OPerATION AFTer SerVICING.
32
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 off of oil
from metal parts, and will disappear in a short while.
strange sounds
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered
normal. See “Condensation” in this manual.
condensation
Whenever the water heater is lled with cold water, some
condensate will form while the burner is on. A water heater may
appear to be leaking when in fact the water is condensation.
This usually happens when:
a. A new water heater is lled with cold water for the rst time.
b. Burning gas produces water vapor in water heaters,
particularly high efciency models where ue temperatures
are lower.
c. large amounts of hot water are used in a short time and the
rell water in the tank is very cold.
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the
burner or other hot surfaces to produce a “sizzling” or “frying” noise.
operational conditions
hot water odor
The water heater has at least one anode rod for corrosion
protection of the tank. Certain water conditions will cause a
reaction between this rod and the water. The most common
complaint associated with the anode rod is one of a “rotten egg
odor” in the hot water. The odor is a result of four factors which
must all be present for the odor to develop:
a. A concentration of sulfate in the supply water.
b. little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused
by the corrosion protective action of the anode.
Hot water odor may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material,
and then chlorinating the water heater tank and all water lines.
Contact the local water heater supplier or service agency for
further information regarding an Anode replacement Kit and this
chlorination treatment.
If the hot water odor persists after the anode replacement and
chlorination treatment, we suggest that chlorination or aeration of the
water supply be considered to eliminate the water problem.
Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.
“air” in hot water faucets
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.
high water temperature shut off system
This water heater is equipped with a manual reset type high
limit (energy Cutout) switch. The high limit switch interrupts
the main burner gas ow should the water temperature reach
203°F (95°C).
In the event of high limit switch operation, the water heater
cannot be restarted unless the water temperature is reduced to
approximately 120°F (49°C). The high limit reset button on the
front of the thermostat then needs to be depressed. See Figure 2
for the location of the reset button.
for your information
33
trouBleshooting
complaint cause
remedy
user Qualified serVice agency
*Water not hot enough
Thermostat set too low.
Set thermostat dial to a higher
temperature
Upper and/or lower temperature
probe out of calibration.
Call qualied service agency
Check continuity and resistance (Ohms)
of upper and lower temperature probes.
replace probes if out of specication.
*Insufcient hot water
*See WATer TeMPerATUre
CONTrOl WArNING (on page
12).
Thermostat set too low.
Set thermostat dial to a higher
temperature
Upper and/or lower temperature
probe out of calibration.
Call qualied service agency
Check continuity and resistance (Ohms)
of upper and lower temperature probes.
replace probes if out of specication.
Main manual gas shutoff valve
partially closed.
Open main manual gas shutoff
valve to fullest extent.
Heater too small for demand.
Space usage to give heater time
to restore water temperature.
Heater recovery is slower. Call qualied service agency
Check gas input. If incorrect, adjust gas
pressure or replace burner orices.
Water temperature too hot. Thermostat set too high. Set thermostat to a lower setting.
Heater makes sounds: sizzling.
Condensation on outside of
tank, normal.
rumbling.
Sediment accumulation on
bottom of tank.
Drain a quantity of water through
drain valve. If rumbling persists,
call a qualied service agency.
Delime heater.
Ticking or metallic sounds.
expansion and contraction -
normal.
Pounding or water hammer.
Air chambers in piping have
become waterlogged. Thermal
expansion tank damaged,
improperly charged, or
improperly sized.
Drain piping system and rell.
Heater must be off while this
is being done. Check thermal
expansion tank charge pressure
when the water system pressure
is zero.
Follow the manufacturer's instructions
for proper charging of the thermal
expansion tank.
Combustion noises.
Too much primary air. Call qualied service agency.
Overred heater; Incorrect
burners or orice for type of gas
used.
Call qualied service agency. Check and correct as necessary.
Water leaks.
Drain valve not closed tightly.
If drain valve cannot be closed
tightly, replace.
Possible condensation if tank
is undersized or stored water is
below 110 degrees.
Increase tank temperature
setting (have service agent add
a mixing valve if setting will be
above 120 degrees).
If leakage source cannot be
corrected or identied, call
qualied service agency.
Shut off gas supply to heater
and close cold water inlet valve
to heater.
repair or in case of suspected tank
leakage, be certain to conrm before
replacing heater.
Gas odors.
Heater is over red
Shut off gas supply to heater
and call a qualied service
agency.
Check for sooted ue passage.
Check for obstructed vent line.
Check backdraft or lack of draft
Possible gas leaks.
Shut off gas supply to heater
and call gas company at once
34
water piping diagrams
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI FLUE - (1 UNIT) WITH VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FINISHED
FLOOR
HOT WATER
TO FIXTURES
COLD WATER
SUPPLY
EXPANSION
TANK
ALT. COLD WATER
CONNECTION
HOT WATER RETURN
FROM FIXTURES
PIPE T&P TO
OPEN DRAIN
35
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI FLUE - (1 UNIT) WITH HORIZONTAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FINISHED
FLOOR
HOT WATER TO FIXTURES
COLD WATER
SUPPLY
HOT WATER
RETURN FROM
FIXTURES
ALTERNATE
LOCATION
CIRCULATING PUMP
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
36
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
MULTI FLUE - (1 UNIT) WITH MIXING VALVE TWO TEMPERATURE
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
TEMPERED
WATER
RETURN
TEMPERED
WATER
OUTLET
HOT
WATER
OUTLET
HOT
WATER
RETURN
COLD WATER
SUPPLY
COLD
HOT
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
37
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
MULTI FLUE - (2 UNITS)
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
TO FIXTURES
COLD WATER
SUPPLY
HOT WATER
RETURN
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
38
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FINISHED
FLOOR
COLD WATER
SUPPLY
HOT WATER
TO FIXTURES
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
RETURN
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
39
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI FLUE - (2 UNITS) WITH VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FINISHED
FLOOR
COLD WATER
SUPPLY
HOT WATER
TO FIXTURES
ALTERNATE
COLD WATER
CONNECTION
HOT WATER
RETURN
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
40
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI FLUE - (2 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
FINISHED
FLOOR
HOT WATER TO FIXTURES
COLD WATER
SUPPLY
HOT WATER
RETURN FROM
FIXTURES
ALTERNATE
LOCATION
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
41
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
MULTI FLUE (2 UNITS) TWO TEMPERATURE
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BOOSTER WATER RETURN
PRE-HEATED
WATER TO
BOOSTER
BOOSTER WATER
TO FIXTURES
HOT WATER
TO FIXTURES
EXPANSION TANK
HOT WATER
RETURN
COLD WATER
SUPPLY
1st HEATER
BOOSTER
HEATER
42
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
MULTI FLUE (2 UNITS) WITH BOOSTER TWO TEMPERATURE
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
EXPANSION
TANK
BOOSTED
WATER
OUTLET
TYPICAL
BOOSTER
HEATER
PRE-HEATER
PRE-HEATER
MUST BE IDENTICAL HEATERS
FINISHED FLOOR
COLD WATER
SUPPLY
HOT OUTLET
AT STORED
TEMPERATURE
BOOSTER RETURN
(IF USED)
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
43
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
MULTI-FLUE (3 UNITS)
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
TO FIXTURES
HOT WATER
RETURN
COLD WATER
SUPPLY
EXPANSION
TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
44
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI-FLUE (3 UNITS) WITH VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
TO FIXTURES
HOT WATER
RETURN
ALT. COLD WATER
CONNECTION
STORAGE TANK
HOT WATER
HEATERHEATERHEATER
FINISHED FLOOR
COLD WATER
SUPPLY
EXPANSION TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
45
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI-FLUE (3 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
RETURN
ALTERNATE
LOCATION
HOT WATER TO FIXTURES
STORAGE TANK
HEATERHEATERHEATER
FINISHED FLOOR
EXPANSION TANK
COLD WATER
SUPPLY
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
46
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
MULTI FLUE FLUE (4 UNITS)
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
TO FIXTURES
FINISHED FLOOR
HOT WATER
RETURN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
47
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI-FLUE (4 UNITS) WITH VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
TO FIXTURES
HOT WATER
RETURN
COLD WATER
SUPPLY
EXPANSION
TANK
ALT. COLD
WATER
CONNECTION
STORAGE TANK
HEATERHEATERHEATERHEATER
FINISHED FLOOR
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
48
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. The Tank Temperature Control should be wired to and control the pump between the water heater(s) and the storage tank(s).
5. The water heater’s operating thermostat should be set 5 degrees F higher than the Tank Temperature Control.
MULTI-FLUE (4 UNITS) WITH HORIZONTAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALVE
TEMPERATURE GAGE
WATER FLOW SWITCH
CHECK VALVE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HOT WATER
TO FIXTURES
HOT WATER
RETURN
COLD WATER
SUPPLY
ALTERNATE
LOCATION
STORAGE TANK
HEATERHEATERHEATERHEATER
FINISHED FLOOR
EXPANSION TANK
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
PIPE T&P TO
OPEN DRAIN
49
manifold kits
MANIFOLD KITS
TWO UNIT MANIFOLD KIT
(PART NO. 9003426205)
THREE UNIT MANIFOLD KIT
(PART NO. 9003427205)
FOUR UNIT MANIFOLD KIT
(PART NO. 9003428205)
MODEL DIMENSION "A"
BTR-500 81.5"
50
limited warranty
effectiVe
For 3 years,
in the event of a tank leak, we will repair or, at our
discretion, replace the defective water heater.
For 1 year, in the event of part failure, we will repair or, at our
discretion, replace the defective part.
We warrant this product against defects in materials or
workmanship as described in this document if installed within
the United States or Canada and provided the product remains
at its original place of installation.
Warranty coverage begins the date of installation Or the date of
manufacture if installation cannot be veried.
what's coVered
Subject to these terms, in the event of defect in materials and/
or workmanship resulting in a tank leak during the rst three
years, we will:
• replace the water heater should the tank leak.
Subject to these terms, in the event of a defect in materials and/or
workmanship appearing during the rst year, we will:
• repair or, at our discretion, replace any part of the water
heater covered under this limited warranty excluding parts
subject to normal maintenance (example: non-electronic
anode rod, lter, etc)
service/labor, shipping, delivery, installation, handling or any
other costs are not covered at any time under this warranty.
Any replacement part or product will be warranted only for
the unexpired portion of the original water heater’s limited
warranty period.
If an identical model is no longer available due to a change in law,
regulation, or standard, we will replace the product with one having
comparable capacity and input. In these instances, the owner will
have the option of paying the difference between what was paid for
the original model and the new model with the additional features,
or receiving a refund of the portion of the purchase price, on a
pro-rata basis allocable to the unexpired portion of the warranty.
what's not coVered
• Problems caused by improper: gas supply line sizing, gas type,
venting, connections, combustion air, voltage, wiring, or fusing
• Failure to follow applicable codes
• Failure to follow printed instructions
• Abuse, misuse, accident, re, ood, Acts of God
• Improper installation, sizing, delivery, or maintenance
• Claims related to rust, noise, smell, or taste of water
• Failure to conduct authorized factory start up if required
• Alterations to the water heater
• Non-outdoor heaters installed outdoors
• Damages due to a failure to allow for thermal expansion
• Heat exchanger failure due to lack of adequate / proper supply
of water
• Heaters moved from their original location
• Service trips to explain proper installation, use, or maintenance
of the product/unit or to describe compliance requirements
under applicable codes and regulations
• Charges related to accessing your heater including but not
limited to door/wall removal, equipment rental, etc.
• replacement parts after expiration of this warranty
limitations
NOTWITHSTANDING ANyTHING elSe TO THe CONTrAry,
THIS IS yOUr SOle AND eXClUSIVe WArrANTy.
All OTHer WArrANTIeS INClUDING A WArrANTy
OF MerCHANTABIlITy Or FITNeSS FOr PArTICUlAr
PUrPOSe Are eXPreSSly DISClAIMeD. Seller SHAll
NOT Be lIABle FOr ANy CONSeQUeNTIAl, INCIDeNTAl,
SPeCIAl, PUNITIVe Or OTHer INDIreCT DAMAGeS. TOTAl
lIABIlITy ArISING AT ANy TIMe SHAll NOT eXCeeD THe
PUrCHASe PrICe PAID WHeTHer BASeD ON CONTrACT,
TOrT, STrICT lIABIlITy Or ANy OTHer leGAl THeOry.
serVice inQuiries:
for service inquiries call the telephone number listed below. Be prepared to provide the following information:
name, address, and telephone number; the model and serial number of the water heater; proof of installation; and a clear description
of the problem.
For your records, fill in the product:
Serial: ___________________
Model: ___________________
U.S. Customers: Canadian Customers:
a. o. smith corporation p. o. Box 310 – 768 erie street
500 tennessee waltz parkway stratford (ontario) n5a 6t3
ashland city, tennessee 37015 800-265-8520
800-527-1953
www.hotwater.com
commercial
water heater
limited warranty
51
notes
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Technical Support: 800-527-1953 • Parts: 800-433-2545
www.hotwater.com
Copyright © 2014 A. O. Smith, All rights reserved.
