COMMERCIAL GAS WATER HEATERS
Instruction Manual
PRINTED 1016 100276615
PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
MODELS
BCL380T1206NOX, BCL380T1546NOX,
BCL380T1806NOX, BCL380T1996NOX,
BCL3100T1996NOX, (A)BCL3100T2506NOX,
(A)BCL3100T2756NOX, (A)BCL386T3106NOX,
(A)BCL386T3666NOX, (A)BCL386T3906NOX
Ultra Low NOx SERIES 200
INSTALLATION - OPERATION - SERVICE - MAINTENANCE -
LIMITED WARRANTY
Complies with SCAQMD Low NOx Rule 1146.2
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.
•
•
•
•
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.
www.americanwaterheater. com
American Water Heater
Johnson City, TN 37605
2
VENTING INSTALLATION ...................................................... 18
Venting ............................................................................... 18
Multiple Heater Manifold .................................................... 18
WATER HEATER INSTALLATION ........................................... 21
Water Line Connections ..................................................... 21
T&P Valve Discharge Pipe ................................................. 21
Installation Diagrams - Top Inlet/Outlet Usage ................... 22
Heater Wiring ..................................................................... 23
Gas Piping.......................................................................... 24
Gas Line Leak Testing ........................................................ 24
Purging ............................................................................... 24
START UP ............................................................................... 25
Prior to Start Up ................................................................. 25
Initial Start Up..................................................................... 25
Checking Venting ............................................................... 26
Checking the Input ............................................................. 26
Water Temperature Adjustment .......................................... 26
SEQUENCE OF OPERATION ................................................ 27
Lighting & Operating Label................................................. 27
Sequence of Operation Flow Chart .................................... 28
MAINTENANCE ..................................................................... 29
Venting System .................................................................. 29
Intake Air Screen ................................................................ 29
Temperature-Pressure Relief Valve Test ............................ 29
Anode Rod Inspection ........................................................ 29
Draining and Flushing ........................................................ 30
Periodic Removal of Lime Deposits from Tank Type Commercial
Water Heaters .................................................................... 30
Deliming Solvents .............................................................. 30
Tank Cleanout Procedure................................................... 31
Deliming Using Flo-Jug Method ......................................... 31
SERVICE ................................................................................. 32
Ignition Control System ...................................................... 32
System Diagnostics............................................................ 32
Electrical Servicing ............................................................. 32
FOR YOUR INFORMATION .................................................... 33
Start Up Conditions ............................................................ 33
Operational Conditions....................................................... 33
TROUBLESHOOTING ............................................................ 34
WATER PIPING DIAGRAMS ................................................... 35
NOTES .................................................................................... 50
LIMITED WARRANTY ............................................................. 51
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 ............................................ 6
Controls ................................................................................ 6
The Eliminator (self-cleaning system) .................................. 6
High Limit Switch.................................................................. 7
Electronic Ignition Control .................................................... 7
Blower/Burner Assembly ...................................................... 7
INSTALLATION CONSIDERATIONS ........................................ 8
Rough In Dimensions ........................................................... 8
Locating the Water Heater ................................................... 9
Clearances ........................................................................... 9
NSF Leg Kit ........................................................................ 10
Insulation Blanket ............................................................... 10
Hard Water ......................................................................... 10
Circulation Pumps .............................................................. 10
High Altitude 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
Combustible Material Storage ............................................ 14
Contaminated Air................................................................ 14
Air Requirements ............................................................... 15
Unconned Space .............................................................. 15
Conned Space.................................................................. 15
Fresh Air Openings for Conned Spaces ........................... 16
Outdoor Air Through Two Openings ................................... 16
Outdoor Air Through One Opening .................................... 16
Outdoor Air Through Two Horizontal Ducts ........................ 16
Outdoor Air Through Two Vertical Ducts ............................ 17
Air From Other Indoor Spaces ........................................... 17
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.
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 Hazard
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water damage.
For continued protection against
risk of fire:
Fire 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.
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.
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.
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.
•
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.
5
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN
EXPOSED TO FLOODING OR WATER DAMAGE. Immediately
call a qualied 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 water
heater be opened for several minutes before using any electrical
appliance connected to the hot water system. If hydrogen is
present there will probably be an unusual sound such as air
escaping through the pipe as the water begins to ow. THERE
SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE
FAUCET AT THE TIME IT IS OPEN.
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.
Improper installation, use and service may result
in property damage.
•
Do not operate water heater if exposed to flooding or
water damage.
•
Inspect anode rods regularly, replace if damaged.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
CAUTION
GENERAL SAFETY INFORMATION
GENERAL SAFETY INFORMATION
6
FEATURES AND COMPONENTS
Thank You for purchasing this water heater. Properly installed
and maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating, and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
QUALIFICATIONS
Qualied Installer or Service Agency
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by
ANSI below) in the eld involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical
supply are required in addition to electrical testing skills when
performing service.
ANSI Z223.1 2012 Sec. 3.3.85: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person or
through a representative is engaged in and is responsible for (1)
the installation, testing or replacement of gas piping or (2) 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.
INTRODUCTION
PREPARING FOR THE INSTALLATION
1. Read the "General Safety Information" section, pages 4-5 of
this manual rst and then the entire manual carefully. If you
don’t follow the safety rules, the water heater will not operate
properly. It could cause DEATH, SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, operation,
and maintenance of the gas-red 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. Since
we cannot put everything on the rst few pages, RE AD THE
ENTIRE MANUAL BE FORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
2. The installation must conform with these instructions and the
local code authority having jurisdiction. 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 or CAN/
CSA-B149.1 the Natural Gas and Propane Installation 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.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility
or the manufacturer whose name appears on the rating plate.
4. Carefully plan the place where you are going to put the
water heater. Correct combustion, vent action, and vent pipe
installation are very important in preventing death from possible
carbon monoxide poisoning and res.
Examine the location to ensure the water heater complies with
the “Locating the Water Heater” section in this manual.
5. For California installation this water heater must be braced,
anchored, or strapped 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, 400 P Street, Sacramento, CA 95814.
CONTROLS
FIGURE 1.
THE ELIMINATOR (SELF-CLEANING SYSTEM)
These units include The Eliminator (Self-Cleaning System)
installed in the front water inlet, see Figure 2. 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 significantly
reduce outlet water temperatures during heavy draws.
7
BLOWER/BURNER ASSEMBLY
The fan-assisted combustion system includes a spark-to-pilot
igniter, 100% premix stainless steel burners, and prejets for input
rate and precision air/gas ratio control.
2-BURNER / BLOWER ASSEMBLY
(for Input of 199KBtu/H or Less)
3-BURNER / BLOWER ASSEMBLY
(for Input of 250KBtu/H or Higher)
FIGURE 5.
The intake air screen is attached to the inlet of the combustion
blower. Inspect the intake air screen every six months. The intake
air screen should be cleaned of any buildup of debris or foreign
material.
Note: The Eliminator may have 1, 3 or 7 cross tubes.
FIGURE 2.
HIGH LIMIT SWITCH
The digital thermostat (Figure 3) contains the high limit (energy
cutout) switch. The high limit switch interrupts 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.
Contact your dealer or service agent if continued high limit switch
operation occurs.
RESET
BUTT
ON
LED
LIGHTS
FUSE
140
130
DIGITAL THERMOSTAT
FIGURE 3.
ELECTRONIC IGNITION CONTROL
Each heater is equipped with an ignition control. The solid state
ignition control (Figure 4), ignites the burner by utilizing an
intermittent spark-to-pilot igniter. Spark and pilot gas ON until
lightoff or trial for ignition ends. If pilot fails to light, pilot gas and
spark OFF (100% shutoff). After 5 minutes delay, a new trial for
ignition is initiated. This sequence continues until lightoff or "Call
for Heat" is removed.
IGNITION CONTROL
FIGURE 4.
8
ROUGH IN DIMENSIONS
FIGURE 6.
TABLE 1. ROUGH-IN-DIMENSIONS
MODEL DIM.
BCL380T1206NOX - 1996NOX BCL3100T1996NOX - (A)2756NOX (A)BCL386T3106NOX - 3906NOX
inches cm inches cm inches cm
A 63-3/4 161.93 71-3/4 182.25 71-3/4 182.25
B 37 93.98 37 93.98 37 93.98
C 65 165.1 73 185.42 73 185.42
D 52-3/4 133.99 60-3/4 154.31 60-3/4 154.31
E 20-3/4 52.71 20-1/2 52.07 20-1/2 52.07
F 21 53.34 21 53.34 21 53.34
G 3/4 NPT 3/4 NPT 3/4 NPT
H 53 134.62 61 154.94 61 154.94
I 6 15.24 6 15.24 6 15.24
J 27-3/4 70.49 27-3/4 70.49 27-3/4 70.49
K 1 1/2 NPT 1 1/2 NPT 1 1/2 NPT
L
1 1/2 NPT 1 1/2 NPT 1 1/2 NPT
M - - 8 20.3 8 20.3
Approx. Shipping Weight STD 605 275 665 302 740 335
Approx. Shipping Weight ASME N/A N/A 715 324 790 358
TABLE 2. RECOVERY CAPACITIES, BASED ON 80% THERMAL EFFICIENCY
Model
Input
Kbtuh
Input
Kw
U.S.
Gal.
Liters
Eff.%
U.S. Gallons/hr and Liters/hr at Temperature Rise Indicated
°F 36 40 50 54 60 70 72 80 90 100 108 110 120 126 130 140
°C 20 22 28 30 33 39 40 44 50 56 60 61 67 70 72 78
BCL380T1206NOX
120 81 80 GPH 320 288 230 213 192 165 160 144 128 115 107 105 96 91 89 82
35 307 LPH
1212 1091
872 808 727 623 606 545 485 436 404 397 364 346 336 312
BCL380T1546NOX
154 81 80 GPH 411 370 296 274 246 211 205 185 164 148 137 134 123 117 114 106
45 307 LPH
1555 1399 1120 1037
933 800 777 700 622 560 518 509 466 444 431 400
BCL380T1806NOX
180 81 80 GPH 480 432 346 320 288 247 240 216 192 173 160 157 144 137 133 123
53 307 LPH
1818 1636 1309 1212 1091
935 909 818 727 654 606 595 545 519 503 467
BCL380T1996NOX
199 81 80 GPH 531 478 382 354 319 273 265 239 212 191 177 174 159 152 147 137
58 307 LPH
2009 1808 1447 1340 1206 1033 1005
904 804 723 670 658 603 574 556 517
BCL3100T1996NOX
199 100 80 GPH 531 478 382 354 319 273 265 239 212 191 177 174 159 152 147 137
58 378 LPH
2009 1808
1447
1340 1206 1033 1005
904 804 723 670 658 603 574 556 517
(A)BCL3100T2506NOX
250 100 80 GPH 667 600 480 445 400 343 333 300 267 240 222 218 200 191 185 171
73 378 LPH
2524 2272 1818 1683 1515 1298 1262 1136 1010
909 841 826 757 721 699 649
(A)BCL3100T2756NOX
275 100 80 GPH 734 660 528 489 440 377 367 330 293 264 245 240 220 210 203 189
81 378 LPH
2777 2499 1999 1851 1666 1428 1388 1250 1111 1000
926 909 833 793 769 714
(A)BCL386T3106NOX
310 86 80 GPH 827 744 595 551 496 425 413 372 331 298 276 271 248 236 229 213
91 325 LPH
3130 2817 2254 2087 1878 1610 1565 1409 1252 1127 1043 1024
939 894 867 805
(A)BCL386T3666NOX
366 86 80 GPH 976 879 703 651 586 502 488 439 391 352 325 320 293 279 270 251
107 325 LPH
3696 3326 2661 2464 2217 1901 1848 1663 1478 1330 1232 1209 1109 1056 1023
950
(A)BCL386T3906NOX
390 86 80 GPH
1040
936 749 694 624 535 520 468 416 375 347 340 312 297 288 268
114 325 LPH
3938 3544 2835 2625 2363 2025 1969 1772 1575 1418 1313 1289 1181 1125 1091 1013
TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS
Model Gas Type
Gas Supply Pressure
Volts / Hz Amperes
Minimum Maximum
BCL380T1206NOX-100T2756NOX Natural 3.5" W.C. (0.87 kPa) 14" W.C. (3.48 kPa) 120/60 <5
(A)BCL386T3106NOX-86T3906NOX Natural 4.5" WC (1.12 KPA) 14" W.C. (3.48 kPa) 120/60 <5
INSTALLATION CONSIDERATIONS
9
heater is installed in a carpeted alcove, the entire oor shall
be covered by the panel.
The heater shall be located or protected so it 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 heater or connections will not
result in damage to adjacent area or to the lower floors of
the structure.
When such locations cannot be avoided, a suitable drain pan
should be installed under heater. Such pans should be fabricated
with sides at least 2” deep, with length and width at least 2” greater
than diameter of heater and must be piped to an adequate drain.
Pan must not restrict combustion air ow.
CLEARANCES
This water heater is approved for installation on combustible
ooring in an alcove with minimum clearance from combustion
construction as indicated in Figure 7 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 6” (15.2 cm) clearance unless an approved reducing
thimble is used.
When the water heater is installed directly on carpeting, the water
heater shall be installed on a metal or wood panel extending
beyond the full width and depth of the water heater by at least
3 in (76.2 mm) in any direction or, if the water heater is installed
in an alcove or closet, the entire oor shall be covered by the
panel. The panel must be strong enough to carry the weight of
the heater when full of water.
A service clearance of at least 24” (61 cm) should be maintained
from serviceable parts.
TABLE 4. MINIMUM CLEARANCES TO COMBUSTIBLE OR
NON-COMBUSTIBLE CONSTRUCTION
Model "A" Right Side "B" Left Side "C" Back "D" Ceiling
All
0" 0" 0" 12"
0 cm 0 cm 0 cm 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 ammable liquids or engine driven equipment or vehicles
are stored, operated or repaired. Flammable vapors are heavy
and travel along the oor and may be ignited by the heater's
igniter or main burner ames causing re or explosion. Some
local codes permit operation of gas appliances in such areas if
they are installed 18" or more above the oor. This may reduce
the risk if location in such an area cannot be avoided.
Do not install this water heater directly on a carpeted oor.
A re 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 in any direction. If the
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 front of the combustion
chamber ange plate to insure that the spark igniter, ame
sensor, and sightglass remain uncovered.
• DO NOT cover the gas control valve or the Temperature-
Pressure Relief Valve.
• DO NOT apply insulation within 5” (13 cm) of the blower, to
insure the safe operation of the blower assembly.
• DO NOT apply insulation on the control box that encloses
the thermostat, ignition control, and variable frequency drive.
• 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.
See the Circulation Pump Wiring Diagrams (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.
Stainless steel circulating pumps are recommended for use with
commercial water heaters.
FIGURE 7.
NSF LEG KIT
FIGURE 8.
The NSF Leg Kit (part number 9008883005) is needed only for
applications that must conform to NSF/ANSI Standard 5. The
installed height of the water heater will increase by 4" (10.2 cm)
when the leg kit is installed. Follow these steps to install the Leg Kit.
Use caution to prevent damage to the unit when installing the Leg Kit
1. Lift, tilt or lay the unit on its side to access the bottom of the legs.
2. Position the extension under leg aligning the holes in the leg
extension with the holes in the leg. Assemble the bolt, bevel
washers, at washers, and nut through the aligned holes in
the leg and leg extension as shown in Figure 8.
3. Once in place, tighten the nut and bolt assembly. Torque to 70
ft.lbs (9.67 kgf-m).
4. Insure that all four nut and bolt assemblies are torqued to the
specied value before placing the unit on the oor.
11
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.
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.
Special consideration must be taken with
installations above 10,100’ (3078m) for
standard models.
Gas and carbon monoxide detectors are
available.
The water heaters covered by this manual are certied for use
without modication for an altitude of 10,100 feet (3,078 m). Consult
the factory for installation at altitudes over 10,100 feet (3,078 m).
Some gas utility companies derate their gas for altitude, making
it unnecessary to install high altitude orices. Call the local gas or
utility company to verify BTU content.
Due to the input rate 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.
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
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.
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
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
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.
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.
12
Some addition adjustment maybe required later to maintain
a steady gas supply pressure.
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.
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 5 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 5.
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.
(3.49 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 appliance
gas valves. If your low pressure system does NOT meet these
requirements, the installer is responsible for the corrections.
High Pressure building supply systems use pressures that exceed
14” W.C. (3.49 kPa) (1/2 PSI Gauge). These systems must use
eld supplied regulators to lower the gas pressure to less than
14” W.C. (3.49 kPa) (1/2 PSI Gauge). Appliances 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 building pressure should be designed by gas delivery
professionals for best performance. Water heaters connected to
gas supply systems that exceed 14” W.C. (3.49 kPa) (1/2 PSI
Gauge) at any time must be equipped with a gas supply regulator.
GAS PRESSURE REQUIREMENTS
All models require a minimum gas supply pressure as shown in
Table 3 on page 8. The minimum supply pressure is measured
while gas is owing (dynamic pressure). The supply pressure
(dynamic) should never fall below that indicated in Table 3 page
8. 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 control 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 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 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 7 on page 24.
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.
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
flow pressures between 15 and 25 pounds per square inch
(103 kPa and 173 kPa). Flow pressures above 25 pounds
per square inch (173 kPa), or below 15 pounds per square
inch (103 kPa), will result in improperly sanitized dishes.
Where pressures are high, a water pressure reducing or flow
regulating control valve should be used in the 180°F (82°C)
line to the 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 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.
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 agency to have a
thermal expansion tank installed.
See Water Line Connections on page 21 and Water Piping
Diagrams starting on page 35.
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.
COMBUSTIBLE MATERIAL STORAGE
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating label.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
Keep water heater area clear and free of combustible materials,
gasoline and other ammable vapors and liquids.
CONTAMINATED AIR
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Corrosion of the ue ways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion
may result in failure and risk of asphyxiation.
Combustion air that is contaminated can greatly diminish the
life span of the water heater and water heater components such
as 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).
15
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
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.
AIR REQUIREMENTS
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near water heater.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
An insufcient supply of air can cause recirculation of combustion
products resulting in contamination that may be hazardous to
life. Such a condition often will result in a yellow, luminous burner
ame, causing sooting of the combustion chamber, burners and
ue tubes and creates a risk of asphyxiation.
Do not install the water heater in a conned space unless an
adequate supply of air for combustion and ventilation is brought
in to that space using the methods described in the Conned
Space section that follows.
Never obstruct the ow of ventilation air. If you have any doubts
or questions at all, call your gas supplier. Failure to provide the
proper amount of combustion air can result in a re or explosion
and cause property damage, serious bodily injury or death.
UNCONFINED SPACE
An Unconned Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconned space.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and replaces shall
also be considered in determining the adequacy of a space to
16
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 18 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 14. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (l50
mm) from the front of the appliance. 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 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3 inches (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.
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 18 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
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.
This heater is not approved for direct vent installation.
Heater must be protected from freezing downdrafts.
Remove all soot or other obstructions from the chimney that will
retard a free draft.
Water Heaters covered by these instructions are Category I,
Natural Draft appliances. Type B venting is required with these
heaters. For typical venting application see TECHNICAL DATA
VENTING on pages 19 and 20.
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 Natural Draft 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
red equipment to the duct work of ventilation systems.
FIGURE 11. FIGURE 12.
• Where a separate vent connection is not available and the
vent pipe from the heater must be connected to a common
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 tables on pages 19 and 20 should be used for
horizontally manifolding two or more heaters.
FIGURE 13.
19
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 6. TECHNICAL DATA VENTING
Model BCL380T1206NOX
Input: 120,000 Btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
120,000 1 ft. 6 6 5 5 5 5 5 5
120,000 2ft. 5 5 5 5 5 5 5 5
120,000 3ft. 5 5 5 5 5 5 5 5
Number of 120 Heaters
Combined Input in
Thousands of Btu/hr
Manifold and Common Vent Diameter (Inches)
2 240,000 7 7 6 6 6 6 6 6
3 360,000 8 8 7 7 7 6 6 6
4 480,000 9 9 9 8 8 7 7 6
Model BCL380T1546NOX
Input: 154,000 Btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
154,000 1 ft. 6 6 6 6 6 6 6 6
154,000 2ft. 6 6 6 6 6 6 6 6
154,000 3ft. 6 6 6 6 6 6 6 6
Number of 154 Heaters
Combined Input in
Thousands of Btu/hr
Manifold and Common Vent Diameter (Inches)
2 308,000 7 7 6 6 6 6 6 6
3 462,000 8 8 7 7 7 6 6 6
4 616,000 9 9 9 8 8 7 7 6
Model BCL380T1806NOX - 100T1996NOX
Input: 180,000 and 199,000 Btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
180,000 1 ft. 7 7 6 6 6 6 6 6
199,000 1 ft. 7 7 7 6 6 6 6 6
180,000 2ft. 6 6 6 6 6 6 6 6
199,000 2ft. 7 7 6 6 6 6 6 6
180,000 3ft. 6 6 6 6 6 6 6 6
199,000 3ft. 6 6 6 6 6 6 6 6
Number of Heaters
Combined Input in
Thousands of Btu/hr
Manifold and Common Vent Diameter (Inches)
2
360,000 8 8 8 7 7 7 6 6
398,000 8 8 8 7 7 7 6 6
3
540,000 10 9 9 9 8 8 7 7
597,000 10 9 9 9 8 8 7 7
4
720,000 12 12 10 10 9 9 8 8
796,000 12 12 10 10 9 9 8 8
Model BCL3100T2506NOX
Input: 250,000 Btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
250,000 1 ft. 8 8 7 7 7 6 6 6
250,000 2ft. 7 7 7 7 6 6 6 6
250,000 3ft. 7 7 7 7 6 6 6 6
Number of 250 Heaters
Combined Input in
Thousands of Btu/hr
Manifold and Common Vent Diameter (Inches)
2 500,000 9 9 9 8 8 7 7 7
3 750,000 12 12 10 10 10 9 8 8
4 1,000,000 14 14 12 12 10 10 9 9
20
TABLE 6. TECHNICAL DATA VENTING (Continued)
Model BCL3100T2756NOX
Input: 275,000 btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
275,000 1 ft. 8 8 8 7 7 6 6 6
275,000 2 ft. 8 8 7 7 7 6 6 6
275,000 3 ft. 7 7 7 7 7 6 6 6
Number of Heaters Combined Input (Btu/hr) Manifold and Common Vent Diameter (Inches)
2 550,000 10 10 9 9 8 8 7 7
3 825,000 14 12 12 10 10 9 9 8
4 1,100,000 14 14 14 12 12 12 10 9
Model BCL386T3106NOX
Input: 310,000 btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
310,000 1 ft. - 8 8 8 7 7 6 6
310,000 2 ft. 8 8 8 7 7 7 6 6
310,000 3 ft. 8 8 8 7 7 7 6 6
Number of Heaters Combined Input (Btu/hr)
2 620,000 12 10 10 9 9 8 8 7
3 930,000 14 14 12 12 10 10 9 9
4 1,240,000 16 14 14 14 12 12 10 9
Model BCL386T3666NOX
Input: 366,000 btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
366,000 1 ft. - - - 8 8 7 7 6
366,000 2 ft. - - 8 8 8 7 7 6
366,000 3 ft. - 8 8 8 7 7 6 6
Number of Heaters Combined Input (Btu/hr)
2 732,000 12 12 12 10 9 9 8 8
3 1,098,000 14 14 14 12 12 12 10 9
4 1,464,000 16 16 16 14 14 12 12 10
Model BCL386T3996NOX
Input: 390,000 btu/hr Total Vent Height (Feet)
Vent connector size: 6 inches 6 8 10 15 20 30 50 100
Input Btu/hr Rise Vent Connector Diameter (Inches)
390,000 1 ft. - - - - 8 7 7 6
390,000 2 ft. - - - 8 8 7 7 6
390,000 3 ft. - - 8 8 8 7 7 6
Number of Heaters Combined Input (Btu/hr)
2 780,000 12 12 12 10 10 9 9 8
3 1,170,000 16 14 14 14 12 12 10 9
4 1,560,000 16 16 16 14 14 14 12 10
21
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.
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. Temperature-Pressure Relief Valve on page 13.
4. Closed Systems and Thermal Expansion on page 13.
5. For multiple water heater installations see Water Piping
Diagrams beginning on page 35.
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 Water Piping Diagrams beginning on page 35 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 35.
The water heater may be installed by itself, or with a separate
storage tank. When used with a separate storage tank, the
circulation may be either by gravity or by means of circulating
pump. 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 the Water Piping Diagrams
beginning on page 35.
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.
22
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.
23
HEATER WIRING
ELECTRICAL WIRING
All electrical work must be installed in accordance with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code,
CSA C22.1 and local requirements. When installed, the water heater must be electrically grounded in accordance with local codes or,
in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1. If any
of the original wire as supplied with the water heater must be replaced, it must be replaced with 105°C rated wiring or its equivalent,
except in the burner housing. In this case 200°C rated wire must be used.
The controls of this water heater are polarity sensitive. Be certain to properly wire the hot and neutral connections.
24V
24V
(GND)
GND
PV
MV/PV
MV
SPARK
4
2
BK
BK
R
R
RR
LOWER
PROBE
UPPER
PROBE
THERMOSTAT
BLOWER
PRESSURE
SWITCH
1a
1b
1
120 VAC HOT
120 VAC NUETRAL
EARTH GROUND
PILOT
IGNITION MODULE
GAS VALVE
BLOWER
FACTORY INSTALLED
BY INSTALLER
POWER RELAY
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED US ONLY 18 AWG
105
C 600V UL AWM STYLE #1015 WIRE EXCEPT GAS VALVE CABLE WHICH MUST USE
2 CONDUCTOR 18 AWG 80
C 300V UL CATEGORY QPTZ POWER LIMITED CIRCUIT CABLE
327382-000 REV. 00
R
R
R
BLK
W
W
BLK
W
LEGEND:
R= RED
W= WHITE
BLK= BLACK
Y= YELLOW
Y
M
P
BLUE
BLK
LOW GAS
PRESSURE
SWITCH
(SELECT MODELS)
FIGURE 20.
WIRING DIAGRAM
24
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 7. 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 current edition 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 current edition 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.-
natural gas, (1/2 pound per square inch gage) supply gas pressure.
Exposure to higher supply pressure may cause damage to the gas
control 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 control 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 7 - GAS SUPPLY PIPE LENGTHS (IN FEET)
Maximum Equivalent Pipe Length - Natural Gas Only
Input rate
(BTU/HR)
Schedule 40 Steel or Wrought Iron Pipe
1/2" 3/4" 1" 1 1/4" 1 1/2"
120,000 20 70 200 200 200
154,000 10 40 150 200 200
180,000 - 30 100 200 200
199,000 - 30 90 200 200
250,000 - 20 60 200 200
275,000 - 10 50 200 200
310,000 - 10 40 150 200
366,000 - - 30 100 200
390,000 - - 20 100 200
Fitting Type* Equivalent length in feet
45°Ell 0.7 1.0 1.2 1.6 1.9
90°Ell 1.6 2.1 2.6 3.5 4.0
Tee 3.1 4.1 5.2 6.9 8.0
Natural Gas 0.60 Specic Gravity, 0.50" W.C. Pressure Drop
*Screwed Fittings
It is important to guard against gas control 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 edition of the National Fuel Gas Code.
To prevent damage, care must be taken not to apply too much torque
when attaching gas supply pipe to gas control 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
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.
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.
25
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 27.
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 27 and the Sequence Of
Operation Flow Chart on page 28.
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 on page 24.
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 24
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 on page 24.
4. Wait ve (5) minutes for any residual gas to clear.
5. Open the Supply Gas Pressure Port on the gas control valve
by turning the center screw counter-clockwise. Connect the
manometer to the supply gas pressure test port, see Figure 22.
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.
FIGURE 22. – TOP VIEW
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 from the Supply Gas Pressure Port
and turn the center screw clockwise until the port is closed.
Supply Gas Pressure Adjustment
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.
26
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.
• If the back draft cannot be corrected by the normal method or
if a suitable draft cannot be obtained, a blower type ue gas
exhauster must be employed to assure proper venting and
correct combustion.
CHECKING THE INPUT
Follow these instructions to determine the ring rate of the water
heater.
1. Follow the procedure described in the "Initial Start Up" section
on page 25 to measure the static and dynamic supply gas
pressures. Verify that the static and dynamic supply gas
pressures conform to the values listed in Table 3 on page 8.
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: (BCL3100T1996NOX)
T = 18.1 seconds
H = 1000 BTU/Cu.Ft.
Btuh = (3,600/18.1) x 1,000 = 199,000
(Compare with BCL3100T1996NOX model and rating.)
UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED
THE INPUT SHOWN ON THE HEATER'S RATING PLATE.
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. 3,
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. 3, is accessible by
removing the control 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.
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 Water Heater Installations:
In multiple water heater installations or in installations where
the installed water heater(s) share a common gas supply main
with other gas red appliances; the supply gas pressures shall
be measured at each water heater with all gas red appliances
connected to a common main ring at full capacity.
On multiple water heater installations the supply gas line regulators
shall be adjusted to provide gas pressure to each water heater
within the minimum and maximum supply pressure requirements
listed in Table 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 24. 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 water heater
shall operate continuously.
5. Inspect vent system for leakage 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.
27
8. If the Ignition Control does not sense the pilot ame during the
ignition trial period, the Ignition Control shuts the Pilot Gas Valve
and turns off the Spark Igniter. After 5 minute delay, a new trial for
ignition is initiated. This sequence continues until the unit lights
or “Call for Heat” is removed.
9. If the pilot ame is proved during the ignition trial period, the
Ignition Control will energize the main gas control valve to start
the heating cycle. If the ame signal is lost during the heating
cycle, the Ignition Control closes the gas control valve and re-
starts the ignition process at step 5.
10. Once the unit is satised, the Thermostat will turn off the 24vac power
to the blower relay and the Ignition Control, and the unit will be in
standby mode until another call for heat is initiated by the thermostat.
See the ow chart on page 28 for more detailed information.
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. Blower power relay is energized to start the blower.
4. The blower pressure switch is closed, 24VAC power is applied to
the Ignition Control Module.
5. The Ignition Control performs diagnostic self check on system
components.
6. After 30 seconds delay, the Ignition Control begins the trial for
ignition by turning on the Spark Igniter and the Pilot Gas Valve.
7. The Ignition Control monitors the Flame Sensor during the ignition
trial period.
LIGHTING & OPERATING LABEL
FIGURE 23.
28
SEQUENCE OF OPERATION FLOW CHART
Description of this ow chart can be found in the “SEQUENCE OF OPERATION” section found on page 27.
Thermostat calls for heat
Switch power on to unit
Blower engages Prover Switch
Ignition Control monitors
flame signal
Loss of flame signal?
YES
YES
NO
NO
Blower power relay is energized to
start blower
Ignion Control provides power to Spark
Igniter and Pilot Gas Valve and monitors
Flame Sensor to determine if Burner is lit
24VAC power to the Ignion
Control and self check
Trial for ignion
Spark Off and Open main Gas Valve
5 minutes retry
delay
Close pilot gas
valve and Spark off
Flame Proved?
Close Main valve
and Pilot valve
30 Seconds Prepurge
Thermostat is sasfied
Blower – off; Blower Prover – opens
Ignion Control – off; Gas Valve – closes
FIGURE 24.
29
VENTING SYSTEM
Examine the venting system every six months for obstructions
and/or deterioration of the vent piping. Check all vent system
connections for leakage and repair or reseal as necessary.
Remove all soot or other obstructions from chimney which will
retard free draft.
INTAKE AIR SCREEN
The intake air screen is attached to the inlet end of the combustion
blower. Inspect the intake air screen every six months. The intake air
screen should be cleaned of any buildup of debris or foreign material.
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 25. 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 30. Replace the Temperature-
Pressure Relief Valve with a properly rated/sized new one,
see Temperature-Pressure Relief Valve on pages 13-14 for
instructions on replacement.
FIGURE 25.
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 13. The Temperature-Pressure Relief Valve
is not intended for the constant relief of thermal expansion.
Temperature-Pressure Relief Valve leakage due to pressure build
up in a closed system that does not have a thermal expansion
tank installed is not covered under the limited warranty. Thermal
expansion tanks must be installed on all closed water systems.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized temperature-
pressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
ANODE ROD INSPECTION
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 tank,
water ions attack and eat away the anode rod. This does not affect
water’s taste or color. The rod must be maintained to keep 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 technician, 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 rod replacement is not covered
by warranty.
NOTE: Articially softened water requires the anode rod to be
inspected annually.
MAINTENANCE
30
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.
To Drain the Water Heater Storage Tank:
1. Turn off the 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. Turn on the gas supply to the water heater at the Main Gas
Shutoff Valve.
13. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
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.
Lime accumulation may affect the life of equipment, the efciency
of the heater, and fuel consumption characteristics. 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 years
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 26.
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.
31
Chemical Hazard
• Product contains phosphoric acid.
• Keep out of reach of children.
• Use rubber or neoprene gloves.
UN•LIME 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.
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.
32
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 a qualied service agency, 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.
IGNITION CONTROL SYSTEM
Before calling your qualied service agency, the following
checklist should be examined to eliminate obvious problems
from those requiring replacement or servicing.
• Check that “main gas shutoff valve” is fully open and that gas
service has not been interrupted.
• 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 water heater thermostat (calling for heat)?
• It is possible that the high limit (E.C.O.) has functioned to shut
off the water heater. See page 7 - High Limit Switch for reset
procedure. Contact your service agent if limit continues to
function to shut off water heater.
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 27.
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 27.
9. Install the long plastic male adapter insert tting into the
drain valve opening of heater after applying Teon tape or
paste to 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 27, being
careful to keep the vent in the handle above the liquid level
SERVICE
SYSTEM DIAGNOSTICS
Your water heater is equipped with an ignition control that
incorporates a diagnostic system to assist in troubleshooting the
water heater. The green LED codes on the ignition module are
as follows:
TABLE 9.
2 FLASHES 5 Minutes Retry Delay
3 FLASHES Recycle - ame failed during run
4 FLASHES Flame sensed out of sequence
6 FLASHES Control Internal Error
7 FLASHES Flame rod shorted to ground
8 FLASHES Low secondary voltage supply
If an internal control failure is indicated, replace the ignition control.
Use this diagnostic system in conjunction with “TROUBLESHOOTING”
and the “SEQUENCE OF OPERATION” to troubleshoot the water
heater.
ELECTRICAL SERVICING
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
33
Contact the local water heater supplier or service agency for
further information concerning an Anode Replacement Kit and
this chlorination treatment.
If hot water odor persists after anode replacement and chlorination
treatment, we can only suggest that chlorination or aeration of
the water supply be considered to eliminate the water problem.
Do not remove the anode rod 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 that the hot water
faucet located farthest away from the water heater 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 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.
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.
OPERATIONAL CONDITIONS
Hot Water Odor
In each water heater there is installed 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 smell” in the hot water. The smell 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.
FOR YOUR INFORMATION
34
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, check
for inlet air blockage and/or ue gas
exhaust blockage.
Water temperature too hot. Thermostat set too high. Set thermostat to a lower setting.
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.
Water leaks. Drain valve not closed tightly. If drain valve cannot be closed
tightly, replace.
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. Possible gas leaks. Shut off gas supply to heater
and call gas company at once
TROUBLESHOOTING
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 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
WATER PIPING DIAGRAMS
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).
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 VALV
E
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
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 - (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
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).
MULTI FLUE - (2 UNITS)
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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
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 VALV
E
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 VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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
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.
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 VALV
E
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
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) TWO TEMPERATURE
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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 RETUR
N
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
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 (2 UNITS) WITH BOOSTER TWO TEMPERATURE
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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 WATE
R
RETURN
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.
MULTI-FLUE (3 UNITS)
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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 WATE
R
RETURN
COLD WATER
SUPPLY
EXPANSION
TANK
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 VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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 WATE
R
RETURN
ALT. COLD WATER
CONNECTION
AOS
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
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.
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 VALV
E
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
AOS
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
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.
MULTI FLUE FLUE (4 UNITS)
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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 WATE
R
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
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 VERTICAL STORAGE TANK
LEGEND
TEMPERATURE & PRESSURE
RELIEF VALVE
PRESSURE RELIEF VALVE
CIRCULATING PUMP
TANK TEMPERATURE CONTROL
DRAIN
FULL PORT BALL VALV
E
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
AOS
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
49
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 VALV
E
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
AOS
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
NOTES
50
51
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:
American Water Heaters
500 Princeton Road
Johnson City, TN 37605
800-999-9515
www.americanwaterheater.com
COMMERCIAL
WATER HEATER
LIMITED WARRANTY
American Water Heater
Product Service and Support
PO Box 1597, 500 Princeton Road
Johnson City, TN 37605
Phone: 800-999-9515
Copyright © 2015 American Water Heater Company. All rights reserved.
