null  User manual
Instruction Manual
Commercial Gas Water Heaters
GAS MODELS POWER VENT BTF-80
WITH HOT SURFACE IGNITION
500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.hotwater.com
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
PRINTED 1012
Keep this manual in the pocket on heater for future reference
whenever maintenance adjustment or service is required.
1
197440-002
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you
and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
water heater can cause low level exposure to some of the substances listed in the Act.
Approvals
2
GENERAL SAFETY
3
GENERAL SAFETY
Precautions
Do not use this water heater if any part has been under water.
Immediately call a qualified service agency 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 agency.
1. External fire.
2. Damage.
3. Firing without water.
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
flammable. To reduce the risk of injury under these conditions,
it is recommended that a hot water faucet served by this water
heater be opened for several minutes before using any electrical
appliance connected to the hot water system. If hydrogen is
present there will probably be an unusual sound such as air
escaping through the pipe as the water begins to flow. There
should be no smoking or open flame near the
faucet at the time it is open.
4
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.........................................2
Approvals..........................................................................................2
GENERAL SAFETY...............................................................................3
Contaminated Air............................................................................................. 18
Venting............................................................................................................. 18
U.S. Horizontal Vent Clearances..................................................................... 19
Vent Pipe Termination...................................................................................... 20
Planning the Vent System................................................................................ 20
Blower Assembly Installation........................................................................... 21
Installation of Vent System.............................................................................. 21
Vent Terminal Installation, Sidewall.................................................................. 21
Installation of Vent System, Sidewall............................................................... 22
Installation of Vertical Vent System.................................................................. 22
Precautions........................................................................................................ 4
Hydrogen Gas Flammable................................................................................. 4
INTRODUCTION....................................................................................5
Preparing for the Installation.............................................................................. 5
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF
MASSACHUSETTS................................................................................6
Features and Components.........................................................7
TEMPERATURE REGULATION..........................................................24
FOR YOUR INFORMATION.................................................................25
Replacement Parts and Deliming Products....................................................... 7
INSTALLATION Considerations.....................................................8
Start Up Conditions.......................................................................................... 25
Operational Conditions.................................................................................... 25
Rough-In-Dimensions........................................................................................ 8
Circulation Pumps.............................................................................................. 8
Facts to Consider About the Location................................................................ 9
Insulation Blankets........................................................................................... 10
PERIODIC MAINTENANCE.................................................................26
Venting System Inspection.............................................................................. 26
Burner Operation and Inspection..................................................................... 26
Burner Cleaning............................................................................................... 26
Housekeeping.................................................................................................. 26
Anode Rod Inspection..................................................................................... 27
Temperature-Pressure Relief Valve Operation................................................ 27
Draining and Flushing...................................................................................... 28
Service............................................................................................................. 28
INSTALLation Requirements...................................................... 11
Mixing Valves................................................................................................... 11
Water Piping.................................................................................................... 11
Closed Water Systems.................................................................................... 11
Thermal Expansion.......................................................................................... 11
Temperature-Pressure Relief Valve................................................................. 12
Gas Supply Systems....................................................................................... 13
Supply Gas Regulator...................................................................................... 13
Gas Piping....................................................................................................... 13
Sediment Trap................................................................................................. 15
Gas Line Leak Testing..................................................................................... 15
Purging............................................................................................................ 15
Filling the Water Heater................................................................................... 15
Air Requirements............................................................................................. 16
Combustible Material Storage......................................................................... 18
LEAKAGE CHECKPOINTS..................................................................29
TROUBLESHOOTING GUIDELINES...................................................30
Troubleshooting............................................................................................... 30
Wiring Diagrams............................................................................32
Circulation Pump Wiring Diagrams.................................................................. 33
Piping Diagrams.............................................................................34
Notes:................................................................................................40
Model BTF Limited Warranty....................................................43
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired 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 first few
pages, READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO
INSTALL OR OPERATE THE WATER HEATER.
Abbreviations Found In This Instruction Manual:
•
•
•
•
•
•
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
ASME - American Society of Mechanical Engineers
AHRI - Air-Conditioning, Heating and Refrigeration Institute
UL - Underwriters Laboratories Inc.
CSA - Canadian Standards Association
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 and the National Electrical
Code, NFPA 70 or CAN/CSA-B149.1 the Natural Gas and Propane
Installation Code and CSA C22.1. 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.
This gas-fired water heater is design certified by Underwriters
Laboratories Inc. under American National Standard for Gas Water
Heaters ANSI Z21.10.3 - CSA 4.3 (current edition).
Qualified Installer or Service Agency Installation and service of this
water heater requires ability equivalent to that of a Qualified Agency
(as defined by ANSI below) in the field involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical supply are
required in addition to electrical testing skills when performing service.
3. The water heater when installed must be grounded in accordance with
the local codes, or in the absence of local codes: the National Electrical
Code (NFPA 70) or the Canadian Electrical Code, CSA C22.1.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any individual, firm,
corporation or company that either in person or through a representative
is engaged in and is responsible for (a) the installation, testing or
replacement of gas piping or (b) the connection, installation, testing,
repair or servicing of appliances and equipment; that is experienced
in such work; that is familiar with all precautions required; and that has
complied with all the requirements of the authority having jurisdiction.” If
you are not qualified (as defined by ANSI above) and licensed or certified
as required by the authority having jurisdiction to perform a given task do
not attempt to perform any of the procedures described in this manual.
If you do not understand the instructions given in this manual do not
attempt to perform any procedures outlined in this manual.
4. 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.
5. 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 fires, see Figure 1. and Figure 2.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
6. 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 Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
Preparing for the Installation
1. Read the “General Safety” section, page 3 and 4 of this manual first
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.
7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00. For more information see next page.
5
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed
in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the
area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber
or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard
wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certified.
SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54
as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the
equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of
a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases,
but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.
6
Features and Components
Replacement Parts and Deliming Products
(A)VENT PIPE
(B)ANODE
(C)HOT WATER OUTLET
(D)OUTLET (120 VAC)
(E)FLUE BAFFLE
(F) GAS SUPPLY
(G) MAIN MANUAL GAS
SHUT OFF VALVE
(H) GROUND JOINT UNION
(J)SEDIMENT TRAP
(K)OUTER DOOR
(L)UNION
(M) INLET WATER SHUT
OFF VALVE
(N)COLD WATER INLET
Replacement parts and recommended delimer may be ordered
through authorized servicers or distributors. Refer to the Yellow Pages
for where to call or contact the water heater manufacturer at, 500
Tennessee Waltz Parkway, Ashland City, TN 37015. When ordering
parts, please call 1-800-433-2545 and provide complete model and
serial numbers (see rating plate), quantity and name of part desired,
see Figure 1. Standard hardware items may be purchased locally.
VACUUM RELIEF VALVE
(O) INLET DIP TUBE
(P)TEMPERATURE AND PRESSURE RELIEF VALVE
(Q)RATING PLATE
(R)INSULATION
(S)VENT TERMINAL
(T)DRAIN VALVE
(U) IGNITER AND MAIN
BURNER
(V)FLUE
(W) METAL DRAIN PAN
(X) GAS CONTROL/THERMOSTAT
(Y)CONTROL HARNESS*
(Z) MOTOR & BLOWER
(AA)CONDENSATE FITTING
*INSTALL PER LOCAL
CODES
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A CLOSED
WATER SYSTEM.
(X) GAS CONTROL/THERMOSTAT
(U) NATURAL GAS MAIN BURNER
WITH IGNITER ASSEMBLY
(U) PROPANE GAS MAIN BURNER
WITH IGNITER ASSEMBLY
(SIDE VIEW)
Figure 1.
7
INSTALLATION Considerations
Rough-In-Dimensions
TOP VIEW
Figure 2.
Table 1.
Model
BTF-80
Units
inches
cm
A
68.0
172.7
B
57 1/4
145.4
C
29 5/8
75.2
D
25 3/8
64.5
E
15
38.1
F
4
10.2
G
15 5/8
39.7
H
16
40.6
J
2
5.1
K
1
NPT
L
1/2
NPT
M
11 15/16
30.3
Table 2. - Recovery Capacities
Model
BTF-80
Input
Approx. Approx.
Rating
Btu/Hr
Rating
KW/Hr
Gal.
Cap.
Liter
Cap.
80,000
23.4
74
284
Temp.
°C
17
22
28
33
39
44
50
56
61
67
72
78
Rise °F
30
40
50
60
70
80
90
100
110
120
130
140
LPH
GPH
979
259
734
194
587
155
489
129
419
111
367
97
326
86
294
78
267
71
245
65
226
60
210
55
Recovery capacity based on 80% thermal efficiency.
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 in this manual for electrical hookup information. Install in accordance with the current edition of
the National Electrical Code, NFPA 70 or the Canadian Electrical Code, CSA C22.1.
All bronze or stainless steel circulating pumps are recommended for used with commercial water heaters.
Some circulating pumps are manufactured with sealed bearings and do not require further lubrication. Some circulating pumps must be
periodically oiled. Refer to the pump manufacturer’s instructions for lubrication requirements.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing, and other sanitizing needs can scald and permanently injure
you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly, children,
the infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is a local
code or state law requiring a certain temperature water at the hot
water tap, then you must take special precautions. In addition to
using the lowest possible temperature setting that satisfies your
hot water needs, a means such as a Mixing Valve should be used
at the hot water taps used by these people or at the water heater.
Mixing valves are available at plumbing supply or hardware stores.
Consult a Qualified Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the “Temperature
Regulation” section in this manual, see Figure 22.
This water heater has been design certified as complying with ANSI
Z21.10.3-CSA 4.3 for water heaters and is considered suitable for:
Water (Potable) Heating and Space Heating: All models are
considered suitable for water (potable) heating and space heating.
8
INSTALLATION Considerations
Facts to Consider About the Location
serious burns to anyone in the area.
Carefully choose an indoor location for the new water heater, because
the placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
water heater. This water heater is not for use in manufactured
(mobile) homes or outdoor installation.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
Whether replacing an old water heater or putting the water heater
in a new location, the following critical points must be observed:
1.Select a location indoors as close as practical to the vent terminal or
location to which the water heater vent piping is going to be connected,
and as centralized with the water piping system as possible.
2.Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install
the water heater in an attic or upper floor. When such locations cannot
be avoided, a suitable metal drain pan should be installed under the
water heater. Drain pans are available at your local hardware store.
Such a drain pan must have a clearance of at least 1.0” (2.5cm)
greater than any point on the water heater’s outer jacket and must
be piped to an adequate drain. The pan must not restrict combustion
air flow. For example, if a circular pan is used, it must be a minimum
of 27” (69cm) in diameter, see Figure 1.
Water heater life depends upon water quality, water pressure and
the environment in which the water heater is installed. Water heaters
are sometimes installed in locations where leakage may result in
property damage, even with the use of a drain pan piped to a drain.
However, unanticipated damage can be reduced or prevented by
a leak detector or water shut-off device used in conjunction with a
piped drain pan. These devices are available from some plumbing
supply wholesalers and retailers, and detect and react to leakage
in various ways:
• Sensors mounted in the drain pan that trigger an alarm or turn off
the incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to
the entire home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
• Devices that will turn off the gas supply to a gas water heater while
at the same time shutting off its water supply.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable
liquids (such as gasoline, solvents, propane (LP or butane, etc.) and
other substances (such as adhesives, etc.) emit flammable vapors
which can be ignited by a gas water heater’s hot surface igniter or
main burner. The resulting flashback and fire can cause death or
This water heater must not be installed directly on carpeting. Carpeting
must be protected by metal or wood panel beneath the water heater
extending beyond the full width and depth of the water heater by at
least 3” (7.6 cm) in any direction, or if the water heater is installed in
an alcove or closet, the entire floor must be covered by the panel.
Failure to heed this warning may result in a fire hazard.
9
Figure 5.
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater or water heaters be
installed so that combustion and ventilation air be taken from outside
these areas.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from
the front and 12” (30.5 cm) from the top (standard clearance). If
clearances stated on the heater differ from standard clearances,
install water heater according to clearances stated on the heater.
Propellants of aerosol sprays and volatile compounds (cleaners,
chlorine based chemicals, refrigerants, etc.), in addition to being highly
flammable in many cases, will also react to form corrosive hydrochloric
acid when exposed to the combustion products of the water heater.
The results can be hazardous, and can also cause product failure.
Adequate clearance 24” (61.0 cm) for servicing this water heater
should be considered before installation, such as changing the
anodes, etc.
A minimum clearance of 5.5” (14.0 cm) must be allowed for access to
replaceable parts such as the thermostats, drain valve and relief valve.
Insulation Blankets
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the wall as
practicable and as centralized with the water piping system as
possible.
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. Your water heater
meets or exceeds the Energy Policy Act standards with respect
to insulation and standby loss requirements, making an insulation
blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (for identification of components
mentioned below, see Figure 1.). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury, or death.
Figure 3.Figure 4.
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area such
as a closet, unless you provide air as shown in the “Locating The
New Water Heater” section. Never obstruct the flow of ventilation
air. If you have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amount of combustion air can result
in a fire or explosion and cause death, serious bodily injury, or
property damage.
•Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
•Do not cover the outer door, thermostat or temperature & pressure
relief valve.
•Do not allow insulation to come within 2” (5.1 cm) of the floor to
prevent blockage of combustion air flow to the burner.
•Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
•Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
•Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air flow.
10
INSTALLation Requirements
Mixing Valves
Water Piping
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing,
dish washing, and other sanitizing needs can scald and cause
permanent injury upon contact. Short repeated heating cycles caused
by small hot water uses can cause temperatures at the point of use to
exceed the water heater’s temperature setting by up to 20°F (11°C).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the infirm and the
physically/mentally disabled. Table 3. shows the approximate timeto-burn relationship for normal adult skin. If anyone using hot water
provided by the water heater being installed fits into one of these
groups or if there is a local code or state law requiring a certain water
temperature at the point of use, then special precautions must be taken.
This water heater should not be connected to any heating systems
or component(s) used with a non-potable water heating appliance.
All piping components connected to this unit for space heating
applications should be suitable for use with potable water.
In addition to using the lowest possible temperature setting that
satisfies the demand of the application a Mixing Valve should be
installed at the water heater (see Figure 1.) or at the hot water taps
to further reduce system water temperature.
Toxic chemicals such as those used for boiler treatment, should not
be introduced into this system.
When the system requires water for space heating at temperatures
higher than required for domestic water purposes, a mixing valve must
be installed. Please refer to Figure 2. for suggested piping arrangement.
Mixing valves are available at plumbing supply stores. Consult
a Qualified Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
These water heaters cannot be used in space heating applications only
Table 3.
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
Closed Water Systems
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed
devices such as pressure reducing valves, check valves, and back
flow preventers. Devices such as these cause the water system to
be a closed system.
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)
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.
HOT WATER
OUTLET
12” TO 15”
(30-38 cm)
TEMPERED WATER
OUTLET
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.
CHECK
VALVE
COLD
WATER
INLET
CHECK
VALVE
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric
unions or couplings be installed on this water heater when
connected to copper pipe.
MIXING
VALVE
TO TANK
INLET
All gas piping must comply with local codes and ordinances or with the
National Fuel Gas Code (ANSI Z223.1/ NFPA-54). Copper and brass
tubing and fittings (except tin lined copper tubing) should not be used.
Figure 6.
11
laboratory that maintains periodic inspection of production of listed
equipment of materials as meeting the requirements for Relief Valves
for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code
requirements of ASME.
If replaced, the new T&P valve must meet the requirements of local
codes, but not less than a combination Temperature-Pressure Relief
Valve rated/sized and certified as indicated in the above paragraph. The
new valve must be marked with a maximum set pressure not to exceed
the marked hydrostatic working pressure of the water heater (150 psi =
1,035 kPa) and a discharge capacity not less than the water heater Btu/
hr or kW input rate as shown on the water heater’s model rating label.
Note: In addition to the factory installed Temperature-Pressure Relief
Valve on the water heater, each remote storage tank that may be
installed and piped to a water heater 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 TemperaturePressure Relief Valve for remote storage tanks.
Figure 7.
Figure 7. shows typical attachment of water piping to water heater. The
water heater is equipped with 3/4 inch NPT water connections.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the water heater connections. Do not
solder the water lines directly to the water heater connections.
It will harm the dip tube and damage the tank.
T & P Valve and Pipe Insulation (if supplied)
Remove insulation for T & P valve and pipe connections from carton.
For safe operation of the water heater, the Temperature-Pressure Relief
Valve must not be removed from its designated opening nor plugged.
The Temperature-Pressure Relief Valve must be installed directly
into the fitting of the water heater designed for the relief valve. Install
discharge piping so that any discharge will exit the pipe within 6 inches
(15.2 cm) above an adequate floor drain, or external to the building. In
cold climates it is recommended that it be terminated at an adequate
drain inside the building. Be certain that no contact is made with any live
electrical part. The discharge opening must not be blocked or reduced
in size under any circumstances. Excessive length, over 30 feet (9.14
m), or use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve.
No valve or other obstruction is to be placed between the TemperaturePressure Relief Valve and the tank. Do not connect discharge piping
directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent
bodily injury, hazard to life, or property damage, the relief valve must be
allowed to discharge water in adequate quantities should circumstances
demand. If the discharge pipe is not connected to a drain or other
suitable means, the water flow may cause property damage.
CAUTION
Water Damage Hazard
• Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
Figure 8.
Fit pipe insulation over the incoming cold water line and the hot
water line. Make sure that the insulation is against the top cover of
the heater. Fit T & P valve insulation over valve. Make sure that the
insulation does not interfere with the lever of the T & P valve.
Secure all insulation using tape.
Temperature-Pressure Relief Valve
Explosion Hazard
T&P Valve Discharge Pipe Requirements:
•Shall not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
•Shall not be plugged or blocked.
•Shall not be exposed to freezing temperatures.
•Shall be of material listed for hot water distribution.
•Shall be installed so as to allow complete drainage of both the
Temperature-Pressure Relief Valve and the discharge pipe.
•Must terminate a maximum of six inches above a floor drain or
external to the building. In cold climates, it is recommended that the
discharge pipe be terminated at an adequate drain inside the building.
•Shall not have any valve or other obstruction between the relief valve
and the drain.
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 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.
Burn hazard.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
This water heater is provided with a properly rated/sized and certified
combination Temperature-Pressure Relief Valve (T&P valve) by the
manufacturer. The valve is certified by a nationally recognized testing
12
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.
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)
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. while the water heater
is operating is recommended and will generally provide good water
heater operation. Some addition adjustment maybe required later
to maintain a steady gas supply pressure.
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.
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 12.
Gas Piping
Contact your local gas utility company to ensure that adequate gas
service is available and to review applicable installation codes for
your area.
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.
Be sure that the gas meter has sufficient capacity to supply the
rated gas input of the water heater as well as the requirements of
all other gas fired equipment supplied by the meter. If the gas meter
is undersized, the gas company will have to install a properly sized
gas meter.
Gas Supply Systems
Low pressure building gas supply systems are defined as those
systems that cannot under any circumstances exceed 14” W.C. (1/2
PSI Gauge). These systems do not require pressure regulation.
Measurements should be taken to insure that gas pressures are stable
and fall within the requirements stated on the water heater rating plate.
Readings should be taken with all gas burning equipment off (static
pressure) and with all gas burning equipment running at maximum rate
(dynamic pressure). The gas supply pressure must be stable within 1.5”
W.C. from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy
combustion or nuisance outages. Increases or spikes in static pressure
during off cycles may cause failure to ignite or in severe cases damage
to appliance gas valves. If your low pressure system does NOT meet
these requirements, the installer is responsible for the corrections.
Make sure the gas supplied is the same type listed on the model
rating plate. The inlet gas pressure must not exceed 14.0” W.C.
(2.49 kPa) water column (3.5 kPa) for natural and propane gas
(L.P.). The minimum inlet gas pressure shown on the rating plate
is that which will permit firing at rated input.
High Pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use field supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI
Gauge). Water heaters require gas regulators that are properly
sized for the water heater input and deliver the rating plate specified
pressures. Gas supply systems where pressure exceeds 5 PSI often
require multiple regulators to achieve desired pressures. Systems in
excess of 5 PSI building pressure should be designed by gas delivery
professionals for best performance. Water heaters connected to gas
supply systems that exceed 14” W.C. (1/2 PSI Gauge) at any time
must be equipped with a gas supply regulator.
The water heaters covered in this manual require supply gas
regulators to maintain required supply gas pressure. Exposure
to higher gas supply pressure may cause damage to the gas
controls which could result in fire or explosion. If overpressure
has occurred such as through improper testing of gas lines or
malfunction of the supply system the water heater’s gas valve
must be checked for safe operation by a Qualified Service Agency.
Ensure supply regulator vent lines and the safety vent valves are
protected against blockage. These are components of the gas
supply system, not the water heater. Vent blockage may occur
during ice storms.
All models require a minimum gas supply pressure of 5.0” W.C. for
natural gas and 11.0” W.C. for propane gas. The minimum supply
pressure is measured while gas is flowing (dynamic pressure). The
supply pressure should never fall below 5.0” W.C. for natural gas and
11.0” W.C. for propane gas. The supply pressure should be measured
with all gas fired appliances connected to the common main firing
at full capacity. If the supply pressure drops more than 1.5” W.C. as
gas begins to flow to the water heater then the supply gas system
including the gas line and/or the gas regulator may be restricted
or undersized. See Supply Gas Regulator section and Gas Piping
section of this manual. The gas valve on all models has a maximum
gas supply pressure limit of 14” W.C. The maximum supply pressure
is measured while gas is not flowing (static pressure).
It is important to guard against gas valve fouling from contaminants
in the gas ways. Such fouling may cause improper operation,
fire or explosion. If copper supply lines are used they must be
internally tinned and certified for gas service.
Gas Line Sizing
Depending on the developed equivalent length and/or the number
of appliances connected to a common main, the size of supply
gas lines may have to be increased.
Supply Gas Regulator
Size the supply/main gas line(s) in accordance with Table 4. or
Table 5. The values given in Table 4. and Table 5. are for straight
lengths of iron pipe at 0.5” W. C. (125 Pa) pressure drop, which
is considered normal for low pressure systems. Note that fittings
such as elbows and tees will add to the pipe pressure drop.
The maximum allowable gas supply pressure for this water heater
is 14.0” W. C. (2.49 kPa) for natural gas and propane gas. Install a
positive lock-up gas pressure regulator in the gas supply line if inlet
gas pressure can exceed these pressures at any time.
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 4. on page 14.
Schedule 40 Steel or Wrought Iron Pipe is the preferred material
for the gas line of this water heater. It is imperative to follow the
sizing recommendations in the latest version of the National Fuel
Gas Code if Corrugated Stainless Steel Tubing (CSST) is used
as the gas line for this water heater.
13
Supply Gas Line Sizing U. S. Units
Failure to replace the standard orifice with a high altitude orifice when
installed could result in improper and inefficient operation of the water
heater, producing carbon monoxide gas in excess of safe limits, which
could result in serious injury or death. Contact your gas supplier for
any specific changes which may be required in your area.
Table 4.
Normal Iron Pipe Sizes (inches)
Input in Thousands Btu/hr
Length
in
Feet
1/2”
3/4”
1”
1 1/4”
1 1/2”
2”
10
175
360
680
1400
2100
3960
20
120
250
485
950
1460
2750
2200
30
97
200
375
770
1180
40
82
170
320
660
990
1900
50
73
151
285
580
900
1680
60
66
138
260
530
810
1520
70
61
125
240
490
750
1400
80
57
118
220
460
690
1300
90
53
110
205
430
650
1220
100
50
103
195
400
620
1150
125
44
93
175
360
550
1020
150
40
84
160
325
500
950
175
37
77
145
300
460
850
200
35
72
135
280
430
800
Use pipe joint compound or teflon tape marked as being resistant to
the action of petroleum [Propane (L.P.)] gases.
The water heater and its gas connection must be leak tested before
placing the water heater in operation.
Supply Gas Line Sizing Metric Units
Table 5.
The water heater and its individual shut-off valve should be
disconnected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of 1/2 pound per
square inch (3.5 kPa). It should be isolated from the gas supply
piping system by closing its individual manual shut-off valve during
any pressure testing of the gas supply piping system at test pressures
equal to or less than 1/2 pound per square inch (3.5 kPa).
Normal Iron Pipe Sizes (inches)
Input in kW
Length
in
Meters
1/2”
3/4”
1”
1 1/4”
1 1/2”
2”
3.0
51
105
199
410
615
1160
6.1
35
73
142
278
428
805
9.1
28
59
110
225
346
644
12.2
24
50
94
193
290
556
15.2
21
44
83
170
264
492
18.3
19
40
76
155
237
445
21.3
18
37
70
143
220
410
24.4
17
35
64
135
202
381
27.4
16
32
60
126
190
357
30.5
15
30
57
117
182
337
38.1
13
27
51
105
161
299
45.7
12
25
47
95
146
278
53.3
11
23
42
88
135
249
61.0
10
21
40
82
126
234
Connecting the gas piping to the gas control valve of the water heater
can be accomplished by either of two methods shown in Figure 9.
and Figure 10.
Figure 9.
GAS PIPING WITH FLEXIBLE CONNECTOR.
When installed at elevations above 7,700 feet (2,347 meters), input
rating should be reduced at the rate of 4 percent for each 1,000 feet
(305 meters) above sea level which requires replacement of the burner
orifice in accordance with National Fuel Gas Code (ANSI Z223.1/
NFPA 54). Contact your local gas supplier for further information.
Figure 10.
GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL.
14
Purging
Sediment Trap
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.
A sediment trap should be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The sediment
trap should be either a tee fitting with a capped nipple in the bottom
outlet or other device recognized as an effective sediment trap. If a
tee fitting is used, it should be installed in conformance with one of
the methods of installation shown in Figure 9. and Figure 10.
Contaminants in the gas lines may cause improper operation of the
gas control valve that may result in fire or explosion. 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. The sediment trap must be readily
accessible. Install in accordance with the “Gas Piping” section. Refer
to the current edition of the National Fuel Gas Code (ANSI Z223.1/
NFPA 54).
Gas Line Leak Testing
Figure 11.
Filling the Water Heater
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
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.
Never use this water heater unless it is completely full of water. To
prevent damage to the tank, the tank must be filled with water. Water
must flow from the hot water faucet before turning “ON” gas to the
water heater.
Any time work is done on the gas supply system perform a leak test
to avoid the possibility of fire or explosion.
1. For test pressures exceeding 1/2 psi (3.45 kPa) disconnect the water
heater and its Main Gas Shutoff Valve from the gas supply piping
system during testing, see Figure 11. The gas supply line must be
capped when disconnected from the water heater.
2. For test pressures of 1/2 psi (3.45 kpa) or less, the water heater need
not be disconnected, but must be isolated from the supply gas line
by closing the Main Gas Shutoff Valve during testing.
3. Paint all supply gas line joints and connections upstream of the
water heater with a rich soap and water solution to test for leaks.
Bubbles indicate a gas leak. Do not use matches, candles, flame or
other sources of ignition for this purpose.
4. Repair any leaks before placing the water heater in operation.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the right
(clockwise). The drain valve is on the lower front of the water heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when the
water heater is in use.
3. To insure complete filling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow is
obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as
needed.
15
Air Requirements
Confined Space
A Confined 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.
Breathing Hazard - Carbon Monoxide Gas
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in confined spaces. The required size
for the openings is dependent on the method used to provide
fresh air to the confined space and the total Btu/hr input rating
of all appliances installed in the space.
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.
Direct Vent Appliances
Appliances installed in a Direct Vent configuration that derive
all air for combustion from the outdoor atmosphere through
sealed intake air piping are not factored in the total appliance
input Btu/hr calculations used to determine the size of openings
providing fresh air into confined spaces.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Exhaust Fans
For safe operation an adequate supply of fresh uncontaminated air
for combustion and ventilation must be provided.
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed
in the same space with a water heater, sufficient openings
to provide fresh air must be provided that accommodate the
requirements for all appliances in the room and the exhaust
fan. Undersized openings will cause air to be drawn into the
room through the water heater’s vent system causing poor
combustion. Sooting, serious damage to the water heater and
the risk of fire or explosion may result. It can also create a risk
of asphyxiation.
An insufficient supply of air can cause recirculation of combustion
products resulting in contamination that may be hazardous to life.
Such a condition often will result in a yellow, luminous burner flame,
causing sooting of the combustion chamber, burners and flue tubes
and creates a risk of asphyxiation.
Do not install the water heater in a confined space unless an
adequate supply of air for combustion and ventilation is brought in
to that space using the methods described in the Confined Space
section that follows.
Louvers and Grilles
Never obstruct the flow of ventilation air. If you have any doubts or
questions at all, call your gas supplier. Failure to provide the proper
amount of combustion air can result in a fire or explosion and cause
property damage, serious bodily injury or death.
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 specified.
Where the louver and grille design and free area are not
known, it shall be assumed that wood louvers will have 25%
free area and metal louvers and grilles will have 75% free
area. Non motorized louvers and grilles shall be fixed in the
open position.
Unconfined Space
An Unconfined Space is one whose volume is not less than
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconfined space.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and fireplaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
Fresh Air Openings For Confined Spaces
The following instructions shall be used to calculate the size,
number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces
only. Do not refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 18 for complete
venting installation instructions.
Unusually Tight Construction
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in the
Confined Space section that follows.
16
Outdoor Air Through Two Openings
2. Not less than the sum of the areas of all vent connectors in the
space.
Outdoor Air Through Two Horizontal Ducts
Figure 14.
Figure 12.
The confined space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The horizontal ducts shall communicate directly with
the outdoors. See Figure 14.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 12.
Each duct opening shall have a minimum free area of 1 square
inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
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).
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts shall be not less than
3 inches.
Outdoor Air Through One Opening
Outdoor Air Through Two Vertical Ducts
The illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces only.
Do not refer to these illustrations for the purpose of vent installation.
See Venting Installation on page 18 for complete venting installation
instructions.
Figure 13.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 13. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (150
mm) from the front 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:
Figure 15.
The confined space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts shall communicate directly with the
outdoors. See Figure 15.
1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total input
rating of all appliances located in the enclosure, and
17
Contaminated Air
Each duct opening shall have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches.
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.
Air From Other Indoor Spaces
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Corrosion of the flue ways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion may
result in failure and risk of asphyxiation.
Combustion air that is contaminated can greatly diminish the life
span of the water heater and water heater components such as hot
surface igniters and burners. Propellants of aerosol sprays, beauty
shop supplies, water softener chemicals and chemicals used in dry
cleaning processes that are present in the combustion, ventilation
or ambient air can cause such damage.
Figure 16.
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).
The confined space shall be provided with two permanent openings,
one commencing within 12 inches (300 mm) of the top and one
commencing within 12 inches (300 mm) of the bottom of the
enclosure. See Figure 16.
Each opening shall communicate directly with an additional room(s)
of sufficient volume so that the combined volume of all spaces meets
the criteria for an Unconfined Space.
If the water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater(s) be installed in
a Direct Vent configuration so that all air for combustion is derived
directly from the outdoor atmosphere through a sealed intake air
pipe. See Venting Installation on page 18.
Each opening shall have a minimum free area of 1 square inch per
1,000 Btu/hr (2200 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).
Venting
Combustible Material Storage
Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell gas.
Do not expose water heater controls to excessive gas
pressure.
Use only the gas shown on the water heater rating label.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
periods of non-use.
Read instruction manual before
installing, using or servicing
water heater.
Keep water heater area clear and free of combustible materials,
gasoline and other flammable vapors and liquids.
18
U.S. Horizontal Vent Clearances
POWER VENT
(using room air for combustion)
EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION
G
V
D
H
A
v E
L
v
B
FI X E D
CLOSED
V
OPERABLE
V
F
B
B
C
OPERABLE
V
B
B
FI X E D
CLOSED
M
X
V
A
V
X
V
K
J
B
V
VENT TERMINAL
X
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Figure 17.
Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
Canadian Installations
A
Clearance above grade,
veranda, porch, deck or 12 inches (30 cm)
balcony
B
Clearance to window
or door that may be
opened
1
6 inches (15 cm) for appliances up to
10,000 Btu/hr (3 kW), 12 inches (30
cm) for appliances between 10,000
Btu/hr (3 kW) and 100,000 Btu/hr (30
kW), 36 inches (91 cm) for appliances
above 100,000 Btu/hr (30 kW)
US Installations
12 inches (30 cm)
4 feet (1.2 m) below
or to side of opening;
1 foot (30 cm) above
opening
2
Canadian Installations
H
I
Clearance to each side
of center line extended
above meter/regulator
assembly
Clearance to service
regulator vent outlet
US Installations
2
3 feet (91 cm) within a height 15 feet
(4.5 m) above the meter/
regulator assembly
3 feet (91 cm) within a
height 15 feet (4.5 m)
above the meter/regulator
assembly*
3 feet (91 cm)
3 feet (91 cm)*
6 inches (15 cm) for appliances up
to 10,000 Btu/hr (3 kW), 12 inches
(30 cm) for appliances between
10,000 Btu/hr (3 kW) and 100,000
Btu/hr (30kW), 36 inches (91cm)
for appliances above 100,000 Btu/
hr (30 kW)
6 feet (1.83 m)
C
Clearance to
permanently closed
window
12 inches (30 cm)*
12 inches (30 cm)*
J
Clearance to a non
mechanical air supply
inlet into building or
combustion air inlet to
any other appliance
D
Vertical clearance to
ventilated soffit located
above the terminal
within a horizontal
12 inches (30 cm)*
distance of 2 feet (61
cm) from the center line
of the terminal
12 inches (30 cm)*
K
Clearance to a
mechanical air supply
inlet
E
Clearance to
unventilated soffit
12 inches (30 cm)*
12 inches (30 cm)*
L
Clearance above paved
sidewalk or paved
7 feet (2.13 m)†
driveway located on
public property
F
Clearance to outside
corner
2 feet (60 cm)*
2 feet (60 cm)*
M
Clearance under
veranda, porch, deck, or 12 inches (30 cm) ‡
balcony
G
Clearance to inside
corner
18 inches (45 cm)*
18 inches (45 cm)*
1 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code.
2 In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
19
1
4 feet (1.2 m) below or to
side of opening; 1 foot
(30 cm) above opening.
3 feet (91 cm) above if
within
10 feet (3 m) horizontally
7 feet (2.13 m)
12 inches (30 cm) ‡
Vent Pipe Termination
field supplied fittings
Field supplied fittings should be equivalent to the piping material
being installed. Field installed/supplied fittings will add equivalent
feet to the vent or intake air piping as indicated below. All field
supplied/installed fittings and piping must be factored into the
equivalent feet calculations.
The first step is to determine where the vent pipe will terminate.
The vent may terminate through the roof as shown in Figure 21. or
through a sidewall as shown in Figure 20.
IMPORTANT
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the
National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and
Propane Installation Code CAN/CSA-B149.1, see Figure 17.
• 90° elbows (short or long radius) are equivalent to 5 linear
feet (152 cm) of pipe.
• 45° elbows (short or long radius) are equivalent to 2.5 linear
feet (76 cm) of pipe.
For your convenience instructions on proper installation through a
sidewall are provided in Figure 19.
primer and cement
Tetrahydrofuran (THF) primer should be used to prepare the
surfaces of pipe and fittings for solvent welding. if CPVC or ABS
pipe and fittings are used, then the proper cement must be used
for all joints, including joining the pipe to the factory provided
terminations (PVC material). PVC materials should use ASTm
D-2564 Grade Cement; CPVC materials should use ASTm F-493
Grade Cement and ABS materials should use ASTm D-2235
Grade Cement.
Planning the Vent System
Plan the route of the vent system from the discharge of the blower
to the planned location of the vent terminal.
1. Layout the total vent system to use a minimum of vent pipe and
elbows. Take into consideration that an elbow will be necessary
to make the first vent pipe connection to the power venter outlet,
see Figure 18.
2. This water heater is capable of venting the flue gases the equivalent
of thirty (30) feet of 3 inch pipe or one-hundred (100) feet of 4 inch
pipe as listed in Table 6.
NOTE: A. For water heaters in locations with high ambient
temperatures (above 100°F) it is recommended that CPVC or
ABS pipe and fittings be used. B. A 22.5 degree elbow (2” vent
pipe) or a 45 degree elbow (3” and 4” vent pipe) with an installed
screen VENT TERMINAL must be used in all cases.
Table 6.
Number of
90° Elbows
3” Maximum
Pipe (Feet)
4” Maximum
Pipe Feet
ONE (1)
25
92
TWO (2)
20
84
THREE(3)
15
76
FOUR (4)
10
68
FIVE (5)
---
60
Condensate
Condensate formation does not occur in all installations of
power vented water heaters, but should be protected against
on installations where it can form in the venting system.
Condensation in the venting system of power vented water
heaters is dependent upon installation conditions including, but
not limited to ambient temperature and humidity of installation
location, ambient temperature and humidity of venting space,
vent discharge and slope, and product usage. In certain
conditions, installations in unconditioned space or having long
horizontal or vertical vent runs may accumulate condensate.
In these conditions, the vent pipe should be sloped downward
away from the blower assembly (not less than 1/8” (3.2 mm)
nor greater than 1/2” (12.7 mm) per foot maximum). If the vent
piping is vented level or sloped upwards away from the blower
assembly, then adequate means for draining and disposing of
the condensate needs to be made by the installer (if condensate
is detected). If you have condensate, then a 3/8” drain hose
can be connected to the built-in drain port of the rubber boot on
the blower assembly. For your convenience, the rubber boot is
supplied with a removable cap on the built-in drain port. Prior
to operating the water heater, make sure the removable cap is
installed on the drain port (if a drain hose is not needed).
Minimum of one (1) elbow and 2 feet of straight pipe must be installed
for 3” and 4” pipe.
NOTE: The equivalent feet of pipe listed above are exclusive
of the “45° Elbow” termination. That is, the termination “45°
Elbow”, with installed screen, is assumed to be in the system
and the remainder of the system must not exceed the thirty (30)
equivalent feet of 3 inch pipe or one-hundred (100) equivalent
feet of 4 inch pipe.
3. The blower discharge adapter is made to accept only straight
sections of 3” pipe. To start a minimum of 2 inches of 3” pipe must
be attached to the blower discharge, see Figure 17.
If using 3 inch vent pipe:
A minimum of 2 inches, maximum of 4 feet of 3” pipe must be
attached to the blower before the first 3-inch elbow. After the first
elbow add the additional venting required for the installation. The
total system cannot exceed 30 equivalent feet of venting, where
each elbow is equal to 5 feet of straight pipe.
If using 4 inch vent pipe:
Two inches of 3” pipe must be attached to the blower discharge.
A 4” x 3” reducer is added and then up to maximum 4 feet of
4 inch pipe added before the first elbow. An additional 4” x 3”
reducer and (1) foot of 3” pipe must be added to the end of the
vent system before terminating into the 3” 45° elbow. The total
system cannot exceed 100 equivalent feet of 4” venting, where
each elbow is equal to 8 feet of straight pipe.
Approved Vent Material
Approved vent and intake air pipe materials that may be used
in the United States:
• PVC Schedule 40 (ASTm D 2241 / CSA B181.2, ASTm D1785
/ CSA B137.3
• CPVC Schedule 40 (ASTm F-411 / CSA B137.6)
• ABS (ASTm D-2661)
Approved vent and intake air pipe materials that must be used
in Canada:
• ULC S636 PVC / CPVC
20
Blower Assembly Installation
The water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding
conductor must be run with the circuit conductors and
connected to the equipment grounding terminal or lead on
the water heater, see Figure 26.
H. Replace cover plate and secure with two screws.
5. The blower discharge boot is made to accept only straight
sections of 3” pipe. To start off with an elbow, a short section
of the furnished pipe, a minimum of 2 inches, must be cut and
glued into the end of the elbow that will mount on the discharge
boot, see Figure 18.
Installation of Vent System
Before beginning installation of piping system thoroughly read the
section of this manual VENT PIPE PREPARATION.
1. Check to make sure that the wire harness is attached to the gas
valve and blower control box.
If you are installing your system so that it vents through the roof, please
refer to section titled INSTALLATION OF VERTICAL VENT SYSTEM.
2. Make sure no material is still attached to the outside or inside of
blower assembly.
Vent Terminal Installation, Sidewall
1. Install the vent terminal by using the cover plate as a template to
mark the hole for the vent pipe to pass through the wall. BEWARE
OF CONCEALED WIRING AND PIPING INSIDE THE WALL.
2. If the Vent Terminal is being installed on the outside of a finished
wall, it may be easier to mark both the inside and outside wall.
Align the holes by drilling a hole through the center of the template
from the inside through to the outside. The template can now be
positioned on the outside wall using the drilled hole as a centering
point for the template.
3. A) MASONRY SIDE WALLS
Chisel an opening approximately one half inch (1.3 cm) larger
than the marked circle.
B) WOODEN SIDE WALLS
Drill a pilot hole approximately one quarter inch (0.64 cm) outside
of the marked circle. This pilot hole is used as a starting point
for a saws-all or sabre saw blade. Cut around the marked circle
staying approximately one quarter inch (0.64 cm) outside of the
line. (This will allow the vent to easily slide through the opening.
The resulting gap will be covered up by the Vent Terminal cover
plate.) Repeat this step on inside wall if necessary.
Figure 18.
BLOWER ASSEMBLY
SEQUENCE OF INSTALLATIONS
Cut a length of PVC pipe about 3.5 inches (8.9 cm) longer than the
wall thickness at the opening. Glue the vent terminal to this section
of pipe. Slide the wall plate over the pipe to stop against the vent
terminal. Place a bead of caulking (not supplied) around the gap
between the pipe and cover plate. Apply enough to fill some of the
gap between the pipe and wall. Place some of the caulking on the
back of the plate to hold it against the wall after installation. If the
vent pipe is installed up to the wall, with a coupling on the end against
the wall opening, the pipe with the vent terminal can be prepared
for gluing before inserting through the wall. Slide the pipe through
the wall and insert into the coupling on the other side of the wall,
making sure that the vent terminal ends up pointed in the correct
position, see Figure 19.
3. Make sure that plastic tubing is still attached to the pressure switch
and fan housing. Also make sure that wiring connector from motor
to control box is securely attached.
4. Do not plug in power cord until vent system is completely installed.
The Power Vent operates on 120 Vac, therefore a grounded outlet
must be within reach of the 6 foot flexible power cord supplied
with the vent. The power cord supplied may be used on unit only
where local codes permit. If local codes do not permit use of flexible
power supply cord:
A. Remove screws that hold cover plate on control box and
remove plate.
B. Cut flexible power cord on inside of control box, as close to
inside wall as possible.
C. If flexible cord and strain relief are removed, then opening in
box must be covered by a plastic cap on the front side of the
control box.
D. Remove plastic cap on the right side of control box and install
suitable conduit fitting in enclosure.
E. Splice field wiring into existing wiring using code authorized
method (wire nuts, etc.).
F. Be certain that neutral and line connections are not reversed
when making these connections.
G. Ground heater properly. This water heater must be grounded
in accordance with the National Electrical Code ANSI/NFPA70,
CSA C22.1, the Canadian Electrical Code, and/or local codes.
These must be followed in all cases.
Figure 19.
VENT TERMINATION
21
Installation of Vent System, Sidewall
Installation of Vertical Vent System
With the route of the venting system and selection of materials
completed, as discussed in the section of this manual titled PLANNING
THE VENT SYSTEM, the through the wall vent terminal in place and
the first section of piping, up to first elbow, installed at the blower it is
time to complete the installation of the venting system for the sidewall
installation.
A proper flashing or “BOOT” should be used to seal the pipe where it
exits the roof. The total vent system should not exceed the equivalent
feet of pipe as listed in Table 4.
Provide support for all pipe protruding through the roof. All piping
should be properly secured. The vent system piping should be
supported every 5 feet (1.5 m) of vertical run and every 3 feet (91 cm)
of horizontal run. All piping and fittings must be joined by the proper
procedures as described under: VENT PIPE PREPARATION.
Figure 20.
Before completing the installation of the venting system be sure to read
the sections of this manual discussing the proper method of cutting
and cementing PVC pipe and fittings: VENT PIPE PREPARATION.
It is recommended that the completion of the venting system start at
the blower assembly and run to the coupling on the inside wall of the
vent terminal, see Figure 20.
Figure 21.
IMPORTANT
The vent system piping should be supported every 5 feet (1.5 m) of
vertical run and every 3 feet (91 cm) of horizontal run. All piping and
fittings must be joined by the proper procedures as described under:
VENT PIPE PREPARATION.
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the National
Fuel Gas Code (ANSI Z223.1) or CAN/CSA-B149.1, the Natural Gas
and Propane Installation Code as shown in Figure 17.
22
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss
of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. Do NOT try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric 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.
C. Use only your hand to push in the gas control
buttons. Never use tools. If the control buttons will
not push in, don’t try to repair them, call a qualified
service technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately contact a qualified
installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit. It
must be replaced!
OPERATING INSTRUCTIONS
5. This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
6. Wait five (5) minutes to clear out any gas.
If you then smell gas,
STOP! Follow "B"
in the safety information above on this label. If you
don't smell gas, go to the next step.
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control box to the
"ON" position.
1.
9. Set the thermostat to the desired setting by first
pressing the COOLER
and HOTTER
buttons
together and holding for 1 second. Then press the
HOTTER
button.
STOP! Read the safety information above on
this label.
10.WATER TEMPERATURE ADJUSTMENT
approximately 120°F.
2. Set the ON/OFF switch on the control box to the
"ON" position.
is
CAUTION: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature.
3. Set the thermostat to the lowest setting by first
pressing the COOLER
and HOTTER
buttons
together and holding for 1 second. Then press the
COOLER
button until the warm indicator light
appears.
11.If the appliance will not operate, follow the instructions
"TO TURN OFF GAS TO THE APPLIANCE" and call
your technician or gas supplier.
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING.
4. Set the ON/OFF switch on the control box to the
"OFF" position.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the lowest setting by first
pressing the COOLER
and HOTTER
buttons together and holding for 1 second. Then
press the COOLER
button until the warm
indicator light appears.
2. Set the ON/OFF switch on the control box to the
"OFF" position.
3. Turn off all electrical power to the appliance if service
is to be performed.
23
TEMPERATURE REGULATION
Any water heater’s intended purpose is to heat water. Hot
water is needed for cleansing, cleaning, and sanitizing (bodies,
dishes, clothing). Untempered hot water can present a scald
hazard. Depending on the time element, and the people
involved (adults, children, elderly, infirm, etc.) scalding may
occur at different temperatures.
The water temperature setting was factory set at the lowest
temperature; Pressing the “COOLER”
temperature and pressing the “HOTTER”
the temperature.
button decreases
button increases
Setting the water heater temperature at 120°F (49°C) (Approx.
“ ” mark on temperature setting of gas valve) will reduce the
risks of scalds. Some states require settings at specific lower
temperatures.
It is recommended that lower water temperatures be used
to avoid the risk of scalding. It is further recommended, in
all cases, that the water temperature be set for the lowest
temperature which satisfies your hot water needs. This will also
provide the most energy efficient operation of the water heater.
To avoid any unintentional changes in water temperature settings,
the control has a tamper resistant feature for changing the
temperature setting. To change the temperature setting follow
these instructions:
Figure 22. shows the approximate water temperatures produced
at various thermostat settings. Short repeated heating cycles
caused by small hot water uses can cause temperatures at
the point of use to exceed the thermostat setting by up to 30°F
(17°C). If you experience this type of use you should consider
using lower temperature settings to reduce scald hazards.
1. “Wake Up” the temperature indicators by holding down both
“COOLER” and “HOTTER” temperature adjustment buttons at
the same time for one second, see Figure 22. One or two of the
temperature indicators will light up. These indicators will only
remain on for 30 seconds if no further buttons are pressed. After
30 seconds the control will go back to “Sleep” mode.
Valves for reducing the point-of-use temperature by mixing
cold and hot water are available, see Figure 2. Also available
are inexpensive devices that attach to faucets to limit hot
water temperatures. Contact a licensed plumber or the local
plumbing authority.
2. Release both of the temperature adjustment buttons.
a. To decrease the temperature press and release the
“COOLER” button until the desired setting is reached.
b. To increase the temperature press and release the
“HOTTER” button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or raise
the temperature setting. The button must be pressed and released
for each temperature change desired.
Should overheating occur or the gas supply fail to shut off, turn off
the manual gas control valve to the water heater.
HOT WATER CAN SCALD: Water heaters are intended to
produce hot water. Water heated to a temperature which will
satisfy space heating, clothes washing, dish washing, and other
sanitizing needs can scald and permanently injure you upon
contact. Some people are more likely to be permanently injured
by hot water than others. These include the elderly, children, the
infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is
a local code or state law requiring a certain temperature water
at the hot water tap, then you must take special precautions. In
addition to using the lowest possible temperature setting that
satisfies your hot water needs, a means such as a mixing valve
should be used at the hot water taps used by these people or
at the water heater. Mixing valves are available at plumbing
supply or hardware stores, see Figure 2. Follow manufacturer’s
instructions for installation of the valves. Before changing
the factory setting on the thermostat, read the “Temperature
Regulation” section in this manual, see Figure 22.
Temperature Setting
Never allow small children to use a hot water tap, or to draw
their own bath water. Never leave a child or handicapped person
unattended in a bathtub or shower.
The water heater should be located in an area where the
general public does not have access. If a suitable area is not
available, a cover should be installed over the thermostat to
prevent tampering.
Display
BCDEF
F = approx. 180°F (82°C)
Nearly Instantaneous
E = approx. 170°F (77°C)
Nearly Instantaneous
D = approx. 160°F (71°C)
About 1/2 Second
C = approx. 150°F (65°C)
About 1 1/2 Seconds
B = approx. 140°F (60°C)
Less than 5 Seconds
B = approx. 130°F (54°C)
More than 30 Seconds
= approx. 120°F (49°C)
More than 5 Minutes
Figure 22.
24
Time to Produce
2nd & 3rd Degree
Burns on Adult Skin
FOR YOUR INFORMATION
Start Up Conditions
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that chlorination or
aeration of the water supply be considered to eliminate the water
problem.
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.
Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered normal.
See “Condensate” in this section.
Operational Conditions
SMELLY WATER
In each water heater there is installed at least one anode rod (see
parts section) 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:
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 flammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances
which are connected to the hot water system are used (such as a
dishwasher or washing machine). If hydrogen gas is present, there
will probably be an unusual sound similar to air escaping through the
pipe as the hot water faucet is opened. There must be no smoking
or open flame near the faucet at the time it is open.
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.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
This water heater is equipped with an automatic gas shut-off system.
This system works when high water temperatures are present. Turn
“OFF” the entire gas supply to the water heater. The high temperature
shut-off is built into the gas control valve. It is non-resettable. If the
high temperature shut-off activates, the gas control valve must be
replaced. Contact your gas supplier or service agency.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material,
and then chlorinating the water heater tank and all water lines.
Contact the local water heater supplier or service agency for
further information concerning an Anode Replacement Kit and this
chlorination treatment.
25
PERIODIC MAINTENANCE
Venting System Inspection
You should also check for sooting. Soot is not normal and will impair
proper combustion. A visual inspection of the main burner and HSI
igniter assembly should also be done at least once a year, see
Figure 23.
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until repairs
are made, because failure to correct the cause of the sooting can
result in a fire causing death, serious injury, or property damage.
At least once a year a visual inspection should be made of the venting
system. You should look for:
Figure 23.
Burner Cleaning
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
2. Damage or deterioration which could cause improper venting or
leakage of combustion products.
In the event your burner or burner air openings require cleaning, turn
the blower switch to the “OFF” position and allow the burner to cool.
Call a service agency to remove and clean the burner and correct
the problem that required the burner to be cleaned.
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gasses which could cause deadly asphyxiation.
Housekeeping
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to correct
the problem and clean or replace the flue and venting before
resuming operation of the water heater.
Burner Operation and Inspection
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a qualified installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit! It must be replaced!
At least once a year a visual inspection should be made of the
main burner and the hot surface igniter assembly for proper flame
characteristics and ignition sequences. This can be done by removing
the Outer Door and viewing the main burner operation through the
Viewport on the Inner Door, see Figure 1. The main burner should
provide complete combustion of gas, ignite rapidly, give reasonably
quiet operation, and cause no excessive flame lifting from the burner
ports. If the proper flame characteristics are not evident, see Figure 23.,
make sure that the flow of combustion and ventilation air is not blocked.
INSTALLED IN SUITABLE AREA: To insure sufficient ventilation
and combustion air supply, proper clearances from the water heater
must be maintained. See “Locating the New Water Heater” section.
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent to
the water heater which can cause a fire.
26
Anode Rod Inspection
Restart the water heater as directed under “Operating Your Water
Heater.” See the Repair Parts Illustration for anode rod location.
Figure 24.
ANODE ROD DEPLETION DETAIL.
Each water heater contains at least one anode rod, which will slowly
deplete (due to electrolysis) prolonging the life of the water heater
by protecting the glass-lined tank from corrosion. Adverse water
quality, hotter water temperatures, high hot water usage, and water
softening methods can increase the rate of anode rod depletion. Once
the anode rod is depleted, the tank will start to corrode, eventually
developing a leak.
Temperature-Pressure Relief Valve Operation
Certain water conditions will cause a reaction between the anode
rod and the water. The most common complaint associated with
the anode rod is a “rotten egg smell” produced from the presence
of hydrogen sulfide gas dissolved in the water. IMPORTANT: Do
not remove this rod permanently as it will void any warranties. The
parts list includes a special anode rod that can be ordered if water
odor or discoloration occurs. NOTE: This rod may reduce but not
eliminate water odor problems. The water supply system may require
special filtration equipment from a water conditioning company to
successfully eliminate all water odor problems.
The temperature-pressure relief valve must be manually operated
at least once a year.
Artificially 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. NOTE: artificially softened water requires the anode
rod to be inspected annually.
The following are typical (but not all) signs of a depleted anode rod:
* The majority of the rods diameter is less than 3/8”.
* Significant sections of the support wire (approx. 1/3 or more of the
anode rod’s length) are visible.
If the anode rod show signs of either or both it should be replaced.
NOTE: Whether re-installing or replacing the anode rod, check for
any leaks and immediately correct if found.
Figure 25.
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, see Figure 25.
In replacing the anode:
1.
2.
3.
4.
5.
6.
Turn off gas supply to the water heater.
Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
Drain approximately 5 gallons of water from tank (Refer to “Draining
and Flushing” for proper procedures). Close drain valve.
Remove old anode rod.
Use Teflon® tape or approved pipe sealant on threads and install
new anode rod.
Turn on water supply and open nearby hot water faucet to purge air
from water system. Check for any leaks and immediately correct
any if found.
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, and replace the
temperature-pressure relief valve with a new one.
If the temperature-pressure relief valve on the water heater weeps
or discharges periodically, this may be due to thermal expansion.
You may have a check valve installed in the water line or a water
meter with a check valve. Consult your local water supplier or service
agency for further information. Do not plug the temperature-pressure
relief valve.
27
Draining and Flushing
If the water heater is going to be shut down for an extended period,
the drain valve should be left open.
IMPORTANT: Condensation may occur when refi lling the tank and
should not be confused with a tank leak.
Service
Before calling for repair service, read the “Start Up Conditions”
and “Operational Conditions” found in the “For Your Information”
section of this manual.
If a condition persists or you are uncertain about the operation of
the water heater contact a service agency. If you are not thoroughly
familiar with gas codes, your water heater, and safety practices,
contact your gas supplier or qualified installer to check the water
heater.
It is recommended that the tank be drained and fl ushed every 6
months to remove sediment which may build up during operation. The
water heater should be drained if being shut down during freezing
temperatures. To drain the tank, perform the following steps:
Use the ”Leakage Checkpoints” guide to check a “Leaking” water
heater. Many suspected “Leakers” are not leaking tanks. Often the
source of the water can be found and corrected.
1.
2.
3.
4.
Turn off the gas to the water heater at the manual gas shut-off valve.
Open a nearby hot water faucet until the water is no longer hot.
Close the cold water inlet valve.
Connect a hose to the drain valve and terminate it to an adequate drain or external to the building.
5. Open the water heater drain valve and allow all of the water
to drain from the tank. Flush the tank with water as needed to
remove sediment.
6. Close the drain valve, refill the tank, and restart the heater as
directed in this manual.
Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
Never use this water heater unless it is completely filled with water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
28
LEAKAGE CHECKPOINTS
Never use this water heater unless it is completely filled with
water. To prevent damage to the tank, the tank must be filled
with water. Water must flow from the hot water faucet before
turning “ON” gas to the water heater.
B
A *Condensation may be seen on pipes in humid weather
or pipe connections may be leaking.
D
B. *The anode rod fitting may be leaking.
C. Small amounts of water from temperature-pressure relief
valve may be due to thermal expansion or high water
pressure in your area.
C
D. *The temperature-pressure relief valve may be leaking at
the tank fitting.
E . Water from a drain valve may be due to the valve being
slightly opened.
F. *The drain valve may be leaking at the tank fitting.
G. Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets
form and drip onto the burner or run on the floor. This
is common at the time of start-up after installation and
when incoming water is cold.
F
G
H . Water in the water heater bottom or on the floor may
be from condensation, loose connections, or the relief
valve. DO NOT replace the water heater until a full
inspection of all possible water sources is made and
necessary corrective steps taken.
E
Leakage from other appliances, water lines, or ground
seepage should also be checked.
* To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet,
follow “Draining” instructions in the “Periodic Maintenance”
section and then remove fitting. Put pipe dope or teflon
tape on the threads and replace. Then follow “Filling the
Water Heater” instructions in the “Installing the New Water
Heater” section.
29
TROUBLESHOOTING GUIDELINES
Troubleshooting
Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician.
Read the GENERAL SAFETY INFORMATION section first.
LED STATUS
PROBLEMSOLUTION
An open earth ground circuit to the 1. Check that the earth ground connection is
B C D E F
ignition system. properly connected.
2. Check that the ground conductor on the
water heater is properly connected.
Wiring error or a high resistance to
1. Check for proper connection of line
B C D E F
earth ground. neutral and hot wires.
2. Check that the water heater is securely
connected to earth ground.
B C D E F
Pressure switch remained closed longer 1. Pressure switch wiring is incorrect.
than 5 seconds after the call for 2. Replace pressure switch.
heat began.
Pressure switch remained open longer
1. Pressure switch wiring is incorrect.
B C D E F
than 5 seconds after the combustion
2. Pressure switch tubing not connected
blower was energized. correctly.
3. Air intake or exhaust obstructed.
WATER HEATER CONTROL
B C D E F
Error in the hot surface ignitor circuit.
1. Check that all wiring is correct and secure.
2. Replace hot surface ignitor.
System in lockout.
1. Gas supply is off or too low to operate.
2. Hot surface ignitor not positioned
correctly.
B C D E F
3. Low voltage to the water heater.
4. Electric polarity to unit is incorrect - test
and correct.
Problem in the gas valve driver circuit.
1. Turn power to the water heater off for
B C D E F
10 seconds and then back on.
2. Replace gas control valve.
Problem with the internal circuit.
1. Turn power to the water heater off for
B C D E F
10 seconds and then back on.
2. Replace gas control valve.
Problem with the internal circuit.
1. Turn power to the water heater off for
B C D E F
10 seconds and then back on.
2. Replace gas control valve.
B C D E F
Flame signal sensed out of proper sequence.
1. Replace gas control valve.
ECO activated.
1. Lower water temperature to below 120°F
B C D E F
and turn power to the water heater off for
10 10 seconds and then back on.
2. Replace gas control valve.
B C D E F
One of the temperature adjust
buttons stuck closed.
1. Press and release each of the buttons once.
2. Replace gas control valve.
B C D E F
Water temperature sensor is either open or short circuited.
1. Check that all wiring is correct and secure.
2. Replace gas control valve.
30
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent.
PROBLEMPOSSIBLE MALFUNCTIONSERVICE TO BE PERFORMED
1) Blower will not run
A) “ON/OFF” control switch turned off
B) Blower unplugged
C) No power at outlet
D) “ON/OFF” switch defective
E) Control harness defective
F) Blower motor defective
2) Blower running, burner not on
A) Fan not running fast enough to close
air switch contacts
B)
C)
D)
E)
F)
Air pressure switch defective
Gas valve defective
Control harness defective
Igniter defective
Unit has completed three trials to light
and failed
G) Discharge air limit tripped
NOT ENOUGH OR
NO HOT WATER
VENT PIPE TOO HOT
(ABOVE 170° F)
YELLOW FLAME
3) Thermostat problems
A) Thermostat set too low
B) Thermostat or ECO defective
C) High limit control circuit open
4) Others
A) Heater undersized
B) Low gas pressure
C) Incoming water is unusually cold
D) Leaking hot water pipes or fixtures
E) Polarity reversed
F) Heater not grounded
A) Blower does not run when heater fired
B) Not enough dilution air to mix with flue
gases
C) Air in room too hot for mixing with flue gases
D) Wrong burner orifice
A) Dirt in burner ports
B) Combustion air path restricted
C) Not enough room air for proper combustion
A) Water on the floor under heater
Improperly sealed, hot or cold supply connections,
relief valve, drain valve or thermostat threads
WATER LEAKS
Leakage from other appliances or water lines
Condensation of flue products
Thermal expansion in closed water system
LEAKING T&P VALVE
Improperly seated valve
HOT WATER ODORS OR COLOR High sulfate or mineral content in water supply or
(Refer to CATHODIC PROTECTION) iron or sulfate reducing bacteria in water supply
HEATER LIGHT GOES OUT Outlet polarity is reversed
IN 4-5 SECONDS
CONDENSATION
31
Turn switch to the “ON” position.
Plug blower back into 115 vac. outlet.
Repair service to outlet.
Replace switch.
Replace control harness.
Replace blower and motor.
Replace switch.
Check for low voltage, less than 102 vac., have service checked
and repaired.
If voltage is above 102 vac., make sure there is not more than 30 equivalent
feet (9.1 equivalent meters) of 3 inch pipe or 100 equivalent feet (30.5
equivalent meters) of 4 inch pipe installed or vent terminal blockage.
If at least 102 vac., less than 30 equivalent feet (9.1 equivalent
meters) of 3 inch pipe or 100 equivalent feet (30.5 equivalent meters)
of 4 inch pipe and not terminal blockage, replace blower.
Replace switch.
Replace gas valve.
Replace harness.
Replace igniter.
Reset cycle by turning switch off and then back on. If unit
does not light in three trials, call an authorized service
representative.
Verify dilution air openings are free of obstructions.
Make sure there is no more than 30 equivalent feet (9.1 equivalent meters)
of 3 inch pipe or 100 equivalent feet (30.5 equivalent meters) of 4 inch pipe.
Check for low voltage, less than 102 vac., have service checked
and repaired.
Make sure vent terminal is not blocked.
Turn temperature control higher.
Replace thermostat.
Replace.
Reduce hot water use.
Contact an authorized service representative.
Allow more time for heater to re-heat.
Have plumber check and repair leaks.
Correct wiring
Correct
Take unit out of service immediately, call an authorized service
representative.
Proper air circulation must be provided for combustion and
dilution of flue temp. Refer to “INSTALLATION” section.
Room air to be used for dilution with combustion products in
flue should be less than 90°F.
Install correct orifice.
Turn off heater and gas, clean burner head.
Clear area around heater and check under heater, remove any
debris under heater and in openings in bottom cover.
Refer to installation manual - Confined and Unconfined Space
statements on page 4 and 5 for required openings.
See “CONDENSATION.”
Turn off heater & water, repair unit.
Inspect other appliances near water heater.
Refer to “CONDENSATION.”
Install thermal expansion tank (DO NOT plug T&P valve).
Check relief valve for proper operation (DO NOT plug T&P valve).
Drain and flush heater thoroughly, chlorinate, refill and flush again
then chlorinate water supply.
Test polarity and correct.
Wiring Diagrams
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN
CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
Figure 26.
POWER VENT WIRING SCHEMATIC.
32
Circulation Pump Wiring Diagrams
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
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.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
Figure 27.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
DISHWASHER
TOGGLE
SWITCH
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
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.
L1 HOT
120 VAC
POWER
CIRC
PUMP
MOTOR
L2 NEUTRAL
Figure 28.
33
34
COLD
COLD WATER
SUPPLY
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
EXPANSION
TANK
COLD
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.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
SINGLE FLUE - (1 UNIT)
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
Piping Diagrams
35
COLD
ALT. COLD
WATER CONNECTION
HOT WATER
TO FIXTURES
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.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
SINGLE FLUE - (1 UNIT) WITH VERTICAL STORAGE TANK
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
HOT WATER
RETURN FROM
FIXTURES
LEGEND
36
COLD
HOT WATER
TO FIXTURES
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
ALTERNATE
LOCATION
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.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
SINGLE FLUE - (1 UNIT) WITH HORIZONTAL STORAGE TANK
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER
RETURN FROM
FIXTURES
LEGEND
37
LINE
TEMPERATURE
CONTROL
HOT WATER
RETURN
TEMPERED
WATER
RETURN
TEMPERED
WATER
OUTLET
DRAIN
PIPE T&P TO
OPEN DRAIN
MINIMUM
10´´ to 12´´
HOT
COLD
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER OUTLET
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.
EXPANSION
TANK
COLD WATER
SUPPLY
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
SINGLE FLUE - (1 UNIT) WITH MIXING VALVE TWO TEMPERATURE
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
38
HOT
COLD
PIPE T&P TO
OPEN DRAIN
HOT
COLD
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.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
SINGLE FLUE - (2 UNITS)
DRAIN
EXPANSION
TANK
COLD WATER
SUPPLY
HOT WATER RETURN
FROM FIXTURES
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
39
HOT
COLD
EXPANSION
TANK
COLD WATER
SUPPLY
PIPE T&P TO
OPEN DRAIN
HOT WATER RETURN
HOT
BOOSTER
HEATER
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.
FINISHED
FLOOR
PIPE T&P TO
OPEN DRAIN
HOT WATER
TO FIXTURES
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
SINGLE FLUE - (2 UNITS) TWO TEMPERATURE ONE PRE-HEATER/ONE BOOSTER HEATER
DRAIN
HIGH
TEMPERATURE
RETURN
HIGH
TEMPERATURE
OUTLET
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
Notes:
40
Notes:
41
Notes:
42
Model BTF Limited Warranty
A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this water heater.
1.
THE TANK
If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable
water therein, during the first THREE years after initial installation, the warrantor will supply a complete new A. O. Smith water heater of equivalent size and current model. Some government agencies are requiring energy efficient standards for water heaters. In the event regulations
prohibit sale of a model of equivalent size and construction, A. O. Smith will provide a model which complies with the regulations of your area,
in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required. The
warranty on the replacement water heater will be limited to the unexpired term of the original warranty.
2.
ALL OTHER PARTS
If within ONE year after initial installation of this water heater, any part or portion shall prove upon examination by the warrantor to be defective
in material or workmanship, the warrantor will repair or replace such part or portion at its option.
3.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes, ordinances and regulations,
the printed instructions provided with it and good industry practices. In addition, a temperature and pressure relief valve, certified by and officially
sanctioned and recognized independent testing agency and approved by the American Society of Mechanical Engineers, must have been installed.
a.
b.
c.
4.
This warranty shall apply only when the heater is:
(1) used at temperatures not exceeding the maximum calibrated setting of its thermostat;
(2) used at water pressure not exceeding the working pressure shown on the heater;
(3) filled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;
(4) used in a non-corrosive and non-contaminated atmosphere;
(5) used with factory approved anode(s) installed;
(6) in its original installation location;
(7) in the United States, its territories or possessions, and Canada;
(8) sized in accordance with proper sizing techniques for commercial and/or residential water heaters;
(9) bearing a rating plate which has not been altered, defaced or removed, except as required by the warrantor;
(10) operated with properly installed dirt leg;
(11) fired with the fuel for which it was factory built;
(12) fired at the factory rated input;
Any accident to the water heater, any misuse, abuse (including freezing or thermal expansion damage) or alteration of, any operation in a modified form, or any attempt to repair tank leaks will void this warranty.
This warranty is void if a device acting as a backflow prevention device (check valves etc.) is installed in the cold water supply the heater
is connected to, unless an effective method of controlling thermal expansion is also installed at the heater(s) and operational at all times.
The relief valve installed on the heater is not an acceptable method.
SERVICE AND REPAIR EXPENSES
Under the limited warranty the warrantor will provide only a replacement water heater or part thereof. The owner is responsible for all other
costs. Such costs may include but are not limited to:
a. Labor charges for service removal, repair or reinstallation of the water heater or any component part;
b. Shipping, delivery, handling, and administrative charges for forwarding the new heater or replacement part from the nearest distributor
and returning the claimed defective heater or part to such distributor.
c. All cost necessary or incidental for any material and/or permits required for installation of the replacement heater or part.
5.
LIMITATIONS ON IMPLIED WARRANTIES
Implied warranties, including the warranty of merchantability imposed on the sale of this heater under state law are limited to one (1) year
duration for the heater or any of its parts. Some states or provinces do not allow limitation on how long an implied warranty lasts, so the above
limitation may not apply to you.
6.
CLAIM PROCEDURE
Any claim under the warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products.
If this is not practicable, the owner should contact:
U.S. Customers
A. O. Smith
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Telephone: 800-323-2636
Canadian Customers
A. O. Smith Enterprises Ltd.
P. O. Box, 310 - 768 Erie Street
Stratford, Ontario N5A 6T3
Telephone: (800) 265-8520
a.
The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by
the warrantor.
Dealer replacements are made subject to in-warranty validation by warrantor.
b.
7.
DISCLAIMERS
NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY
OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE
RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR
OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR
DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.
a.
b.
Some states and provinces do not allow the exclusion or limitation of the incidental or consequential damage, so the above limitations or
exclusions may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or province to province.
Fill in the following for your own reference. Keep it. Registration is not a condition of warranty. The model and serial number are found on the heater’s
rating plate.
Model No.__________________________________ Serial No.__________________________________ Date Installed____________________
Dealer's Name________________________________________________________________________________________________________
Dealer's Address___________________________________________________________________ Phone No.__________________________
City and State/Province_______________________________________________________________________Zip/Postal Code______________
KEEP THIS WARRANTY POSTED ADJACENT TO THE HEATER FOR FUTURE REFERENCE.
43
500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.hotwater.com
44
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