∂
To the Installer:
To the Consumer:
Please attach these instructions
next to the water heater.
Please read these and all component
instructions and keep for future reference.
Atmospheric Gas Instruction Manual
Warranty, Registration Card and Parts List are included.
Homeowner: Please remember to return the Registration Card!
∂
! WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause serious injury or property damage. Refer to this manual.
For assistance or additional information, consult a qualified installer or service agency.
∂
! WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or
death.
∂
! WARNING
Do not install on combustible flooring. Install
in accordance with all local codes. In the
absence of local codes, refer to NFPA 54 or
ANSI Z21.10.1.
∂
! CAUTION
The recommended temperature for normal residential use is 120°F. The dial on the aquastat
does not always reflect the out-coming water
temperature and it could occasionally exceed
120°F. Variation in out-coming temperature
could be based on factors including but not
limited to usage patterns and type of installation. Test water at the tap nearest to the water
heater. (See page 9 for measuring the outcoming water temperature.)
∂
! WARNING
Hotter water increases the risk of scald injury.
Before adjusting the water temperature setting,
read this instruction manual. Temperatures at
which injury occurs vary with the person’s age
and the length of exposure. The slower reaction time of children, elderly or physically or
mentally challenged persons increases the
scalding hazard to them. It is recommended
that lower water temperatures be used where
these exposure hazards exist. Households with
small children or invalids may require a temperature setting less than 120°F to prevent accidental contact with hot water. To produce
less than 120°F, use point-of-use temperature limiting devices.
#23412
If higher water temperature is needed in part
of the water system, automatic temperature
limiting devices must be used on all lines to
water taps.
∂
! WARNING
Flammable vapors may be drawn to this water
heater from other areas of the structure by air
currents. Do not store or use any flammable
liquids in the vicinity of this heater.
∂
! WARNING
Water heater blankets may restrict air flow to
the water heater and cause fire, asphyxiation,
personal injury or death.
THIS MANUAL HAS BEEN PREPARED TO
ACQUAINT YOU WITH THE INSTALLATION,
OPERATION, AND MAINTENANCE OF YOUR
WATER HEATER AND TO PROVIDE IMPORTANT
SAFETY INFORMATION.
Read all instructions thoroughly before attempting installation or operation of your
water heater. Keep these instructions for future
reference.
Local plumbing and electrical codes must be
followed in the installation of this water
heater. In the absence of a local code use the
UNIFORM PLUMBING CODE and the NFPA
Code. Local codes may supersede instructions
in this installation manual.
These instructions are a guide for the correct
installation of the water heater. The manufacturer will not be liable for damages caused by
failure to comply with the installation and
operating instructions outlined on the
following pages.
Installation, testing, and replacement of gas
piping, appliances, or accessories, and repair
and servicing of equipment, shall be performed only by a qualified agency.
FAILURE TO FOLLOW THESE INSTRUCTIONS
OR ALL APPLICABLE BUILDING CODES
AND REGULATIONS VOIDS THE WARRANTY
ON THIS WATER HEATER.
Rev1 4/08
SPECIFICATIONS
Figure 1: All Models
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214 73.25 65.5
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EZ 80-199N
80 199,000 191
255
73
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90 199,000 191
263
78
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EZ 100-199N
100 199,000 191
271 70.75
31.5 54.75
18
9
19
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655
Page 2
63
G
183 73.25 65.5
80 156,000 150
F
67 135,000 130
EZ 80-156N
E
D
EZ 75-135N
B
C
H
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(inches)
Inle
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Dimensions
d In
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Model
Sto
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e (G
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)
put
(BT
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ise livery
(GA
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Table 1: Dimensions
Atmospheric Gas
WHEN YOU RECEIVE YOUR NEW WATER HEATER
Check the new equipment to see if all components are in good condition. If damage is observed
or parts appear to be missing, contact your wholesaler.
WATER HEATER PLACEMENT
NOTE: Locate the heater so it is not subject to physical damage from moving vehicles or
flooding. Do not locate the water heater in a room where swimming pool chemicals or large
quantities of water softener salt are kept. Installing a water heater
in this environment will result in premature failure of tank and
burner components due to corrosion caused by these elements
diffusing into the air.
DO NOT INSTALL THE WATER HEATER ON COMBUSTIBLE
FLOORING. Place on noncombustible flooring and maintain clearances prescribed by this manufacturer and per code NFPA 54. If the
water heater must be located on combustible flooring it must be
raised off the floor with a layer of 4'' concrete block laid so the air
holes are aligned as shown in Figure 2. Consult with local code officials before using this method. Please consult local codes, NFPA 54
Figure 2
and/or contact Bock Water Heaters with questions concerning
proper flooring materials. Leave adequate room for periodic maintenance of heater and burner.
The water heater should be placed as near to the chimney as practical in order to keep vent connector length to a minimum. Consult National Fuel Gas Code for proper vent configuration.
Minimum clearance to combustible construction is: SIDES 6"; BACK 6"; FRONT 24";
DRAFT HOOD; 18". The installation of this water heater must conform with local
codes and ordinances. In the absence of local codes, the installation must comply
with the National Fire Protection Association (NFPA 54) Code.
COMBUSTION AND VENTILATION AIR
The water heater must be installed in a location with an adequate air supply for combustion,
ventilation and draft control. Unsafe levels of carbon monoxide (CO), condensation and sooting may result if the room does not have an adequate air supply. See “National Fuel Gas Code
(NFPA 54)” or the discussions of “Unconfined Space” and “Confined Space” below. Poor ventilation will also result in hot spots around the heater. Temperatures over 90° near the water
heater generally indicate a lack of ventilation.
UNCONFINED SPACE
Unconfined space is defined by NFPA 54 as a space with a volume greater than 50 cubic feet
(during typical use) per 1000 BTUH of the total combined input of all fuel burning appliances
in the space. Rooms leading directly to the installation space through doors that cannot be
closed can be considered part of the space. Exception: Buildings with full vapor barriers, tight
doors and windows or air infiltration rates of less than 0.35 air changes per hour will be considered a confined space and require additional air supplies.
CONFINED SPACE
Confined space is defined by NFPA 54 as a space with a volume less than 50 cubic feet (during
typical use) per 1000 BTUH of the total combined input of all fuel burning appliances in the
space. Buildings or rooms of unusually tight construction are also considered a confined space.
See “Unconfined Space: Exception”.
When installing fuel burning appliances in a confined space, air must be supplied to that
space from either inside or outside of the building as conditions allow.
A. Inside Air Supply: A confined space shall be provided with two permanent openings; one
within 12 inches of the top and one within 12 inches of the bottom of the enclosure. These
openings shall lead directly to room(s) of sufficient volume so that the combined volume of
all the space meets the criteria for unconfined space. Each opening shall have a minimum free
area of 1 square inch per 1000 Btu/hr of the combined total input of all fuel burning appliances in the space. Each opening shall have an area of not less than 100 square inches or a
minimum dimension of not less than 3 inches.
Atmospheric Gas
Page 3
B. Outside Air Supply: Confined spaces shall be provided with two permanent openings; one
within 12 inches of the top and one within 12 inches of the bottom of the enclosure. These
openings shall communicate directly, or by ducts, with the outdoors or spaces that
communicate with the outdoors.
1.) Leading directly to the outside or through vertical ducts: Each opening shall have a
minimum free area of one square inch per 4000 Btu/hr of total input rating of all equipment
in the enclosure.
2.) Leading to outside through horizontal ducts: Each opening shall have a minimum free
area of one square inch per 2000 Btu/hr of total input rating of all equipment in the enclosure.
Note: All ducts shall have the same cross sectional area as the free area of each opening to
which they connect. The minimum dimensions of all ducts shall not be less than three inches.
Powered combustion air supplies are also commercially available and may be used.
LOUVERS & GRILLES
In calculating the free area of an opening, consideration must be given to the blocking effects
of louvers or grilles protecting the opening. Any screens used must be no finer than 1⁄4 inch
mesh. If the free area of a louver or grille is known, this should be used in calculating the size
of opening required. If free area is unknown, it may be assumed that wood louvers will have
20 to 25% free area and metal louvers and grilles will have 60 to 75% free area. Louvers and
grilles should be fixed in the open position or interlocked with the equipment so that they
open automatically during equipment operation.
VENTING
The water heater shall be located as close to the chimney as practical. Long lateral runs will
result in intermittent combustion problems and unsafe operating conditions. Total vent
height should be a minimum of 6 feet. Shorter vent heights could result in unstable draft and
nuisance lock outs.
The venting system should be sized according to National Fuel Gas Code: NFPA 54/ANSI
Z223.1 (most recent edition) using the “Natural” column. If you do not have a copy of this
code one can be obtained at www.NFPA.org for a nominal fee. Copies of the NFPA venting tables are also reprinted in the Bock Engineering Manual available from your Bock Representative or download from www.bockwaterheaters.com. Note: Do not reduce vent size more than
one size smaller than the vent connector supplied with the heater. If vent size must be reduced
one size, use full size vent connectors on the vent hood and reduce vent size as far from the
water heater as practical. B vent, L vent or multi-fuel venting may be used. Vent tables supplied by the vent manufacturer may also be used in sizing the vent system.
Venting system must be capable of producing –0.02" WC (inches of water column) draft minimum. If draft of –0.02" WC cannot be produced with an existing vent system, a draft inducer
may be required. Installations common vented with large vent hood equipped appliances such
as heating boilers may require vent dampers on the heating boiler connectors for proper vent
operation during no-heating season.
Check the building for items that can cause severe negative pressure problems such as large
exhaust fans. If these devices are installed in the same building check for their effect on draft
and combustion. All fuel burning appliances must be isolated from the effects of these devices
to operate properly. Failure to address this issue will result in unsafe operation and shorten
appliance life spans.
Your Bock water heater may also be operated with a power venter. The power venter must be
properly sized and adjusted to provide proper draft. Power venter wiring must turn on the
power venter on a call for heat and must prove venter operation before allowing the burner to
start. Refer to the power venter instructions for proper wiring and adjustment procedures.
DRAFT HOOD, DAMPER AND REDUCER COLLAR ASSEMBLY
Your Bock water heater is equipped with a vent hood, reducer collar and an electronic flue
damper. This system has been specifically designed to give your Bock water heater exceptional
reliability and safe operation. The draft hood, damper and reducer collar must be assembled
and installed as shown in Figure 3. Note: Substitution, elimination or relocation of any
of these components will result in unsafe operation and void the warranty of your
water heater. Refer to the instruction sheet provided with the damper for more detail on
damper operation and troubleshooting.
Page 4
Atmospheric Gas
1.
Align the hole in the rear of the damper base with
the hole in the tab on the reducer collar. Insert the
smooth end of the damper base into the reducer collar
and secure in place with a sheet metal screw (provided)
through the damper base and collar tab.
Figure 3
2.
With the damper arm oriented toward the front of
the heater, slide the reducer collar squarely over the
flue. Make certain that the arm does not interfere with
hot water piping and that the damper harness can safely
reach the damper.
3. Attach damper harness (4 pin connector) to the damper.
4. Install the draft hood on top of the damper assembly. The draft hood should fit snugly over
the corrugated section on top of the damper.
CONNECT WATER PIPING
This water heater incorporates fittings that contain a nonmetallic lining. Do not apply heat to
these fittings when making sweat connections to the heater. Sweat tubing to an adapter before
securing adapter to any fittings on the water heater.
The Bock ezFIT series includes hot outlet and cold inlet water connections on the top and side of
the water heater. Choose a cold inlet and hot outlet combination that best suits the installation.
Install dielectric unions and shut off valves on both hot and cold water lines. Recirculation/return lines can be plumbed to a cold water inlet, if necessary.
These models are equipped with an inlet flow diverter
(side cold inlet) installed in the tank. Heaters equipped
with this diverter are labeled with a decal next to the
inlet (shown to the left). The purpose of this diverter is
to help keep the tank bottom free of sediment by aiding
tank flushing. The index line on the diverter nipple must
be aligned with the arrow on the decal (left) to function
properly. Do not allow the diverter to rotate out of position when tightening the inlet fittings.
An approved pressure and temperature relief valve is factory installed in the opening provided
in the upper right-hand side of the water heater. For safe operation of the water heater, the
relief valve must not be removed from this location or plugged. When replacing the relief valve,
the new valve must have a rated discharge capacity equal to or greater than the rated input of
the water heater. It must also have a maximum temperature rating of 210°F and maximum pressure must not exceed 150 psi. Pipe the T&P valve outlet to within 6" of the floor or to a floor
drain with a free flowing drain pipe. No shut off valve should be installed in the line between
the relief valve and the drain. The area around the water heater and the T&P piping should be
protected against possible water damage caused by the functioning of the T&P valve.
∂
! CAUTION
Scalding injury and/or water damage can occur from either the manual lifting of the lever or
the normal operation of the T&P valve if it is not piped to a proper drain. If the valve fails to
flow water or reseat, call your plumber.
Check incoming water line for backflow preventers or water pressure reducing valves, as these
may cause pressure to build up in the water heater and result in tank failure. If this water
heater is installed in a closed system or if backflow preventers and pressure regulators are
installed, a properly sized expansion tank must be installed.
Note: Do not try to heat hard water as this will drastically reduce heater life. Install a water
softener or other scale reducing water treatment system if the water heater is being installed in
a hard water area (water hardness higher than seven grains).
Atmospheric Gas
Page 5
TEMPERATURE CONTROL MODULE
Your Bock water heater is equipped with an electronic temperature control with many advanced features. The temperature control is located in the control enclosure along with the
burner ignition module. This temperature control uses two probes to measure the average
water temperature in the tank. One probe located near the tank bottom senses temperature
and has a two wire harness. The other probe located near the top of the heater contains a temperature sensor and a high limit electronic cut out (ECO). This control also has 4 LED’s that indicate the operating condition. A green LED indicates that power is being delivered to the
control. A series of red LED’s indicates a call for heat, a high limit (ECO) cut out and reset status. The control requires a manual reset if the water temperature exceeds the ECO setting of
200°F. A gray button in the upper right hand corner of the control above the power supply is
the manual reset. Temperature is adjusted with a large black dial on the face of the control.
Temperature settings are marked in white on the dial. The temperature range of this control is
120°F to 180°F.
CONNECT THE ELECTRICITY
Your Bock water heater uses 120VAC, 60Hz line voltage. Total current load is less than 12
amps. This appliance must be electrically grounded and comply with all local codes. In the absence of local codes all wiring must conform with ANSI/NFPA 70—most recent edition. Electrical power to this appliance should be supplied through a fused disconnect switch located on
or near the water heater. A metal junction box is located in the control enclosure (with a prewired power cord) and may also serve as a location for a fused disconnect switch. Line voltage
is supplied to the temperature control module from the junction box. The temperature control
module supplies 24VAC power to the gas valve, burner control module and flue damper. See
Figures 4 and 5 for wiring diagrams.
WIRING DIAGRAM
Figure 4: Connection Diagram
Page 6
Figure 5: Schematic (Ladder) Diagram
Atmospheric Gas
CONNECT THE GAS LINE
∂
! CAUTION
Do not use this water heater with any gas other than the type listed on the rating label.
Check the rating label on the front of the water heater and make sure the gas to be used
matches the gas stated on the rating label. Consult your local gas company or Bock Water
Heaters with any questions.
A manual gas valve, a union, and a sediment trap should all be provided in front of the gas
valve. All gas piping must conform to local codes and/or the National Fuel Gas Code; ANSI
223.1/NFPA 54 (Latest Edition).
Supply piping should be sized according to the charts found in the National Fuel Gas Code
for natural gas applications.
Note: When sizing the gas piping to the heater, make sure that the pressure at the valve is
sufficient when all other appliances are operating. Undersized gas piping will reduce water
heater performance and life as well as result in nuisance lockouts. Also verify that the gas service and meter are sized properly for the load.
Gas piping should be carried oversize, i.e.: 3⁄4 inch or 1 inch or larger for 1⁄2 inch valve to
within 2 feet of the valve itself. This sustains pressure at the valve during start-up to prevent
flashbacks caused by momentary pressure loss. For natural gas, 5" W.C. pressure must be maintained upstream of the gas valve during operation. For LP gas, a minimum of 12" W.C. must be
maintained upstream of the gas valve. A 1⁄8 inch NPT pipe connection should be installed upstream of the manual shut-off valve to check incoming gas pressure.
During pressure testing of the gas supply piping, close the manual gas shut-off valve to the
water heater. Test pressure shall not exceed 1⁄2 PSIG (14" W.C). The gas valve is only rated for
1
⁄2 PSIG. To test at pressure greater than 1⁄2 PSIG, close the manual shut-off valve and disconnect the gas operating valve.
Turn on gas and inspect piping for leaks by “painting” each joint with soap and checking for
bubbles. Do not use open flame. The pipe thread compound that is used on gas piping must be
of the type resistant to propane gas. Do not use teflon tape on gas piping. Note: For high altitude applications (above 2000 feet) contact Bock Water Heaters.
Atmospheric Gas
Page 7
PLACE WATER SYSTEM IN OPERATION
Partially open all hot water faucets. Open cold water inlet valve to the water heater. Close hot
water faucets as they deliver water that is free of air. Start at lowest point in the building and
work upwards. Inspect for leaks.
PLACE THE GAS SYSTEM IN OPERATION AND LIGHT THE BURNER
Turn off all electrical power to the water heater. Verify that the gas main is open and gas
pressure does not exceed 14" W.C. in the gas line. Gas pressures over 14" W.C. will damage the
gas valve. If gas pressure is under 14" W.C. open the gas cock and bleed the gas lines until all
air is purged from the line. Make certain the area is well ventilated while performing this
step. Check for any gas leaks on the burner piping. Prior to initial burner operation, check
that inlet gas pressure is in the correct operating range (5-7" W.C. for natural gas; 12-14" W.C.
for propane gas).
1. Set the thermostat to the lowest setting.
2. Turn off all electrical power to the appliance.
3. DO NOT attempt to light the pilot by hand.
4. Turn gas control knob clockwise to “OFF”. DO NOT FORCE.
5. Wait for five (5) minutes to clear out any gas. If you smell gas, STOP!
∂
! WARNING
LP gas/propane gas is heavier than air and will remain at floor level in the occurrence of a
leak. Spaces below ground level will serve as areas for accumulation of leaking gas. Smell
around the entire appliance area for gas before lighting. Be sure to smell near the floor.
IF YOU SMELL GAS:
• Clear the room, building, or area of all occupants and do not re-enter the area until the
space has been determined to be safe.
• Use all practical means to eliminate sources of ignition. DO NOT OPERATE THE APPLIANCE.
If possible, cut off all electric circuits at a remote source to eliminate operation of automatic
switches in the area. Do not use any telephone in the area of the gas leak.
• Call your gas supplier from a telephone remote from the area of the leak. Follow the gas
supplier’s instructions.
∂
! WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE UNCERTAIN OF THE FOLLOWING:
• LP gas/propane gas and natural gas have an odorant added by the gas supplier that aids
in detection of the gas.
• This odor should be recognizable as a “sulfur” or “rotten egg” smell.
• If you have a diminished sense of smell or are unsure of the presence of gas, contact your
gas supplier from a telephone in another building.
• Consult with your gas supplier about the availability of gas detectors.
If you do not smell gas or the leak is corrected, go to next step.
6. Turn gas control knob counterclockwise to “ON”.
7. Turn on all electric power to appliance.
8. Set thermostat to desired setting.
9. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
Figure 6: Gas Valve
Verify gas inlet and manifold pressure. For natural gas, manifold
gas pressure should be 3.5" W.C. and inlet pressure should be between 5-7" W.C. For propane gas, manifold pressure should be 10" W.C. and inlet pressure
should be between 12-14" W.C. Your Bock water heater uses a built-in pressure regulator and
fixed burner orifice so ordinarily no gas rate adjustments are required.
Page 8
Atmospheric Gas
TO TURN OFF GAS TO APPLIANCE
1.
2.
3.
4.
Set thermostat to lowest setting.
Turn off all electric power to appliance if service is to be performed.
Push in gas control knob slightly and turn clockwise to “OFF”. DO NOT FORCE.
Close main gas valve.
INSPECT THE INSTALLATION AND ADJUST THE CONTROLS
The thermostat has been adjusted to 120°F at the factory. Wait until thermostat has shut off
gas to the main burner. Wait 30 seconds following shut-off of gas, then set thermostat to the
highest temperature. The main burner should relight. Set thermostat to the lowest temperature; the main burner should go out. The thermostat should be adjusted to the minimum
setting that will meet the hot water needs of the homeowner or commercial application.
∂
! CAUTION
There is a scald potential if the thermostat is set too high. The recommended temperature
setting for normal residential use is 120°F. If higher temperature settings are needed for
combined appliance applications or commercial use, an automatic tempering valve
must be installed on all domestic hot water lines. Should overheating occur, or the gas
supply fail to shut off, turn off the electricity to the water heater.
MEASURING THE OUTCOMING WATER TEMPERATURE
The thermostat is factory set at 120°F for domestic use. It is the responsibility of the building
owner to verify that the installer follows the recommended quantitative testing for measuring
the out-coming water temperature. To make sure that the system works properly after installation and in the future, it is recommended that the heater’s performance be measured and monitored. Run water out of the tap nearest the heater until it comes out warm. Using a calibrated
thermometer, take a measurement. If the water is not at a suitable temperature for the installation, have a qualified service person adjust the temperature control. Contact Bock for further
information if needed.
This log (or a similar one) should be filled out as follows:
Date
Time
Person running test
Set temp °F
Outlet temp °F
∂
! WARNING
Hydrogen gas can be produced in a hot water system served by a 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, open the hot water faucet at the highest location in
the house for several minutes before using any electrical appliance connected to the hot
water system. If hydrogen is present, there may be an unusual sound similar to air escaping
through the pipe as the water begins to flow. Do not smoke or allow an open flame near the
faucet at the time it is open.
Atmospheric Gas
Page 9
MAINTENANCE
Notice to the Owner: If you are having a mechanical problem with your water heater, contact your service company or installer.
Lime and Sediment: A program of regular maintenance should be established to keep your
water heater operating at peak efficiency. Important: The tank can fail prematurely from
an accumulation of lime and sediment in the bottom, excessive pressure and/or
corrosion. Prevention of these damaging factors will extend the life of your water heater
appreciably.
All Bock atmospheric gas water heaters have hand holes that permit the visual inspection of
the tank interior for lime. The hand hole is large enough to reach in and loosen such deposits
by brushing or scraping. A commercial lime dissolving chemical can also be employed. The
loosened residue can be flushed away through the hand hole or drain.
These accumulations can be controlled to an extent by softening the water or using other scale
reducing water treatment systems. The tank should be inspected every six months: Turn off
gas and electrical power, drain, remove the hand hole cover and make a visual check of the
tank interior. If lime (or sediment) has accumulated, remove with a commercial lime dissolving chemical or scrape loose the deposit and flush it away through the hand hole or drain.
Excessive pressure is controlled by the pressure relief valve. Water expands when heated and
the extra volume must have a place to go. If water cannot expand into the cold water line
because of a check valve or pressure regulator, pressure builds as the water heats. The pressure
relief valve opens and dumps the extra water. If the relief valve is faulty, or none has been
installed, the tank can fail due to excessive pressure. Open the relief valve at least once a
year to make sure the seat is not stuck.
∂
! CAUTION
Before opening the relief valve, be certain that the discharge line directs the flow of
water to the drain. Stand away from the outlet to avoid contact with the water.
Anode rods are installed in the head of the tank to help prevent corrosion. When inspecting
the tank interior for lime or sediment accumulations, also inspect the condition of the anode
rods. When the diameter of either rod has eroded to about 2⁄3 of its original diameter
(original=0.90”), it must be replaced.
Electrolysis can be reduced by installing dielectric connections on the cold water inlet and hot
water outlet.
The vent system should be checked at least once a year for damage and/or blockage. Also
check for correct draft and damper operation.
If the water heater is to be shut off during cold weather, the tank and water lines should be
drained to prevent freezing.
The water heater warranty will be invalid if the tank fails due to excessive pressure, the accumulation of lime or sediment, corrosion, or freezing. The warranty explicitly documents
further causes of invalidation.
If necessary, the water heater flue may be cleaned with a brush or a flexible wire. Before proceeding:
• Turn the gas valve to OFF.
• Wait at least 5 minutes for the combustion chamber and flue to cool.
• Use a brush or flexible wire to clean the flue. This can be done through the top of the flue.
It is not necessary to remove the burner or baffle.
• Slide the flexible wire or brush down the flue at the base of each row of fins. This should
knock any rust flakes into the combustion chamber for removal.
∂
! WARNING
If the flue is blocked with soot this indicates serious combustion problems related to the
building and/or installation. These must be addressed before placing the water heater back
in operation.
• Vacuum or sweep out any sediment collected in the combustion chamber before restarting
the heater. This can be done through the chamber inspection port.
Page 10
Atmospheric Gas
CHAMBER INSPECTION PORT
The chamber inspection port is located near the bottom of your Bock water heater. If access to
the combustion chamber for flame inspection or maintenance is necessary, following these
steps:
• Wear protective handwear. Areas around the combustion chamber may be hot after operation of the appliance.
• Remove the sheet metal screws at the right and left sides of the
sheet metal door.
• Swing the door clockwise or counterclockwise on the rivet to
expose the inspection port plug. Use needle-nose pliers to pinch
and pull the plug from position. Two pinch points are located on
the front-center of the plug.
Figure 7: Main Burner Flame
• Following inspection of the flame or maintenance, replace the
plug and sheet metal screws to their initial locations.
Inspecting the burner and pilot flames. These flames should
be visually inspected at least once a year to determine if the flames
have altered in appearance in any way. Such a change can indicate
the need for service.
The main burner flame should be steady and appear blue on the
burner face with well defined yellow and orange tips. Flame shape
should be similar to that shown in Figure 7. Pilot flame shape
should be similar to that shown in Figure 8.
Products of combustion should also be checked with instruments.
High levels of CO could indicate a problem with the heater such as
a blocked flue or other installation related problems.
Figure 8: Pilot Ignitor
TROUBLESHOOTING
Burner and pilot will not light:
1. Follow instructions under “Place the Gas System in Operation and Light the Burner”.
2. Check temperature control reset status. LED’s indicate control status. Reset the control by
pressing the reset button. See temperature control drawing and “Temperature Control
Module” section.
3. Check 3 amp fuse on temperature control module.
4. Verify that the temperature control is calling for heat. If the tank is cold but control is not
calling for heat, check resistance of the temperature sensors. Resistance of temperature
sensors should be in the kilo ohm range. ECO resistance should be 0.
5. Check voltage to burner control. 24VAC should be supplied to the burner module. For a detailed burner control troubleshooting guide, see Table 2.
6. Verify that power is supplied to the damper and that it is free to rotate. See the instruction
sheets included with the damper for more detailed troubleshooting.
7. Check for spark at the pilot. If no spark check wire condition. Replace if needed. If wires
are good replace burner control.
8. Check wiring connections to the gas valve. Verify that 24VAC is supplied to the gas valve. If
burner lights and immediately shuts off check the gas valve ground and ground wire. If gas
valve is not opening, replace valve and double check gas supply pressure.
Atmospheric Gas
Page 11
Table 2: Honeywell S8600M Module Troubleshooting
BURNER CONVERSION KIT
The Bock ezFIT series is designed for use with natural gas or LP gas. Do not operate this water
heater with a gas other than the type listed on the rating label. A burner conversion kit shall
be purchased and installed in the event that a fuel change from natural to LP gas is desired.
The conversion kit will include a complete burner, rating label that indicates the new fuel
type, and detailed instructions. Please contact your sales representative or Bock Water Heaters
with any questions.
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Atmospheric Gas
PARTS LIST
Figure 9: ezFIT Parts
Table 3: ezFIT Parts
Atmospheric Gas
Page 13
PARTS LIST
Figure 10: ezFIT Control Enclosure Parts
Figure 11: ezFIT Burner Parts
Table 4: ezFIT Control Enclosure and Burner Parts
Page 14
Atmospheric Gas
FIVE YEAR LIMITED WARRANTY
Warranty Coverage
The glass-lined tank in any Bock gas-fired water heater is warranted not to leak due to defects
in workmanship or materials for five years from original date of installation. It is also warranted that no other part of a Bock gas-fired water heater will fail due to defects in workmanship or materials for a period of one (1) year from date of original installation.
Company Responsibility
Bock Water Heaters responsibility is to repair or replace, at our option with the prevailing
comparable model, any part of the equipment sold by the Company which proves to be defective in material or workmanship, including the tank, during the warranty period when installed in accordance with applicable codes and ordinances and operated and maintained in
accordance with our instructions, subject to the conditions and exceptions indicated below.
Our liability, in the event of leakage or other malfunction, is strictly limited to repair or replacement of the defective heater or part as provided herein. We are not responsible hereunder
for incidental property damage or personal injury, consequential costs or damage.
Owner Responsibility
At the company’s request, the owner is to return to Bock Water Heaters, Madison, WI, any
part, including the tank, defective in material or workmanship, and pay all transportation
charges for such return parts or replacement parts sent from the factory to the owner.
The owner will pay all labor charges for the removal and installation of such parts, including
the tank. Any replacement water heater furnished under this warranty shall remain in warranty only for the unexpired portion of the original warranty.
The owner is required to have at least annual anode rod inspections and replace them as necessary. Bock Water Heaters requires paid receipts as proof of anode rod replacements on all
glass-lined tank claims. Failure to inspect at least annually and replace anode rods as
necessary shall void the limited warranty. Bock Water Heaters, Inc. reserves the right to
inspect all claims for warranty and deny any claim due to lack of maintenance.
Note: Local water conditions influence anode rod consumption and their rate of replacement.
Also, the use of a water softener (or phosphate treated water) may increase anode rod consumption and requires more frequent inspection.
Exceptions
This limited warranty does not cover leaks or malfunctions caused by defective installations,
misuse, abuse, neglect, alteration, addition of non-approved components or apparatus, operation with inappropriate fuels (not covered under UL Standard), operation at inappropriate settings, accident, disconnection, the installation and/or use of an insulation blanket, excessive
temperature, excessive pressure, adverse local conditions (specifically lime, silt or sediment accumulation), corrosive atmosphere, exterior tank corrosion due to leaks at fittings not factory
installed, or the removal of anode rods. This limited warranty also does not cover: the production of noise, odor, discolored or rusty water, units installed outside of the United States (excluding Canada), or units on which the serial numbers are missing or have been altered. This
limited warranty also does not apply when the water heater is installed without a CSA/ANSI
certified/approved temperature and pressure relief valve; or is not installed in accordance with
applicable state or local codes, housing or building codes and ordinances or good industry
practices; or is installed, operated or maintained contrary to the written instructions provided
with this product.
Atmospheric Gas
Page 15
Our Total Warranty Commitment
NO OTHER EXPRESS WARRANTY HAS BEEN MADE OR WILL BE MADE ON BEHALF OF BOCK
WITH RESPECT TO THE UNIT. We will not assume, nor authorize any person to assume for us,
any other liability in connection with the sale or operation of any Bock product. ANY IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR APPLICATION, IMPOSED ON THE SALE OF ANY BOCK UNIT UNDER LAWS OF THE STATE OF
SALE ARE LIMITED TO ONE YEAR. BOCK SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR TORT.
Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so the above limitations or exclusions may not
apply to you. This limited warranty gives you specific legal rights; you may also have other
rights which vary from state to state.
Registration Card
The enclosed limited warranty registration card should be returned within 30 (thirty) days of
the date of installation, otherwise, the date of manufacture will be recorded as the date of installation for the purpose of this limited warranty.
Bock reserves the right to verify any claim of defect by inspection.
MODEL NO. _____________________________________________________
SERIAL NO. ______________________________________________________
INSTALLED BY __________________________________________________
INSTALLATION DATE ____________________________________________
Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703
Telephone 608 -257-2225 • Fax 608 -257-5304
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#23412
Rev1 4/08
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