Solar/Gas Hybrid Water Heater Installation and Operation Manual

Solar/Gas Hybrid Water Heater Installation and Operation Manual
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.
Installation and Operation Instructions Manual
®
Solar Indirect Water Heater with
Power Direct Vent Gas Backup
Models: 75-76SKG, 100-76SKG
Warranty, Registration Card and Parts List are included.
Homeowner: Please remember to return the Registration Card!
䊱
! 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.
䊱
! WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or
death.
䊱
! WARNING
Install in accordance with all local codes.
In the absence of local codes, refer to ANSI
223.1/NFPA 54 and/or CSA B149.1.
䊱
! 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 32 for measuring the outcoming water temperature.
䊱
! 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.
#23419
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.
䊱
! 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.
䊱
! 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 2/11
IMPORTANT SAFETY INSTRUCTIONS
䊱
!
WARNING
If the information in these instructions is not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
FOR YOUR SAFETY!
- Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your
building.
• Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
- Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
䊱
!
DANGER
Water heaters utilizing Liquefied Petroleum gas (LP) are different from
natural gas models. A natural gas heater will not function safely on LP gas
and vice versa. To avoid possible equipment damage, personal injury or
fire: DO NOT connect this water heater to a fuel type not in accordance
with the rating label. These units are only certified for a single fuel type.
䊱
!
DANGER
Failure to properly install the vent and combustion air intake system as
outlined in this manual can result in unsafe operation of the water heater.
To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide,
never operate this water heater unless it is properly vented and has
adequate air supply for combustion and dilution of flue gas. Be sure to
inspect the system for proper installation at initial start-up; and at least
annually thereafter. See the Maintenance section for more information.
SAVE THESE INSTRUCTIONS
Page 2
TABLE OF CONTENTS
Section I: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section II: General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section III: Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section IV: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section V: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section VI: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Section VII: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Section VIII: Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section IX: Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Page 3
SECTION I: SPECIFICATIONS
COLD
HOT
Anode
G
HOT
(Space heating supply)
T&P Relief
Valve
C
Gas backup
temp. sensor & ECO
FROM SOLAR
Solar sensor
immersion well
A
B
COLD
(Space heating
return)
Gas/Temp.
Control
D
H
TO SOLAR
E
I
F
I
H
G
INCHES (cm)
F
E
D
C
DIMENSIONS
o
Sto
o
rag
eG
Ra
AL
BT ted I
U/ np (L)
Re HR ut
c
GA over (kW
L/ y @ )
1s HR 77 F
77 t Hr. (L/HR rise
F r De )
ise liv
GA ery
A
L( @
L)
B
Table 1: Dimensions
GAS-FIRED ONLY
In
(N let C
P
on
n.
OuT)
Di
(N tlet
a.
PT Co
nn
Au )
.D
(N x. C
ia.
PT on
)
n
.
Ga
Di
a.
(N s Co
PT nn
.D
Sh )
ia.
LB ippi
S ( ng
kg W
)
eig
ht
Figure 1: All Models
Model
73 76000 96
136 76.88 67.25 26.00 60.00 28.19 16.00 11.00 43.50 18.50 1.00
75-76SKGN (276) (22.3) (363) (515) (195) (171) (68) (152) (72) (41) (28) (110) (47)
1.00
1.00 0.50
469
(213)
98 76000 96
154 76.88 67.25 28.00 60.00 28.19 16.00 11.00 43.50 18.50 1.00 1.00
100-76SKGN (371) (22.3) (363) (583) (195) (171) (71) (152) (72) (41) (28) (110) (47)
1.00 0.50
572
(259)
SOLAR ONLY
Model
Coil Volume Coil Surface Area
GAL (L)
FT2 (m2)
Coil Friction Loss
@ 5 GPM
(feet w.c.)
Recovery***
@ 77°F rise
GAL/HR (L/HR)
1st Hr. Delivery***
@ 77°F rise
GAL (L)
75-76SKGN
2.76 (10.45)
14.14 (1.31)
0.6
32 (121)
98 (371)
100-76SKGN
2.76 (10.45)
14.14 (1.31)
0.6
32 (121)
121 (458)
***Input to coil: 140°F, 2 GPM
For LP models change suffix "N" to "LP"
Working Pressure: 150 PSI (1034 kPa)
Test Pressure: 300 PSI (2068 kPa)
For natural gas: Manifold pressure = 4" W.C. (1.00 kPa); Inlet pressure range 5-14" W.C. (1.25 - 3.49 kPa)
For propane gas: Manifold pressure = 10" W.C. (1.00 kPa); Inlet pressure range 11-14" W.C. (2.74 - 3.49 kPa)
T&P valve installed
All Bock products meet or exceed current ASHRAE standards.
These products are design certified by UL (Underwriters Laboratories) and meet ANSI Z21.10.3 / CSA 4.3 requirements for operation up to 180°F (82°C).
Approved for use as a direct vent automatic storage water heater.
WARNING: Installation shall be in accordance with all national and/or local codes. In the absense of local codes, refer to NFPA 54 and/or CSA B149.1.
CAUTION: The recommended maximum hot water temperature setting for normal residential use is 120°F (49°C). Bock recommends a
tempering valve or anti-scald valve be installed and used according to the manufacturer's directions to prevent scalding.
Page 4
SECTION II: GENERAL INFORMATION
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 TREATMENT/FILTRATION
In areas where poor water conditions are suspected (i.e. lime, iron, and other minerals), it is
essential that the water be tested and appropriate action taken to prevent damage to the
water heater and ensure the quality of the water.
SOLAR WATER HEATER FUNCTION
The solar water heater is designed with an internal coil and gas burner for backup heating.
A heating medium is passed through the solar panels and internal coil as long as there is an
adequate temperature difference between the heating medium and stored water in the tank.
The internal coil is located as close to the bottom as possible to facilitate the transfer of heat
even at lower solar panel temperatures.
During periods of water flow through the water heater, hot water is drawn from the top of the
heater and cold water is delivered to the bottom of the tank (by a diptube). If the hot water
demand should exceed the solar heat output or there is an insufficient temperature difference
between the heating medium and stored water, the gas-fired backup thermostat will activate
the burner for backup heat.
Solar heat output from the internal coil will vary depending on outside conditions and the
temperature of the stored water. The temperature sensor for the gas backup is higher in the
tank to delay burner operation. To further limit the operation of backup heating, connect the
water heater to a programmable timer. Limiting the gas backup operation to off-peak solar
time can increase solar gain in the stored water.
TEMPERATURE CONTROL
The water heater is equipped with a combination gas valve, ignition control, and thermostat
to operate the gas backup system. For domestic hot water, the proper temperature setting is
120°F (i.e. “WARM” setting on control). For commercial applications, the maximum approved
temperature setting is 180°F (i.e. “F” setting on control).
A built-in, automatic reset Energy Cut-Off (ECO) is standard on all models. In the event that
the water temperature becomes excessive (195°F), the ECO will shut off all gas to the water
heater. If the ECO switch opens, it will automatically reset (or close) when the water
temperature drops to 120°F or below. The water heater thermostat will automatically reset
following a three minute standby period once the ECO switch closes.
The thermostat is factory set at 120°F. See Figure 21 for temperature and display settings.
If hotter water is required a tempering device or anti-scald device must be installed at the
domestic hot water outlet of the heater or at the point of use. Table 3 details the approximate
relationship of water temperature and time with regard to scald injury. It is important for the
user to understand the necessity of tempering or anti-scald devices when using hotter water in
domestic water heating systems.
䊱
! CAUTION: Hot water in excess of 120°F can cause scalding!
Bock recommends a tempering valve or anti-scald valve be installed and used according to
the manufacturer’s directions to prevent scalding. Many state and local codes now require
installation of these devices. Point of use temperature may be hotter than the setting on the
water heater thermostat. The tempering valve or anti-scald valve will ensure potable
water temperatures at the desired set point with a higher degree of accuracy.
Page 5
SECTION II: GENERAL INFORMATION (cont.)
TEMPERATURE CONTROL (cont.)
Table 2: Scald Temperature/Time Relationships
APPROXIMATE
TEMPERATURE/TIME
RELATIONSHIPS TO
SCALDING
120°F (49°C)
More than 5 minutes
125°F (52°C)
1 1⁄2 to 2 minutes
130°F (54°C)
About 30 seconds
135°F (57°C)
About 10 seconds
140°F (60°C)
Less than 5 seconds
145°F (63°C)
Less than 3 seconds
150°F (66°C)
About 1 1⁄2 seconds
155°F (68°C)
About 1 second
ANODE RODS
The anode rod is used as a sacrificial element within the volume of the storage tank. The purpose of
the magnesium anode rod is to protect the inside of the tank against corrosion. Anode rods should
be inspected twice in the first year and at least yearly once a time interval for inspection has been
developed. Water conditions can influence the consumption rate of the anode rods. Please see the
Maintenance section of this manual for instructions on how to change the anode rods.
䊱
! CAUTION
Hydrogen gas is produced in a hot water system served by the heater that has not been
used for a long period of time (2 weeks or more). Hydrogen gas is extremely flammable.
To reduce the risk of injury under these conditions, it is recommended that the hot water
faucet be opened for several minutes at the kitchen sink before using any electrical
appliance connected to the hot water system. When 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.
TEMPERATURE AND PRESSURE RELIEF VALVE (T&P)
䊱
! CAUTION
To reduce the risk of excessive pressures and temperatures in this water heater, install
temperature and pressure protective equipment required by local codes and no less
than a combination temperature and pressure relief valve certified by a nationally
recognized testing laboratory that maintains periodic inspection of production of listed
equipment or materials, as meeting the requirements for Relief Valves and Automatic
Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be
marked with a maximum set pressure not to exceed the marked maximum working
pressure of the water heater. Install the valve in an opening provided and marked for
this purpose in the water heater, and orient it or provide tubing so that any discharge
from the valve exits only within 6 inches above, or at any distance below, the structural
floor, and does not contact any live electrical part. The discharge opening must not be
blocked or reduced in size under any circumstances.
Page 6
SECTION II: GENERAL INFORMATION (cont.)
TEMPERATURE AND PRESSURE RELIEF VALVE (T&P) (cont.)
䊱
! 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.
The T&P valve is factory installed. A discharge drain tube must be installed (responsibility
of the installer) and shall terminate plain, not threaded, 6 inches above the floor drain.
The drain tube material must be approved for temperatures of 120 F or greater and a
pressure of 150 PSI or greater.
o
BACKFLOW PREVENTER (CLOSED SYSTEM)
Some local municipal codes and ordinances require the use of these devices on potable
(domestic) water lines. Where backflow preventers, check valves, or pressure regulating valves
are required, it will be necessary to install a thermal expansion tank (designed for use with
potable water) in order to prevent pressure build up in the water heater and associated piping,
which could cause the T&P valve to discharge. Follow the expansion tank manufacturer’s
recommendations when selecting a tank for your hot water system. The expansion tank
pressure shall equal the water heater system pressure prior to initial warm up.
Note: Working pressure of the water heater is 150 PSI. Do not exceed 150 PSI.
CONDENSATION
In some installations condensation will occur in the venting (exhaust) system. It is important
to not allow condensate to collect around mechanical components and bare metal parts on
the water heater. Therefore, if condensation occurs in the venting system it must be routed to
a proper area for drainage. Horizontal sections of the vent system shall slope downward away
from the water heater a minimum of 1/8" per foot. When downward sloping of the vent
system is not possible or a vertical vent arrangement is used, the condensate drain kit must be
installed. See Section IV: Installation / Vent and Combustion Air Intake / Condensate Drain
Kit for installation details.
HIGH ALTITUDE
Contact Bock Water Heaters for installations at altitudes greater than 2,000 feet above sea level.
SECTION III: PRE-INSTALLATION
LOCATION
䊱
! CAUTION
This water heater must be located in an area where leakage of the tank, water line
connections, or the temperature and pressure relief valve will not result in damage to
the area adjacent to the water heater or to lower floors of the structure. When such
location cannot be avoided, a suitable drain pan must be installed under the water
heater. The drain pan depth must be suitable for draining and collecting water. The
drain pan can be purchased from your plumbing professional. The drain pan must be
piped to an adequate drain and all drain piping must be at least 0.75” in diameter
and pitched for proper drainage.
Page 7
SECTION III: PRE-INSTALLATION (cont.)
䊱
! CAUTION
DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors
and/or liquids in the vicinity of the water heater or any other appliance.
IF YOU SMELL GAS:
• DO NOT try to light any appliance.
• DO NOT touch any electric switch; do not use any telephone in your building.
• Immediately call your gas supplier from a telephone in another building. Follow your
gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!
䊱
! CAUTION
Do not drop water heater or lay heater down on its side. Move the water heater into
position by sliding or using an appropriately sized hand truck.
䊱
! CAUTION
If the water heater is installed directly on carpeting, the water heater shall be installed
on a metal or wood panel extending beyond the full width and depth of the water
heater by at least 3 inches (76.2 mm) in any direction or, if the water heater is installed
in an alcove or closet, the entire floor shall be covered by the panel. The panel must be
strong enough to carry the weight of the heater when full of water.
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.
The water heater can be installed on combustible or non-combustible flooring. Maintain
clearances specified in this manual and in accordance with the National Fuel Gas Code (NFPA
54, ANSI Z223.1) unless otherwise directed by state and local code requirements. Locate the
water heater such that plastic vent pipe lengths and the number of connection fittings are
minimized.
Minimum clearances from combustible construction are:
Table 3: Clearances
SIDES
BACK1
FRONT2
TOP3
0 in. (0 cm)
6 in. (15 cm)
24 in. (61 cm)
26 in. (66 cm)
1) Measured from water heater jacket to wall. This clearance accommodates the air intake
boot.
2) Measured from jacket to closet door.
3) Measured from water heater top to ceiling.
This water heater is approved for installation in a closet or alcove with the clearances above.
Page 8
SECTION III: PRE-INSTALLATION (cont.)
COMBUSTION AND VENTILATION AIR
The water heater can be installed to utilize combustion air from either inside or outside the
building. Refer to "Section IV: Installation" for detailed venting specifications. If indoor air is
used for combustion air it is imperative that the room has an adequate air supply. Inadequate
air supplies may lead to unsafe levels of carbon monoxide (CO), condensation of flue gases,
and excessive levels of soot. See NFPA 54 or the discussions of "Unconfined Space" and
"Confined Space" below. In addition, poor ventilation will also result in hot spots around the
heater. Temperatures over 90°F 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.
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.
Page 9
SECTION IV: INSTALLATION
VENT & COMBUSTION AIR INTAKE
䊱
! DANGER
Failure to properly install the vent and combustion air intake system as outlined in this
manual can result in unsafe operation of the water heater. To avoid the risk of fire,
explosion, or asphyxiation from carbon monoxide, never operate this water heater
unless it is properly vented and has adequate air supply for combustion and dilution of
flue gas. Be sure to inspect the system for proper installation at initial start-up; and at
least annually thereafter. See the Maintenance section for more information.
The water heater venting and combustion air intake can be installed as a power direct
vent system (combustion air from outside the building) or power vent system
(combustion air from inside the building). Vertical or horizontal (side-wall) configurations may be used with a two-pipe or concentric vent termination.
Note: If air from inside the building will be used for combustion air, the requirements in Section III, "Unconfined Space" must be met.
The water heater is supplied with a rubber coupling (with clamps) that connects to the
blower assembly outlet. The air intake piping is preassembled to route dilution air to the
blower assembly and combustion air to the burner chamber. All vent length measurements specified in this manual are in addition to the preassembled piping supplied with
the water heater. Equivalent pipe run lengths shall not be greater than the maximum
lengths (or less than minimums) given in Tables 4 and 5.
Note: DO NOT connect the water heater to an existing vent or chimney. It must
be vented separately from all other appliances.
The following materials are approved for use as the vent and combustion air intake
piping:
• PVC (DWV, ASTM-D2665 or CSA B181.2)
• PVC (Schedule 40, ASTM-D1785 or CSA B137.3)
• PVC (SDR Series, ASTM-D2241 or CSA B137.3)
• CPVC (Schedule 40, ASTM-F441 or CSA B137.3)
• CPVC (SDR Series, ASTM-F442)
• ABS (Schedule 40, DWV, ASTM-D2661 or CSA B181.1)
In Canada, check local codes to ensure that SDR series is approved for use. SDR is
not approved for all installations in Canada.
The following materials are approved for use for the fittings in the vent and combustion
air intake systems:
• PVC (Schedule 40 DWV, ASTM D2665)
• CPVC (Schedule 40, ASTM F438)
• ABS (Schedule 40 DWV, ASTM D2661)
Please contact Bock Water Heaters for questions regarding materials that are not listed
above.
Page 10
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
NOTICE
Installations in Canada must conform to the requirements of CSA B149 code. Plastic
vent systems must be assembled with pipe, fittings, cements, and primers listed to ULC
S636. Components of this listed system shall not be interchanged with other vent
systems or unlisted pipe/fittings. In Canada, the primer and cement must be of the
same manufacturer as the vent system; do not mix primers and cements from one
manufacturer with a vent system from a different manufacturer. The supplied plastic
pipe/fittings are certified as part of the water heater.
Minimum and Maximum System Lengths
The water heater should be located such that plastic vent pipe lengths and the number of
connection fittings are minimized. Minimum and maximum equivalent pipe lengths for
the vent and combustion air intake systems are given in Tables 4 and 5. Either 3 in. or 4
in. plastic piping may be used. The water heater is provided with fittings that readily
adapt to 3 in. plastic pipe. DO NOT use less than 3 in. diameter plastic pipe and DO NOT
use unequal sizes except as shown to increase from 3 in. to 4 in. diameter at the point of
connection to the water heater.
NOTE: The equivalent straight pipe length of a 90°, 1/4 inch standard bend elbow
and a 45°, 1/8 inch standard bend elbow is 5 feet and 2.5 feet, respectively. The
concentric vent termination is equivalent to 10 feet of straight pipe. DO NOT use
short bend elbows.
NOTE: Elbows used as termination fittings must be included when determining
the total number of elbows.
Table 4: Minimum and Maximum Vent and Air Intake Pipe Lengths (Two-Pipe Terminations)
Minimum Equivalent Pipe Maximum Equivalent Pipe
Length (per pipe run)
Length (per pipe run)
Model(s)
Pipe Ø (in)
Air Intake
Ft (m)
Vent
Ft (m)
Air Intake
Ft (m)
Vent
Ft (m)
3
5 (1.52)
12 (3.66)
55 (16.76)
55 (16.76)
4
5 (1.52)
12 (3.66)
85 (25.91)
85 (25.91)
75-76SKG,
100-76SKG
Table 5: Minimum and Maximum Vent and Air Intake Pipe Lengths (Concentric Termination)
Minimum Equivalent Pipe Maximum Equivalent Pipe
Length (per pipe run)
Length (per pipe run)
Model(s)
Pipe Ø (in)
Air Intake
Ft (m)
Vent
Ft (m)
Air Intake
Ft (m)
Vent
Ft (m)
3
5 (1.52)
12 (3.66)
45 (13.72)
45 (13.72)
4
5 (1.52)
12 (3.66)
75 (22.86)
75 (22.86)
75-76SKG,
100-76SKG
Page 11
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
For quick reference, Tables 6 and 7 give the maximum allowable length of straight pipe
based on the total number of elbows per pipe run.
Table 6: Maximum Pipe Lengths Quick Reference (Two-Pipe Terminations)
Model(s)
75-76SKG,
100-76SKG
Maximum Equivalent Pipe
Length (per pipe run)
Air Intake
Vent
Ft (m)
Ft (m)
55 (16.76)
55 (16.76)
Pipe Ø (in)
# of 90° Elbows per
pipe run
(including termination fittings)
3
0
3
1
50 (15.24)
50 (15.24)
3
2
45 (13.72)
45 (13.72)
3
3
40 (12.19)
40 (12.19)
3
4
35 (10.67)
35 (10.67)
3
5
30 (9.14)
30 (9.14)
3
6
25 (7.62)
25 (7.62)
4
0
85 (25.91)
85 (25.91)
4
1
80 (24.38)
80 (24.38)
4
2
75 (22.86)
75 (22.86)
4
3
70 (21.34)
70 (21.34)
4
4
65 (19.81)
65 (19.81)
4
5
60 (18.29)
60 (18.29)
4
6
55 (16.76)
55 (16.76)
Pipe Ø (in)
# of 90° Elbows per
pipe run
(including termination fittings)
3
0
3
1
40 (12.19)
40 (12.19)
3
2
35 (10.67)
35 (10.67)
3
3
30 (9.14)
30 (9.14)
3
4
25 (7.62)
25 (7.62)
3
5
20 (6.10)
20 (6.10)
3
6
15 (4.57)
15 (4.57)
4
0
75 (22.86)
75 (22.86)
4
1
70 (21.34)
70 (21.34)
4
2
65 (19.81)
65 (19.81)
4
3
60 (18.29)
60 (18.29)
4
4
55 (16.76)
55 (16.76)
4
5
50 (15.24)
50 (15.24)
4
6
45 (13.72)
45 (13.72)
Table 7: Maximum Pipe Lengths Quick Reference (Concentric Termination)
Model(s)
75-76SKG,
100-76SKG
Page 12
Maximum Equivalent Pipe
Length (per pipe run)
Air Intake
Vent
Ft (m)
Ft (m)
45 (13.72)
45 (13.72)
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
The vent and combustion air intake systems must be sufficiently supported along
vertical and horizontal sections. At minimum, it is recommended that a support is placed
along the vent or air intake piping every 4 feet. For horizontal systems, the first support shall
be located immediately adjacent to the first 90-deg. elbow following the vertical section
connected to the water heater. The support method should act to isolate the vent and
combustion air intake piping from floor joists or other structural members to reduce transmission of noise and vibration.
NOTE: Do not support, pin, or secure the vent and combustion air intake pipe in a
way that restricts the normal thermal expansion and contraction of the venting
material.
For replacement installations, thoroughly inspect the existing vent and combustion air intake
systems prior to installing the new water heater. The following steps shall be taken to properly
inspect the existing vent system:
• Verify that the materials as specified in this manual have been used.
• Verify the maximum and minimum vent and combustion air intake equivalent lengths and
terminal clearances meet the specifications in this manual.
• Inspect the vent and combustion air intake systems for cracking. Pay close attention to joints
between elbows and straight pipe.
• Inspect the system for misalignment of components. This may lead to sagging and unwanted
stresses in the joints.
If any corrections are required they must be computed before installing the replacement water
heater.
Horizontal Venting, Direct Vent 2-pipe termination
This water heater may be vented horizontally (through a sidewall) with a two-pipe
termination. Two holes through an exterior wall are required for the vent and
combustion air intake pipes. Minimum clearances between the terminals must be met as
specified in Figure 3. All clearances must comply with local codes or the latest edition of
NFPA 54/ANSI Z223.1 or CSA B149. See Figure 2 and Table 8 for terminal clearances.
Figure 2: Terminal Clearances
Page 13
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Table 8: Direct Vent Terminal Clearances
Canadian Installations1
US Installations2
12 inches (30 cm)
12 inches (30 cm)
12 inches (30 cm)
12 inches (30 cm)
*
*
*
*
E = Clearance to unventilated soffit
*
*
F = Clearance to outside corner
*
*
G = Clearance to inside corner
*
*
A = Clearance above grade, veranda,
porch, deck, or balcony
B = Clearance to window or door that
may be opened
C = Clearance to permanently closed
window
D = Vertical clearance to ventilated
soffit located above the terminal within
a horizontal distance of 2 feet (61 cm)
from the centerline of the terminal
H = Clearance to each side of centerline 3 feet (91 cm) within a height 15 feet
extended above meter/regulator
above the meter/regulator assembly
assembly
I = Clearance to service regulator vent
3 feet (91 cm)
outlet
J = Clearance to non-mechanical air
supply inlet to building or the
12 inches (30 cm)
combustion air inlet to any other
appliance
K = Clearance to a mechanical air
6 feet (1.83 m)
supply inlet
L = Clearance above paved sidewalk or
paved driveway located on public
7 feet (2.13 m)†
property
M = Clearance under veranda, porch,
12 inches (30 cm)†
deck, or balcony
*
*
12 inches (30 cm)
3 feet (91 cm) above if within
10 feet (3 m) horizontally
†
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.
In addition to the clearances specified, the following items shall be accounted for during
installation:
• Do not terminate near soffit vents or crawl space or other area where condensate or
vapor could create a nuisance hazard or cause property damage.
• Do not locate the exhaust vent terminal where condensate or vapor could cause damage
or could be detrimental to the operation of regulators, relief valves, or other equipment.
• Do not locate the exhaust vent terminal over public area or walkways where condensate
or vapor can cause nuisance or hazard.
• Do not locate the vent terminal in proximity to plants/shrubs.
• The vent and air intake shall terminate a minimum of 12" (25.4 cm) above expected
snowfall level to prevent blockage.
䊱
! CAUTION
Never install air intake terminal above vent (exhaust) terminal.
Page 14
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Install piping through the wall as shown in Figure 3. Adequate length of pipe must protrude
beyond the exterior wall for attachment of the termination fitting. The recommended
distance between the terminal fitting and the exterior wall is 1 in. (2.5 cm). Directions for
cementing joints (such as the terminal fittings to the straight pipe) can be found on page 24.
Two 45° elbows are provided with the water heater for termination fittings. If other fittings are
required (i.e. 90° elbows) they must be purchased separately. Install a screen inside the air
intake termination fitting to prevent items from entering the system. Complete the installation of the remainder of the vent and air intake system and attach to the water heater as
shown in Figure 4. It is recommended that horizontal sections of piping slope downward away
from the water heater a minimum of 1/8 inch per foot (10mm per meter) to prevent
condensate from flowing back towards the water heater.
䊱
! CAUTION
Annular spaces around vent pipe wall penetrations shall be permanently sealed using
approved materials to prevent entry of combustion products into the building.
12" (30 cm)
MIN.
(center-to-center)
Outside of
Building
Inside of
Building
Vent
(Exhaust)
Terminal
Vent Terminal
Vent Pipe
Combustion
Air
Intake
Terminal
(w/
protective
screen)
From
Water
Heater
Wall
12" (30 cm)
or greater
Ground Level
Outside View
CAUTION -NEVER INSTALL AIR INTAKE ABOVE VENT
(EXHAUST) TERMINAL
Wall Section View
Figure 3: Horizontal Venting, 2-pipe termination
Vent (To Outside)
4" MIN
Vertical Length
Before Elbow
Air Intake
(From Outside)
Vent (To Outside)
4" MIN
Vertical Length
Before Elbow
Air Intake
(From Outside)
3" Pipe
4" Pipe
3" Pipe
3" Pipe
4" x 3"
Reducing Coupling
Exhaust
Adapter
3" Pipe
Exhaust
Adapter
3" pipe systems
4" pipe systems
Figure 4: Horizontal Direct Vent Connections to Water Heater
Page 15
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Horizontal Venting, Power Vent 1-pipe termination
This water heater may be vented horizontally (through a sidewall) with a one-pipe
termination. In this case, the water heater will be utilizing air from inside the building for
combustion air. A single hole through the exterior of the building is required for the vent
pipe.
Note: If air from inside the building will be used for combustion air, the requirements in Section III, “Unconfined Space” must be met.
All clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1
or CSA B149. See Figure 5 and Table 9 for vent terminal clearances.
Figure 5: Terminal Clearances
Page 16
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Table 9: Power Vent Terminal Clearances
Canadian Installations1
US Installations2
A = Clearance above grade, veranda,
porch, deck, or balcony
12 inches (30 cm)
12 inches (30 cm)
B = Clearance to window or door that
may be opened
12 inches (30 cm)
4 feet (1.2 m) below or to side
of opening; 1 foot (300 mm)
above opening
C = Clearance to permanently closed
window
*
*
D = Vertical clearance to ventilated
soffit located above the terminal within
a horizontal distance of 2 feet (61 cm)
from the centerline of the terminal
*
*
E = Clearance to unventilated soffit
*
*
F = Clearance to outside corner
*
*
G = Clearance to inside corner
*
*
H = Clearance to each side of centerline 3 feet (91 cm) within a height 15 feet
extended above meter/regulator
above the meter/regulator assembly
assembly
*
I = Clearance to service regulator vent
outlet
3 feet (91 cm)
*
12 inches (30 cm)
4 feet (1.2 m) below or to side
of opening; 1 foot (300 mm)
above opening
6 feet (1.83 m)
3 feet (91 cm) above if within
10 feet (3 m) horizontally
7 feet (2.13 m)†
7 feet (2.13 m)
M = Clearance under veranda, porch,
deck, or balcony
1 In
2
12 inches (30 cm)†
†
J = Clearance to non-mechanical air
supply inlet to building or the
combustion air inlet to any other
appliance
K = Clearance to a mechanical air
supply inlet
L = Clearance above paved sidewalk or
paved driveway located on public
property
*
accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.
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.
In addition to the clearances specified, the following items shall be accounted for during
installation:
• Do not terminate near soffit vents or crawl space or other area where condensate or
vapor could create a nuisance hazard or cause property damage.
• Do not locate the exhaust vent terminal where condensate or vapor could cause damage
or could be detrimental to the operation of regulators, relief valves, or other equipment.
• Do not locate the exhaust vent terminal over public area or walkways where condensate
or vapor can cause nuisance or hazard.
• Do not locate the vent terminal in proximity to plants/shrubs.
• The vent and air intake shall terminate a minimum of 12" (25.4 cm) above expected
snowfall level to prevent blockage.
䊱
! CAUTION
Never install air intake terminal above vent (exhaust) terminal.
Page 17
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Install piping through the wall as shown in Figure 6. Adequate length of pipe must protrude
beyond the exterior wall for attachment of the termination fitting. The recommended
distance between the terminal fitting and the exterior wall is 1 in. (2.5 cm). Directions for
cementing joints (such as the terminal fittings to the straight pipe) can be found on page 24.
Two 45° elbows are provided with the water heater for termination fittings. If other fittings are
required (i.e. 90° elbows) they must be purchased separately. Install a screen inside the air
intake termination fitting to prevent items from entering the system. Complete the installation of the remainder of the vent and air intake system and attach to the water heater as
shown in Figure 7. It is recommended that horizontal sections of piping slope downward away
from the water heater a minimum of 1/8 inch per foot (10 mm per meter) to prevent
condensate from flowing back towards the water heater.
䊱
! CAUTION
Annular spaces around vent pipe wall penetrations shall be permanently sealed using
approved materials to prevent entry of combustion products into the building.
Outside of
Building
Inside of
Building
Vent Pipe
Vent Terminal
From
Water
Heater
Wall
12" (30 cm)
or greater
Ground Level
Figure 6: Horizontal Venting, 1-pipe termination
Wall Section View
Vent (To Outside)
4" MIN
Vertical Length
Before Elbow
4" MIN
Vertical Length
Before Elbow
Vent (To Outside)
Air Intake
(From Inside)
3" Pipe
Fitting w/ protective
screen
3" Pipe
Exhaust
Adapter
4" Pipe
4" x 3"
Reducing Coupling
Air Intake
(From Inside)
3" Pipe
Fitting w/ protective
screen
Exhaust
Adapter
3" pipe systems
3" Pipe
4" pipe systems
Figure 7: Horizontal Power Vent Connections to Water Heater
Page 18
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Horizontal Venting, Direct Vent Concentric termination
This water heater may be vented horizontally (through a sidewall) with a concentric vent
termination kit. One hole through an exterior wall is required for the concentric vent.
Both combustion air intake and vent pipes must be attached to the concentric vent
termination.
All clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1
or CSA B149. See Figure 2 and Table 8 for terminal clearances. See Figure 8 for additional
information.
Figure 8: Concentric Vent Wall Clearances
Cut a 5 in. diameter hole through an exterior wall. Make sure the wye concentric fitting is
cemented to the large diameter pipe and that the rain cap is cemented to the small
diameter pipe. Install the wye concentric fitting and large pipe assembly through the 5 in.
diameter hole in the wall. See Figure 9 for wall attachment details.
䊱
! CAUTION
Annular spaces around vent pipe wall penetrations shall be permanently sealed using
approved materials to prevent entry of combustion products into the building.
Figure 9: Concentric Vent Wall Installation
Note: Do not allow insulation or other materials to accumulate inside pipe assembly
when installing through the wall.
Page 19
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Install the rain cap and small pipe assembly into the wye concentric fitting and large pipe
assembly. Ensure small diameter pipe is bottomed and cemented in wye concentric fitting.
Complete indoor piping runs and connect piping to the water heater. See Figure 4, 3" pipe
systems, for connection details. It is recommended that horizontal sections of piping slope
downward away from the water heater a minimum of 1/8 inch per foot (10 mm per meter) to
prevent condensate from flowing back towards the water heater. Piping must be sufficiently
supported. At minimum, it is recommended that a support is placed along the vent or air
intake piping every 4 feet. For additional information, see installation instructions supplied
with concentric vent kit.
Vertical Venting, Direct Vent 2-pipe termination
This water heater may be vented vertically (through a roof) with a two-pipe termination. Two
holes through the roof are required for the vent and combustion air intake pipes. All
clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1 or CSA
B149. As a basic guide, the following minimum clearances shall be used:
• Minimum 12 inches (30 cm) above roof.
• Minimum 12 inches (30 cm) above anticipated snow level.
• Maximum 24 inches (61 cm) above roof level without additional support for vent.
• 4 feet (1.2 m) from any gable, dormer or other roof structure with building interior access
(e.g. vent or window).
• 10 feet (3 m) from any forced air inlet to the building. Any fresh or make-up air inlet such as
a dryer or furnace area is considered to be a forced air inlet.
• Minimum 12 inches (30 cm) between the vent and combustion air intake terminal
centerlines.
12" (30 cm) MIN
(center-to-center)
Vent
Terminal
Combustion
Air Intake
Terminal
(w/ protective
screen)
Dim Y Requirements
Dim Y
1) Minimum 12 in. (30 cm) above roof.
Support
Bracket
Support
Bracket
From
Water
Heater
2) Minimum 12 in. (30 cm) above
anticipated snow level.
3) Maximum 24 in. (61 cm) above roof
without additional support.
CAUTION - NEVER INSTALL AIR INTAKE ABOVE VENT
(EXHAUST) TERMINAL
To
Water
Heater
Figure 10: Vertical Venting, 2-pipe termination
䊱
! CAUTION
Never install air intake terminal above vent (exhaust) terminal.
Page 20
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Install piping through the roof as shown in Figure 10. Adequate length of pipe must protrude
beyond the exterior of the roof (see dimension Y). Directions for cementing joints (such as the
terminal fittings to the straight pipe) can be found on page 24. Two 90° elbows are
recommended for the intake and exhaust terminations to reduce the risk of rain, snow, or
foreign objects entering the system. Install a screen inside the air intake termination fitting as
well. Complete the installation of the remainder of the vent and air intake system and attach to
the water heater. Piping must be sufficiently supported. At minimum, it is recommended that a
support is placed along the vent or air intake piping every 4 feet. For vertical venting, the
condensate drain kit must be installed to the exhaust adapter.
䊱
! CAUTION
Annular spaces around vent pipe wall penetrations shall be permanently sealed using
approved materials to prevent entry of combustion products into the building.
Vent (To Outside)
Vent (To Outside)
Air Intake
(From Outside)
Air Intake
(From Outside)
3" Pipe
Condensate
Kit
Connection
4" Pipe
3" Pipe
3" Pipe
Exhaust
Adapter
Condensate
Kit
Connection
4" x 3"
Reducing Coupling
3" Pipe
Exhaust
Adapter
3" pipe systems
4" pipe systems
Figure 11: Vertical Direct Vent Connections to Water Heater
Vertical Venting, Power Vent 1-pipe termination
This water heater may be vented vertically (through a roof) with a one-pipe termination.
In this case, the water heater will be utilizing air from inside the building for combustion
air. A single hole through the roof of the building is required for the vent pipe.
Note: If air from inside the building will be used for combustion air, the requirements in Section III, “Unconfined Space” must be met.
All clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1
or CSA B149. As a basic guide, the following minimum clearances shall be used:
• Minimum 12 inches (30 cm) above roof.
• Minimum 12 inches (30 cm) above anticipated snow level.
• Maximum 24 inches (61 cm) above roof level without additional support for vent.
• 4 feet (1.2 m) from any gable, dormer or other roof structure with building interior
access (e.g. vent or window).
• 10 feet (3 m) from any forced air inlet to the building. Any fresh or make-up air inlet
such as a dryer or furnace area is considered to be a forced air inlet.
Page 21
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Vent
Terminal
Dim Y
Dim Y Requirements
1) Minimum 12 in. (30 cm) above roof
(US). Minimum 18 in. (46 cm) above
roof (Canada).
Support
Bracket
From
Water
Heater
2) Minimum 12 in. (30 cm) above
anticipated snow level (US). Minimum
18 in. (46 cm) above anticipated snow
level (Canada).
3) Maximum 24 in. (61 cm) above roof
without additional support.
Figure 12: Vertical Venting, 1-pipe termination
Install piping through the roof as shown in Figure 12. Adequate length of pipe must protrude
beyond the exterior of the roof (see dimension Y). Directions for cementing joints (such as the
terminal fittings to the straight pipe) can be found on page 24. Two 90° elbows are
recommended for the exhaust termination to reduce the risk of rain, snow, or foreign objects
entering the system. Install a screen inside the air intake termination fitting as well. Complete
the installation of the remainder of the vent system and attach to the water heater. Piping
must be sufficiently supported. At minimum, it is recommended that a support is placed along
the vent piping every 4 feet. For vertical venting, the condensate drain kit must be installed to
the exhaust adapter.
Vent (To Outside)
Vent (To Outside)
3" Pipe
Condensate
Kit
Connection
Air Intake
(From Inside)
Fitting w/ protective
screen
3" Pipe
Exhaust
Adapter
4" Pipe
4" x 3"
Reducing Coupling
3" Pipe
Condensate
Kit
Connection
Fitting w/ protective
mesh screen
Exhaust
Adapter
3" pipe systems
3" Pipe
4" pipe systems
Figure 13: Vertical Power Vent Connections to Water Heater
Page 22
Air Intake
(From Inside)
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Vertical Venting, Direct Vent Concentric termination
This water heater may be vented vertically (through a roof) with a concentric vent
termination kit. One hole through the roof is required for the concentric vent. Both
combustion air intake and vent pipes must be attached to the concentric vent
termination.
All clearances must comply with local codes or the latest edition of NFPA 54/ANSI Z223.1
or CSA B149. As a basic guide, the following minimum clearances shall be used (see Figure
14 for additional information):
• Minimum 12 inches (30 cm) above roof.
• Minimum 12 inches (30 cm) above anticipated snow level.
• Maximum 24 inches (61 cm) above roof level without additional support for vent.
• 4 feet (1.2 m) from any gable, dormer or other roof structure with building interior
access (e.g. vent or window).
• 10 feet (3 m) from any forced air inlet to the building. Any fresh or make-up air inlet
such as a dryer or furnace area is considered to be a forced air inlet.
Figure 14: Concentric Vent Roof Clearances
Cut a 5 in. diameter hole through the roof. Make sure the wye concentric fitting is
cemented to the large diameter pipe and that the rain cap is cemented to the small
diameter pipe. Install the wye concentric fitting and large pipe assembly through the 5 in.
diameter hole in the roof and field supplied roof boot/flashing. See Figure 15 for installation details.
Page 23
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
Note: Do not allow insulation or other materials to
accumulate inside pipe assembly when installing
through the roof.
Install the rain cap and small pipe assembly into
the wye concentric fitting and large pipe assembly.
Ensure small diameter pipe is bottomed and
cemented in wye concentric fitting. Complete
indoor piping runs and connect piping to the
water heater. See Figure 11, 3" pipe systems, for
connection details. Piping must be sufficiently
supported. At minimum, it is recommended that
a support is placed along the vent or air intake
piping every 4 feet. For additional information,
see installation instructions supplied with
concentric vent kit. For vertical venting, the
condensate drain kit must be installed to the
exhaust adapter.
Figure 15: Concentric Vent Roof Installation
Assembling Vent and Air Intake Joints
䊱
! WARNING
Cements and primers are highly flammable. Assemble joints in an adequately
ventilated area away from heat sources or open flames. Do not smoke.
Read cautions and warnings on material containers.
䊱
! CAUTION
DO NOT use cement that is lumpy or thick. DO NOT thin cement.
Connections (i.e. joints) between plastic pipe and fittings must be properly sealed. This
requires that an appropriate primer (cleaner) and cement (solvent) are used for the type of
material (PVC, CPVC, ABS) that is used in the venting system. For PVC use ASTM D2564
grade cement, for CPVC use ASTM F493 grade cement, and for ABS use ASTM D2235 grade
cement. The following steps should be taken when connecting plastic pipe and fittings:
• Cut pipe square with hand saw and remove burrs from inside and outside edges.
• Clean fitting socket and pipe joint area of all dirt, grease, or moisture.
• Check dry fit. Pipe should easily go 1/3 of the way into the fitting socket.
• Liberally apply primer to inside of fitting socket and pipe joint area.
Page 24
SECTION IV: INSTALLATION (cont.)
VENT & COMBUSTION AIR INTAKE (cont.)
• Over the wet primer, apply a medium coat of cement to the fitting socket and pipe joint
area.
• Insert pipe into fitting with a slight twisting motion. Ensure that the pipe is bottomed
into the fitting.
• Hold pipe and fitting for 30 seconds to prevent push off.
• Wipe off excess cement. Cure time may be up to 2 hours for Ø3" pipe at 60°F. Longer
cure time is required for larger diameter pipe and/or lower temperatures.
Note: The vent and combustion air intake pipe/fittings must overlap a minimum
of 1/2 inch (1.3 cm) at each joint. DO NOT drill or punch holes in the plastic pipe
or fittings.
Condensate Drain Kit
When downward sloping of the vent system is not possible or a vertical vent arrangement
is used, the condensate drain kit must be installed. Follow these steps to properly install
the kit:
• Turn off all electrical power to the water heater.
• Remove the yellow cap from the exhaust adapter.
• Insert one end of the 3/8" OD plastic tube into the fitting on the exhaust adapter. There
should be a tight fit between the tube and the fitting. If the connection is not tight,
apply adhesive aluminum tape around the connection to secure.
• Form a trap by looping a portion of the plastic tube into approximately a 6" diameter
circle. With respect to the water heater, form the loop such that it can be mounted on
the upper 1/3 of the heater.
• Use the supplied loop clamps and screws to secure the tubing to the side of the water
heater and hold the loop trap in place.
• The condensate drain tube must terminate over a proper floor drain or collection
bucket. If necessary, add additional tubing to reach a floor drain.
• Prime the loop trap with water prior to resuming operation of the water heater.
Disconnect the end of the tube that was connected to the exhaust adapter. With the free
end above the loop trap, pour water into the tube until the loop is filled halfway.
• Reconnect the free end to the exhaust adapter fitting and turn on electrical power to the
water heater.
䊱
! DANGER
Failure to prime the condensate drain loop with water will result in combustion gas
(which may contain carbon monoxide) entering the room. To avoid the risk of
asphyxiation from carbon monoxide, never operate the water heater unless the
condensate drain loop is sealed with water.
An example of this installation is shown in Figure 17.
Page 25
SECTION IV: INSTALLATION (cont.)
WATER CONNECTIONS
䊱
! CAUTION
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 water heaters.
ALL PIPING SHOULD CONFORM TO LOCAL CODES AND ORDINANCES. It is highly
recommended that unions and shut-off valves are installed at the potable water connections
to allow for isolation and/or movement during service. All piping should be adequately
insulated with an approved material to minimize heat loss.
POTABLE WATER CONNECTIONS
THE WATER HEATER MUST BE FILLED WITH WATER BEFORE LIGHTING THE
BURNER.
1) Close the main water supply valve before continuing with the installation. After the main
water supply is shut-off, relieve the water line pressure by opening a faucet. Once the pressure
has been relieved, close the faucet. The “Cold” and “Hot” potable water connections are
labeled on the water heater. Install a union and shut-off valve at both potable water
connections. All piping should be 3/4" diameter new copper or larger. A tempering valve or
anti-scald valve should be installed at the potable water outlet and used according to the
manufacturer’s specifications to prevent scalding.
2) If a backflow preventer, check valve, or pressure regulating valve is required in the cold
water supply, a properly sized expansion tank must be installed to control thermal expansion.
Do not operate the water heater in a closed system without installing a thermal expansion
tank. Follow the expansion tank manufacturer’s recommendations when selecting a tank for
your system.
3) Following installation of the water lines, open the main water supply valve and fill the
water heater. Open several hot water faucets to relieve air from the system. After water is
flowing through the faucets and the system is void of air, close the faucets and check for water
leaks in the system.
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).
SOLAR CONNECTIONS
䊱
! CAUTION
Temperature of the primary heat source medium (from solar collector) shall not exceed
200°F.
The outlet of the solar collector should be connected to the water heater at the “FROM SOLAR”
fitting. The fitting labeled “TO SOLAR” should be connected to the solar return piping. It is
recommended to install a union and shut-off valve at each solar connection. All pipe and
fittings between the solar system and water heater should be 3/4” diameter or larger.
Reference the solar collector installation instructions or contact the manufacturer for proper
components and solar loop system design.
Page 26
SECTION IV: INSTALLATION (cont.)
GAS CONNECTIONS
䊱
! 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 valve, union, and a sediment trap shall 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 or
CSA B149.1.
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 11" 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 a soapy water solution
and check for bubbles. Make sure that excess solution does not enter the control's plastic
housing and all wiring remains dry.
䊱
! WARNING
DO NOT use an open flame to check for leaks. Serious injury or death could result from
fire or explosion.
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.
The recommended gas piping to the water heater control is shown in Figure 16.
Figure 17 gives an overview of all field piping connections.
Page 27
SECTION IV: INSTALLATION (cont.)
GAS CONNECTIONS (cont.)
Figure 16: Gas Piping to Valve/Control
Exhaust Vent*
* Slope downward and away from water heater
1/8 inch per foot (max.) for horizontal venting.
Blower Assembly
Shut-off Valve
Combustion Air
Intake*
Union
Shut-Off
Valve
Heat Trap (6" min)
Union
Heat Trap
(6" min)
Cold Water
Supply
Hot Water
Outlet to Mixing
Valve (not shown)
Backflow
Preventer (optional)
Condensate Drain Kit
(make Ø 6" loop,
prime with water seal)
Expansion Tank
T&P Relief
Valve
Anode (1 of 2)
Gas Backup
Temperature
Sensor/ECO
From Solar Collector
Solar Sensor
Immersion Well
Relief Valve
Discharge Line
to Floor Drain
(Min. 6" air gap
from floor drain)
See Figure 16
for details
Drain Valve
To Floor Drain
To Solar Collector
Control / Gas Valve
Figure 17: Recommended Water, Gas, Vent Connections
Page 28
SECTION IV: INSTALLATION (cont.)
WIRING
All electrical wiring and connections must be in accordance with local codes. In the absence
of local codes, wiring must conform to the National Electric Code ANSI/NFPA No. 70 or the
Canadian Electrical Code C22.1. This water heater must be electrically grounded. Electrical
power should be supplied through a fused disconnect switch located near the water heater.
Where local codes permit, use the supplied power cord for field connection. A grounding
receptacle is required. If local codes do not permit the used of the supplied cord, remove the
power cord from the blower assembly and replace with suitable power supply (120V, 60 Hz)
wiring and connections. The water heater draws less than 5 amps (maximum). Check for
proper polarity at the main power connection prior to operating the water heater.
The factory installed immersion well is designed to accommodate insertion of a thermistor.
The solar system controller and thermistor is not supplied with this water heater.
䊱
! CAUTION
Turn off or disconnect the electrical power supply to the water heater before servicing.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper operation after servicing.
A component and schematic wiring diagram is shown in Figure 18.
Figure 18: Component and Schematic Wiring Diagrams
Page 29
SECTION V: OPERATION
Figure 19: Instructions To Put The Water Heater In Operation
Page 30
SECTION V: OPERATION (cont.)
SEQUENCE OF OPERATION
Figure 20 gives a step-by-step description of
the sequence of operations for the gas-fired
water heater. See Troubleshooting section of
this manual for solutions to error codes.
APPLY POWER TO
APPLIANCE
NO
DISPLAY ERROR CODE
IS FIELD WIRING
CORRECT?
1 OR 2
YES
REQUEST
FOR HEAT
PRESENT?
NO
YES
IS
PRESSURE SWITCH
PROVEN OPEN WITHIN
NO
5 SECONDS?
WAIT FOR PRESSURE
SWITCH TO OPEN
DISPLAY ERROR
NUMBER3
YES
IS
PRESSURE SWITCH
PROVEN OPEN WITHIN
NO
WAIT FOR PRESSURE
SWITCH TO OPEN
DISPLAY ERROR
NUMBER3
5 SECONDS?
YES
COMBUSTION
BLOWER ON
IS
PRESSURE SWITCH
PROVEN CLOSED
COMBUSTION
BLOWER ON
NO
WITHIN 5
SECONDS?
WAIT FOR PRESSURE
SWITCH TO CLOSE
DISPLAY ERROR
NUMBER
4
YES
IS
PRESSURE SWITCH
PROVEN CLOSED
ONE HOUR AUTO
LOCKOUT RESET
DELAY
NO
WITHIN 5
SECONDS?
WAIT FOR PRESSURE
SWITCH TO CLOSE
DISPLAY ERROR
NUMBER
4
YES
PREPURGE
IS
IGNITOR
OKAY?
NO
TURN OFF INDUCER
DISPLAY ERROR CODE
NUMBER
5
YES
COMBUSTION
BLOWER OFF
TURN OFF INDUCER
AFTER POST-PURGE
DISPLAY ERROR
6
IGNITOR ON FOR
WARM-UP TIME
MAIN VALVE OPENS
YES
INTERPURGE
MAIN
BURNER LIGHTS
AND IS SENSED
DURING TRIAL
FOR
IGNITION
NO
LESS
MAIN VALVE CLOSES
THAN 3 TRIES
FOR IGNITION?
YES
NO
YES
IGNITOR TURNS OFF
IS
FLAME SENSE
LOST?
NO
NO
YES
LOST
MAIN VALVE CLOSES
LESS THAN
TIMES?
3
YES
NO
IS
REQUEST FOR HEAT
SATISFIED?
YES
MAIN VALVE OFF
COMBUSTION
BLOWER OFF AFTER
POST-PURGE DELAY
Figure 20: Sequence of Operation
Page 31
SECTION V: OPERATION (cont.)
HEATING OPERATIONS
Condition 1: The minimum temperature difference (for heat transfer) between the potable
water at the bottom of the tank and the solar collector is sensed by the solar controller. In
addition, the tank temperature is below the maximum tank temperature setpoint (on solar
control).
Action 1: The solar controller energizes a pump to flow fluid through the solar collector and
heat exchanger. Heat is transferred to the potable water until the temperature difference is
reduced to a desired value or the maximum tank temperature has been reached.
Condition 2: The gas backup thermostat senses that the potable water temperature in the
upper area of the tank drops below the thermostat set-point.
Action 2: The gas burner is on and heats the potable water to the set-point temperature, at
which point the gas valve closes.
INSPECT THE INSTALLATION AND ADJUST THE CONTROLS
For natural gas, the manifold pressure is preset at 4.0” w.c. and the acceptable inlet pressure is
in the range of 5-14” w.c. For propane gas, the manifold pressure is preset at 10.0” w.c. and the
acceptable inlet pressure is in the range of 11-14” w.c. See the “Pre-Installation” section of this
manual for information on clearances, air supply, and venting.
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.
䊱
! 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.
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 outlet 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, adjust the setting on the control.
Press the COOLER and HOTTER buttons at the
same time and hold them for one second. Then,
press either the COOLER or HOTTER buttons
until the desired temperature display setting is
lit.
DISPLAY
B
C
D
E
F
APPROXIMATE
TEMPERATURE
o
F (oC)
120 (49)
130 (54)
140 (60)
145 (63)
150 (66)
155 (68)
160 (71)
165 (74)
170 (77)
175 (79)
180 (82)
Page 32
Figure 21: Temperature and Display Settings
SECTION V: OPERATION (cont.)
MEASURING THE OUTCOMING WATER TEMPERATURE (cont.)
This log (or a similar one) should be filled out as follows:
Date
Time
Person running test
Set temp °F
Outlet temp °F
SECTION VI: MAINTENANCE
NOTICE TO THE OWNER: If you are having a mechanical problem with your water heater,
contact your service company or installer.
WATER PIPING
On an annual basis, all piping should be checked for leakage at joints, shut-off valves, and unions.
T&P RELIEF VALVE
On an annual basis, the temperature and pressure relief valve should be checked for proper
operation. First, attach a drain line to the valve to direct the water discharge to an open drain.
This is very important because the temperature of the discharge could be very hot. Second,
lift the lever at the end of the valve several times. The valve should operate freely and return
to its original position properly. If water does not flow out of the valve, remove and inspect
for corrosion or obstructions. Replace with a new valve if necessary. Do not repair the faulty
valve as this may cause improper operation.
ANODE RODS
Anode rods should be inspected twice in the first year and at least yearly once a time interval
for inspection has been developed. It is recommended to check the rod(s) six months after the
heater is installed. If the anode rod had reduced in size by two-thirds of its original diameter
of 3/4” or shows signs of pitting, it is time for replacement. Take the following steps when
changing the anode rod(s):
1. Shut off water supply.
2. Open any faucet to relieve tank pressure.
3. Remove caps on water heater top; push insulation aside.
4. Use a 1 1/16” six-sided socket wrench and a breaker bar. Snap hard to break the anode rod seal.
5. Remove rod(s) and replace with new rod(s).
6. Turn water supply back on and leave faucet open until air is out of line.
7. Turn faucet off and check that new rod(s) doesn’t leak.
8. Snap caps back into place.
FLUSH THE TANK
Elements in the water such as lime and iron may accumulate in the heater. Accumulation of
these elements can keep your water heater from operating at peak efficiency and may lead to
premature tank failure. It is recommended that the tank is drained and flushed thoroughly
once a year to prevent buildup.
Page 33
SECTION VI: MAINTENANCE (cont.)
SOLAR CONTROLLER AND COLLECTOR PANELS
The solar controller and collector panel manufacturer may have a recommended maintenance
procedure. Refer to the instruction manual that was received with the solar equipment.
INSPECT THE VENTING SYSTEM, FLUE, AND BURNER
The vent and combustion air intake system should be checked at least once a year for damage
and blockage. Make sure all joints are secure and that the system is properly supported.
Inspect the outdoor terminals to make sure they are free of obstructions.
䊱
! CAUTION
For your safety, removal of the blower assembly, cleaning of the flue, and removal of the
burner must be performed by a qualified service technician. If the burner is removed it must
be leak tested following reinstallation before normal water heater operation is resumed. All
parts must be replaced to their original position prior to operating the water heater.
The water heater flue should be inspected periodically to be sure it is clean. In order to inspect
the flue, the blower assembly and flue baffle must be removed. Before removing the blower
assembly make sure the water heater is disconnected from the main power supply
and the gas supply to the water heater is shut off. Wait at least 5 minutes to allow the
flue to cool. Remove the flue baffle and clean the flue with a flexible wire brush. Slide the
brush down the flue at the free end of each row of fins. This should knock any rust flakes into
the combustion chamber for removal.
䊱
! 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 any rust flakes or sediment collected in the combustion chamber before restarting the
heater. Remove the outer and inner access doors. The inner access door is mounted to the tank
skirt with screws. Disconnect the burner tube and wire harness from the gas valve and remove
the burner with the inner access door attached. Remove all debris from the combustion
chamber. Inspect the ignitor and flame sensor. Carefully reinstall the burner. The end of the
burner tube should be positioned under the burner bracket on the inner shield. Tighten the
burner tube into the gas valve and reconnect the wire harness. Remount the inner door to the
tank skirt, using every screw that was originally removed. The inner door must be securely
mounted. Place the flue baffle back into the flue and screw the blower assembly back into
place on the top pan (use every screw!).
Leak test the burner connection to the gas valve prior to resuming operation.
Page 34
SECTION VII: TROUBLESHOOTING
䊱
! CAUTION
For your safety, the repair and servicing of this equipment shall only be performed by a
qualified agency.
Table 10: Troubleshooting
Problem
Possible causes
1) Air in the gas line.
2) Vent or air intake system is blocked.
Unable to light the main
burner
3) Pressure switch stuck in open or closed position.
4) Loose wire connection.
5) Energy Cut-Off (ECO) or Temperature Switch in
blower assembly tripped.
6) Hot surface ignitor is bad.
7) Check control error codes.
Main burner does not stay lit
Condensation in heat
exchanger
Poor combustion (sooting,
yellow flame)
Rumbling noise during burner
operation
1) Energy Cut-Off (ECO) or Temperature Switch in
blower assembly tripped.
2) Flame sensor is bad.
1) Accumulation of scale on burner.
2) Vent or air intake system is blocked.
1) Scale or sediment build-up in tank.
1) Heater undersized for load.
3) Check control error codes.
4) Temperature setting of control is too low.
5) Circulator does not operate.
Water too hot or not hot
enough
T&P relief valve is dripping
water
1) Contact qualified agency to purge the air from the
gas line.
2) Contact qualified agency to inspect the system for
blockage.
3) Make sure pressure switch hoses are not kinked.
Contact qualified service agency for replacement.
4) Contact qualified agency to inspect wiring.
5) Contact qualified agency to inspect safety devices.
6) Contact qualified agency to inspect and/or replace
ignitor.
7) See Table 10.
1) Contact qualified agency to inspect safety devices.
2) Contact qualified agency to inspect and/or replace
sensor.
1) This is normal and will stop after water temperature
reaches setpoint.
1) Heating water for the first time (i.e. following
installation).
2) Horizontal venting not sloped downward and away
2) Contact qualified agency to inspect vent system.
from water heater.
3) Condensate kit not installed (vertical or horizontal 3) Contact qualified agency to install condensate kt.
vent systems).
Refer to this manual.
4) Contact qualified agency to inspect vent & air
4) Vent & air intake system exceeds maximum.
intake system.
2) Low gas pressure.
Insufficient hot water
Recommended Action
6) Undersized solar collectors.
1) Control temperature setting is too high or low.
2) Control is defective.
1) Excessive pressure condition in tank (greater than
150 psi).
T&P relief valve is gushing hot 1) Excessive temperature condition in tank (greater
water
than 210°F).
1) Contact qualified agency to clean burner.
2) Contact qualified agency to inspect the system for
blockage.
1) Drain the water heater to remove scale and
sediment.
1) Reduce hot water usage rate.
2) Check gas supply and manifold pressure
3) See Table 10.
4) See Figure 21 for settings.
5) Check solar controller and power supply. Call
qualified agency to replace.
6) Determine peak usage, compare to tank capacity,
add storage if necessary.
1) Adjust setting as required, see Figure 21.
2) Contact qualified agency to replace the control.
1) Contact qualified agency to inspect water piping
system. Expansion tanks are required in closed
systems.
1) Lower the temperature setting on the control.
See "Section V: Operation" for instructions to
adjust the temperature setting.
Page 35
SECTION VII: TROUBLESHOOTING (cont.)
Table 11: Control LED Codes
LED Error Code
Problem
Error 1
Open earth ground circuit to the ignition system.
B C D E F
Solution
1) Check that the earth ground conductor is properly connected at
the fuse box or breaker panel and the water heater.
2) Check that the grounding conductors on the water heater are
properly connected and secure.
The self diagnostic test detected a wiring error or a high 1) Check for proper connection of the line neutral and line hot wires.
F resistance to earth ground.
2) Check that the water heater is securely connected to earth
ground.
B
Error 2
C D
E
B
Error 3
C D
E
The pressure switch remained closed longer than 5
F seconds after the call for heat began.
1) The pressure switch wiring is incorrect.
2) The pressure switch is defective and must be replaced.
B
Error 4
C D
E
The pressure switch(es) remained open longer than 5
F seconds after the combustion blower was energized.
1) Check wiring to the pressure switch(es).
2) Verify that pressure switch tubing is connected correctly.
3) Check the vent and combustion air intake systems for blockage.
B
Error 5
C D
E
F
B
Error 6
C D
E
The maximum number of ignition retries or recyles has
F been reached and the system is in lockout.
B
Error 7
C D
E
F
B
Error 8
C D
E
F
B
Error 9
C D
E
F
B
Error 10
C D E
F
B
Error 11
C D E
F
B
Error 12
C D E
F
B
Error 13
C D E
Water temperature sensor is either open or short
F circuited.
Page 36
Error in the hot surface ignitor circuit.
1) Check that all wiring is correct and secure.
2) Disconnect the ignitor connector and measure the ignitor
resistance with an accurate ohmmeter between pins 1 and 2.
Resistance should be between 11.5 and 18.8 ohms. If the reading
is incorrect, replace the hot surface ignitor.
1) Gas supply is off or inlet gas pressure is too low to operate. Turn
on gas supply and/or increase inlet gas pressure within specified
range.
2) Hot surface ignitor and flame rod assembly not positioned
correctly.
3) Electric polarity to unit is incorrect - test and correct.
4) Low voltage to the water heater. Supply voltage must equal rated
voltage.
5) Check the vent and combustion air intake systems for blockage.
Problem with the gas valve driver circuit.
1) Turn off power to the water heater for 10 seconds, then turn
power on.
2) Replace the combination control / gas valve.
Problem with the internal microcomputer.
1) Turn off power to the water heater for 10 seconds, then turn
power on.
2) Replace the combination control / gas valve.
Problem with the internal circuit.
1) Turn off power to the water heater for 10 seconds, then turn
power on.
2) Replace the combination control / gas valve.
Flame signal sensed out of proper sequence.
1) Replace the combination control / gas valve.
The high temperature thermal cutoff (ECO) is open.
1) ECO will automatically reset (or close) when the water
temperature drops to 120°F or below. The water heater thermostat
will automatically reset following a three minute standby period once
the ECO switch closes.
1) Make sure that there are no objects leaning against the front of
the control.
2) Lightly press and release each of the buttons once.
3) Replace the combination control / gas valve.
1) Check that all wiring is correct and secure.
2) Replace the combination control / gas valve.
One of the temperature adjust bottons is stuck closed.
SECTION VIII: PARTS LIST
17
16
1
15
2
3
4
5
5
14
6
18
19
20
19
7
8
9
12
11
10
Table 12: SKG Parts
1
Blower Assembly
4
Dip Tube
2
3
5
6
7
8
9
10
Flue Baffle
Figure 22: SKG Parts
Part Description
Hot Outlet Nipple, 1" x 4.5"
Anode Rods
T&P Relief Valve
Control / Gas Valve
Drain Valve
Outer Door
13
Inner Door, Right Side
11
Inner Door, Left Side
14
PVC Pipe, Ø3" x 62.5"
12
13
15
16
17
18
19
20
Air Intake Boot
Trim Plate
PVC Tee, 3" x 3" x 2"
PVC Pipe, Ø2" x 3"
Flex Coupling, Ø2" x 3.5"
Sensor/ECO Harness
Coil Nipple, 1" x 3"
Sensor Immersion Well (solar)
Page 37
SECTION VIII: PARTS LIST (cont.)
1
2
3
4
Figure 23: SKG Burner Parts
Table 13: SKG Burner Parts
1
Burner
3
Ignitor and Flame Sensor Assembly
2
4
Page 38
Part Description
Main Burner Tube (NAT or LP)
Orifice (NAT or LP)
SECTION IX: WARRANTY
LIMITED WARRANTY FOR SOLAR WATER HEATER
Bock Water Heaters, Inc.
110 S. Dickinson Street
Madison, WI 53703
Phone: 608-257-2225
WHAT DOES THIS LIMITED WARRANTY COVER?
This limited warranty applies only to the original consumer purchaser.
General Defects and Malfunctions: This warranty covers defections and malfunctions in your
new water heater for a period of one year from the original installation date. We will repair or
replace, at our option, any defective or malfunctioning component of the water heater. This
limited warranty will terminate if you sell or otherwise transfer the water heater, or the water
heater is installed at a location different from its original installation location.
For water heaters installed in single family dwellings for residential use:
Tank and Heat Exchanger: We also warrant that the tank and heat exchanger will not leak due
to defective materials or workmanship for six years from the date of original installation or from
date of manufacture in the event the Limited Warranty Registration Card was not completed and
returned to manufacturer. If the tank and heat exchanger is leaking and we have verified that
the leak is due to a defect in materials and workmanship, we will replace the tank with a tank
that is the nearest Bock model available at the time of replacement. If a replacement tank is
provided, it will remain warranted under this section as if it were the original tank. For
example, if we send you a replacement tank under this limited warranty three years after the
original installation date, then the replacement tank will remain warranted for the remaining
three years after the original installation date.
For all other water heaters, such as commercial use:
Tank and Heat Exchanger: We also warrant that the tank and heat exchanger will not leak due
to defective materials or workmanship for five years from the date of original installation or
from date of manufacture in the event the Limited Warranty Registration Card was not
completed and returned to manufacturer. If the tank and heat exchanger is leaking and we have
verified that the leak is due to a defect in materials and workmanship, we will replace the tank
with a tank that is the nearest Bock model available at the time of replacement. If a replacement
tank is provided, it will remain warranted under this section as if it were the original tank. For
example, if we send you a replacement tank under this limited warranty two years after the
original installation date, then the replacement tank will remain warranted for the remaining
three years after the original installation date.
HOW DO YOU GET SERVICE UNDER THE LIMITED WARRANTY?
In order for the warranty period to begin on the date of installation, you must return the
warranty registration card attached below within 30 days of purchasing the water heater. You
may also register your water heater online at www.bockwaterheaters.com. You must have a copy
of the original sales receipt at the time you request service. Failure to return the warranty
registration card and provide a copy of the sales receipt will result in the warranty period
beginning from the date of manufacture.
To get service under this limited warranty you should contact either the dealer or installer. If
dealer or installer is unknown you can contact us via e-mail at [email protected]
or call us Monday through Friday between the hours of
8 o’clock a.m. to 5 o’clock p.m. Central Time at the following number: 1-608-257-2225.
You can also write us at the following address:
Bock Water Heaters, Inc.
Warranty Support Group
110 S. Dickinson Street
Madison, WI 53703
We will respond not later than ten days after we have received your request for service.
Page 39
SECTION IX: WARRANTY (cont.)
WHAT DOES THIS LIMITED WARRANTY NOT COVER?
This limited warranty does not cover water heaters that are or were:
• Incorrectly installed, especially where the installation violates state or local plumbing,
housing or building codes.
• Operated at inappropriate settings, excessive pressures or temperatures.
• Exposed to adverse local conditions and specifically sediment or lime precipitation in the
tank or corrosive elements in the atmosphere or unacceptable water quality.
• Installed outside the United States or Canada.
• Accidentally damaged.
Also, we will not cover the following charges, costs and losses:
• Any freight or delivery charges.
• Any removal or installation charges.
• Charges to return the water heater or part to the manufacturer.
• Water damage, loss or damage to property, inconvenience or loss of use.
WHAT WILL VOID THE LIMITED WARRANTY?
If you do any of the following, you will void this limited warranty:
• Fail to return the warranty registration card within 30 days.
• Fail to retain an original copy of your sales receipt.
• Fail to retain the actual rating plate from the water heater.
• Alter or remove the serial number.
• Transfer or sell the water heater.
• Remove the water heater from its original location and install it somewhere else.
• Fail to follow the care and maintenance instructions provided with the water heater.
• Remove the anode rods.
• Fail to inspect and replace the anode rods (you must retain and present your paid receipts
as proof of anode rod replacement).
HOW DOES STATE LAW RELATE TO THIS LIMITED WARRANTY?
This is a limited warranty. WE MAKE NO OTHER EXPRESS WARRANTIES WITH RESPECT TO
THIS WATER HEATER. We will not assume, nor authorize any person to assume for us any
other liability in connection with the sale or operation of this water heater. ANY IMPLIED
WARRANTIES, INCLUDING MECHANTABILITY OR FITNESS FOR A PARTICULAR
APPLICATION, IMPOSED ON THIS SALE UNDER THE LAWS OF THE STATE OF SALE ARE
LIMITED TO ONE YEAR. This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state. Some states do not allow limitations on how long
an implied warranty lasts, so the above limitation may not apply to you.
WE WILL 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 CONTACT OR TORT. Some states do not allow the
exclusion of incidental or consequential damages, so the above exclusion may not apply to
you.
Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703
Telephone 608 -257-2225 • Fax 608 -257-5304
www.bockwaterheaters.com
Page 40
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