Instruction Manual COMMERCIAL GAS WATER HEATERS

MODELS BTP 139(A) Thru 370(A) SERIES 104/105 INSTALLATION - OPERATION - SERVICE 500 Tennessee Waltz Parkway - MAINTENANCE - LIMITED WARRANTY Ashland City, TN 37015

Low Lead Content

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: ‡ Do not try to light any appliance. ‡ Do not touch any electrical switch; do not use any phone in your building. ‡ Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. ‡ If you cannot reach your gas supplier, call the fire department. Read and understand this instruction Installation and service must be manual and the safety messages performed by a qualified installer, herein before installing, operating or service agency or the gas supplier. servicing this water heater. Failure to follow these instructions and safety messages could result in death or serious injury. Thank yRX IRr EXyinJ this enerJy eI¿Fient water heater This manual must remain with the We aSSreFiate yRXr FRn¿denFe in RXr SrRdXFts water heater.

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

PRINTED 0814 194186-003 TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE  3 Air )rRP 2ther IndRRr 6SaFes  18 APPROVALS  3 9ent CRnneFtiRn  19 GENERAL SAFETY INFORMATION 4-5 WATER HEATER INSTALLATION 19-22 PreFautions  5 Water Line CRnneFtiRns  19 Grounding InstruFtions  5 T P 9alYe DisFharJe PiSe  19 Hydrogen Gas Flammable  5 Installation Diagrams - Top Inlet/Outlet Usage  20 INTRODUCTION  6 Burner Installation  20 Abbreviations Used  6 Heater Wiring  21 Quali¿Fations  6 Gas Piping  22 Start Up Requirements  6 Gas Line Leak Testing  22 Preparing for the Installation  6 Purging  22 FEATURES AND COMPONENTS  7 STARTUP AND OPERATION  23 High Limit SwitFh  7 Prior to Start Up  23 EleFtroniF Ignition Control  7 SEQUENCE OF OPERATION 23-27 BarometriF Draft Control  7 SeTuenFe oI Operation Flow Chart  24 Combustion Chamber Observation Port  7 Lighting & Operation Label  25 UnFrating  7 Adjustments 26 INSTALLATION CONSIDERATIONS  8-12 CheFking 9enting  26 Rough In Dimensions  8 CheFking the Input  26 LoFating The Water Heater  10 Setting Burner Operation  27 ClearanFes  10 MAINTENANCE 28-32 Insulation Blanket 11 9enting System and BarometriF DraIt Control  28 Hard Water 11 General  28 CirFulation Pumps 11-12 Remote Storage Tank Temperature Control  28 High Altitude Installations  12 Temperature-Pressure Relief Valve Test  28 INSTALLATION REQUIREMENTS  13-16 Anode Rod InspeFtion 29 Gas Supply Systems  13 Supply Gas Regulator  13 Draining and Flushing  29 Power Supply  13 ReFommended ProFedure for PeriodiF Removal or Lime Deposits from the Tank Type CommerFial Water Heaters  29 Water Temperature Control and Mixing Valves  13 DeLiming Solvents  30 Dishwashing MaFhines  14 Tank Cleanout ProFedure  30 Closed Water Systems  14 Deliming Using Flo-Jug Method 30-31 Thermal Expansion  14 Power Burner  31-32 Temperature-Pressure Relief Valve 14-15 Gas Control Valve  32 Contaminated Air  15 SERVICE  32 Air Requirements  15 EleFtriFal ServiFing  32 UnFon¿ned SpaFe  16 Con¿ned SpaFe  16 TROUBLESHOOTING CHECKLIST  33 VENTING INSTALLATION  16-19 FOR YOUR INFORMATION  34 Venting  16 Start up Conditions  34 BarometriF Draft Control Assembly  16 Operational Conditions  34 Fresh Air Opening for Con¿ned SpaFes  17 WATER PIPING DIAGRAMS 35-49 Outdoor Air Through Two Openings  17 MANIFOLD KITS  50 Outdoor Air Through One Opening  17 REPLACEMENT PARTS LIST  51-52 Outdoor Air Through Two Horizontal DuFts  17 NOTES 53-54 Outdoor Air Through Two VertiFal DuFts  18 WARRANTY  55

2 SAFE INSTALLATION, USE AND SERVICE

The proper installation, use and serviFing of this water heater is extremely important to your safety and the safety of others Many safety-related messages and instruFtions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instruFtions throughout this manual It is very important that the meaning of eaFh safety message is understood by you and others who install, use, or serviFe this water heater

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not avoided, DANGER will result in injury or death.

WARNING indicates a potentially hazardous situation which, if not avoided, could result WARNING in injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in CAUTION minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTION situation which, if not avoided, could result in property damage.

All safety messages will generally tell you about the type of hazard, what Fan happen if you do not follow the safety message, and how to avoid the risk of injury The California Safe Drinking Water and ToxiF EnforFement AFt requires the Governor of California to publish a list of substanFes known to the State of California to Fause FanFer, birth defeFts, or other reproduFtive harm, and requires businesses to warn of potential exposure to suFh substanFes WARNING: This produFt Fontains a FhemiFal known to the State of California to Fause FanFer, birth defeFts, or other reproduFtive harm This applianFe Fan Fause low level exposure to some of the substanFes listed in the AFt

APPROVALS

Low Lead Content

Note: ASME FonstruFtion is optional on the water heaters Fovered in this manual

3 GENERAL SAFETY INFORMATION

Fire or Explosion Hazard Fire Hazard

Do not store or use gasoline or other flammable vapors and For continued protection against liquids in the vicinity of this or any other appliance. risk of fire: Do not install water heater on Avoid all ignition sources if you smell gas. 
carpeted floor. Do not expose water heater controls to excessive gas 
Do not operate water heater if pressure. any part has been exposed to flooding or water damage. Use only the gas shown on the water heater rating label. Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended periods of non-use. Fire and Explosion Hazard Read instruction manual before Use joint compound or Teflon tape installing, using or servicing compatible with propane gas. water heater. Leak test before placing the water heater in operation. Disconnect gas piping and main gas shutoff valve before leak testing. Install sediment trap in accordance with NFPA 54.

Fire and Explosion Hazard Do not use water heater with any gas other than the gas shown on the rating label. Excessive gas pressure to gas valve can cause serious injury or death. Turn off gas lines during installation. Contact a qualified installer or service CAUTION technician for installation and service. Property Damage Hazard

 All water heaters eventually leak. Jumping out control circuits or components can Do not install without adequate drainage.  result in property damage, personal injury or death.  Service should only be performed by a qualified service technician using proper test equipment.  Altering the water heater controls and/or wiring in any way could result in permanent damage to the controls or water Electrical Shock Hazard heater and is not covered under the limited warranty.  Turn off power to the water heater  Altering the water heater controls and/or wiring in any way before performing any service. could result in altering the ignition sequence allowing gas to flow to the main burner before the hot surface igniter is at  Label all wires prior to disconnecting ignition temperature causing delayed ignition which can when performing service. Wiring errors cause a fire or explosion. can cause improper and dangerous operation. Any bypass or alteration of the water heater controls and/or wiring will result Verify proper operation after servicing.  in voiding the water heater warranty.  Failure to follow these instructions can result in personal injury or death.

4 GENERAL SAFETY INFORMATION

Read and understand this instruction Explosion Hazard manual and the safety messages herein before installing, operating or Overheated water can cause servicing this water heater. water tank explosion. Failure to follow these instructions and safety messages could result in death Properly sized temperature and or serious injury. pressure relief valve must be installed in the opening provided. This manual must remain with the water heater.

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. CAUTION Improper installation, use and service may result Children, the elderly and the in property damage. physically or mentally disabled are at highest risk for scald injury. 
Do not operate water heater if any part has been exposed to flooding or water damage. Feel water before bathing or 
Inspect anode rods regularly, replace if damaged. showering. 
Install in location with drainage. Temperature limiting devices such as 
Fill tank with water before operation. mixing valves must be installed 
Properly sized thermal expansion tanks are required on all when required by codes and to closed water systems. ensure safe temperatures at fixtures. Refer to this manual for installation and service.

Verify the power to the water heater is turned off before performing any service procedures.

GENERAL SAFETY INFORMATION

PRECAUTIONS HYDROGEN GAS FLAMMABLE

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN E;POSED TO FLOODING OR WATER DAMAGE Immediately Fall a qualified serviFe teFhniFian to inspeFt the water heater and to make a determination on what steps Explosion Hazard should be taken next If the unit is exposed to the following, do not operate heater Flammable hydrogen gases until all ForreFtive steps have been made by a qualified may be present. serviFe teFhniFian Keep all ignition sources away 1 External ¿re from faucet when turning on 2 Damage hot water. 3 Firing without water

Hydrogen gas Fan be produFed in a hot water system served GROUNDING INSTRUCTIONS by this water heater that has not been used for a long period of time generally two weeks or more  Hydrogen gas is extremely This water heater must be grounded in aFFordanFe with the Àammable To reduFe the risk of injury under these Fonditions, National EleFtriFal Code and/or loFal Fodes These must be it is reFommended that a hot water fauFet served by this water followed in all Fases heater be opened for several minutes before using any eleFtriFal applianFe FonneFted to the hot water system If hydrogen is This water heater must be FonneFted to a grounded, permanent present there will probably be an unusual sound suFh as air wiring system or an equipment grounding FonduFtor must be esFaping through the pipe as the water begins to Àow THERE run with the FirFuit FonduFtors and FonneFted to the equipment SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE grounding terminal or lead on the water heater, see Figure 19 FAUCET AT THE TIME IT IS OPEN 5 INTRODUCTION

Thank You for purFhasing this water heater Properly installed Warranty on this produFt is limited and Fould be void in the and maintained, it should give you years of trouble free serviFe event the unit is not installed per the instruFtions in this manual and/or not started up by an authorized faFtory trained serviFe/ ABBREVIATIONS USED start-up provider

Abbreviations found in this InstruFtion Manual inFlude  PREPARING FOR THE INSTALLATION ‡ ANSI - AmeriFan National Standards Institute 1 Read the ³General Safety´ seFtion, page 4-5 of this manual ‡ ASME - AmeriFan SoFiety of MeFhaniFal Engineers first and then the entire manual Farefully If you don¶t follow ‡ AHRI - Air-Conditioning, Heating and Refrigeration Institute the safety rules, the water heater will not operate properly ‡ NEC - National EleFtriFal Code It Fould Fause DEATH, SERIOUS BODILY INJURY AND/OR ‡ NFPA - National Fire ProteFtion AssoFiation PROPERTY DAMAGE ‡ UL - Underwriters Laboratory This manual Fontains instruFtions for the installation, operation, ‡ CSA - Canadian Standards AssoFiation and maintenanFe of the gas-¿red water heater It also Fontains warnings throughout the manual that you must read and be QUALIFICATIONS aware of All warnings and all instruFtions are essential to the proper operation of the water heater and your safety SinFe we QUALIFIED INSTALLER OR SERVICE AGENCY Fannot put everything on the ¿rst few pages, READ THE ENTIRE Installation and serviFe of this water heater requires ability MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE equivalent to that of a Quali¿ed AgenFy as de¿ned by ANSI THE WATER HEATER below in the ¿eld involved Installation skills suFh as plumbing, 2 The installation must Fonform with these instruFtions and the air supply, venting, gas supply and eleFtriFal supply are required loFal Fode authority having jurisdiFtion In the absenFe of loFal in addition to eleFtriFal testing skills when performing serviFe Fodes, the installation must Fomply with the Furrent editions of the National Fuel Gas Code, ANSI =2231/NFPA 54 or CAN/ ANSI Z223.1 2006 Sec. 3.3.83: ³Quali¿ed AgenFy´ - ³Any CSA-B1491 the Natural Gas and Propane Installation Code individual, ¿rm, Forporation or Fompany that either in person or All doFuments are available from the Canadian Standards through a representative is engaged in and is responsible for (a) AssoFiation, 8501 East Pleasant Valley Road, Cleveland, OH the installation, testing or replaFement of gas piping or (b) the 44131 NFPA doFuments are also available from the National FonneFtion, installation, testing, repair or serviFing of applianFes Fire ProteFtion AssoFiation, 1 BatterymarFh Park, QuinFy, MA and equipment that is experienFed in suFh work that is familiar 02269 with all preFautions required and that has Fomplied with all the requirements of the authority having jurisdiFtion´ 3 If after reading this manual you have any questions or do not understand any portion of the instruFtions, Fall the loFal If you are not quali¿ed (as de¿ned by ANSI above) and liFensed gas utility or the manufaFturer whose name appears on the or Ferti¿ed as required by the authority having jurisdiFtion rating plate to perform a given task do not attempt to perform any of the proFedures desFribed in this manual If you do not understand 4 Carefully plan the plaFe where you are going to put the the instruFtions given in this manual do not attempt to perform water heater CorreFt Fombustion, vent aFtion, and vent pipe any proFedures outlined in this manual installation are very important in preventing death from possible Farbon monoxide poisoning and ¿res

START UP REQUIREMENTS Examine the loFation to ensure the water heater Fomplies with This produFt requires a formal Start-Up by an authorized the ³LoFating the New Water Heater´ seFtion in this manual serviFe/ 5 For California installation this water heater must be braFed, start-up provider that has been approved by the manufaFturer anFhored, or strapped to avoid falling or moving during for this speFi¿F produFt Call 1-800-527-1953 to loFate the an earthquake See instruFtions for ForreFt installation nearest authorized start-up provider and arrange a faFtory proFedures InstruFtions may be obtained from California start-up Please provide as muFh notiFe as possible, preferably OffiFe of the State ArFhiteFt, 400 P Street, SaFramento, 2 weeks Please have the model and serial number ready when CA 95814 you Fall 6 MassaFhusetts Code requires this water heater to be installed in This start-up is required to aFtivate the warranty and ensure aFFordanFe with MassaFhusetts 248-CMR 200 State Plumbing safe, ef¿Fient operation Code and 248-CMR 500

6 FEATURES AND COMPONENTS

HIGH LIMIT SWITCH BAROMETRIC DRAFT CONTROL

The dual bulb Fontroller (¿g 1) Fontains the high limit (energy Futoff) The heater is equipped with a double aFting barometriF draft sensor The high limit switFh interrupts main burner gas Àow should Fontrol This Fontrol assembly is faFtory adjusted to automatiFally the water temperature reaFh 205ƒF (96ƒC) regulate the Fhimney draft imposed on the unit In the event of high limit switFh operation, the applianFe Fannot be restarted unless the water temperature is reduFed by at least 20ƒF (11ƒC) and the high limit reset button on front of limit Fontrol (¿g1) is depressed Continued manual resetting of high limit Fontrol, preFeded by higher than usual water temperature is evidenFe of high limit switFh operation The following is a possible reason for high limit switFh operation ‡ A malfunFtion in the thermostatiF Fontrols would allow the gas Fontrol valve to remain open Fausing water temperature to exFeed the thermostat setting The water temperature would Fontinue to rise until high limit switFh operation ContaFt your dealer or serviFe agent if Fontinued high limit switFh BAROMETRIC DRAFT CONTROL operation oFFurs FIGURE 3.

COMBUSTION CHAMBER OBSERVATION PORT

The Fombustion Fhamber observation aFFess panel is loFated above and to the left of the burner A plug loFated under the panel, see fig 5, is inserted into the Fombustion Fhamber wall This plug should not be removed exFept, in rare Fases, when the Fombustion Fhamber requires Fleaning or replaFement

DIGITAL THERMOSTAT FIGURE 1.

ELECTRONIC IGNITION CONTROL

EaFh heater is equipped with a Honeywell ignition module The DireFt Spark Ignition Control Module Fontrols the ignition FIGURE 4. sequenFe and gas Fontrol operation of the water heater

UNCRATING

UnFrate the heater by removing the outside mat and top loFator The shipping pallet must be removed from the unit It may be possible to simply unbolt the base from the pallet and, with the help of 2 or more persons, work the unit off the pallet Some units will be too heavy and will require the use of jaFks or lifting equipment to safely remove the pallet and move the unit into position Be Fareful when moving this heater It will tip over easily The heater is shipped with a burner and draft Fontrol The burner and draft Fontrol are shipped in separate Fartons They should be installed as reFeived without any alterations IGNITION MODULE DisFard the shipping Frate and paFkaging Fartons in an FIGURE 2. appropriate manner

7 INSTALLATION CONSIDERATIONS

ROUGH IN DIMENSIONS

FIGURE 5.

TABLE 1 . MODELS BTP-139(A) THROUGH BTP-370(A)

APPROX. SHIP. WT. MODELS A B C DE GH JGAS (LBS.) IN OUT ASME STD. BTP-139/A 74 3/4" 65" 26 3/4" 6" 21 3/8" 27 3/4" 38" 85 1/4" 1/2 658 556 1 1/2" 1 1/2" BTP-199/A 74 3/4" 65" 26 3/4" 6" 21 3/8" 27 3/4" 38" 85 1/4" 1/2 635 545 1 1/2" 1 1/2" BTP-270/A 74 3/4" 65" 26 3/4" 8" 21 3/8" 27 3/4" 38" 85 1/4" 3/4 632 547 1 1/2" 1 1/2" BTP-370/A 74 3/4" 65" 26 3/4" 8" 21 3/8" 27 3/4" 38" 85 1/4" 3/4 731 634 1 1/2" 1 1/2"

8 INSTALLATION CONSIDERATIONS

TABLE 2. HEATER PERFORMANCE DATA BTP MODELS

STORAGE MAXIMUM RECOVERY RATE RECOVERY RATE MODELS CAPACITY IMPUT RATING BTU/HR. AMPERES GPH@100°F RISE GPH@140°F RISE U.S. GALLONS 120V, 60Hz, 10

BTP-139/A 81 140,000 136 97 5 BTP-199/A 81 199,000 193 138 5 BTP-270/A 81 270,000 262 187 5 BTP-370/A 81 370,000 359 256 5

Models with letter ³A´ following the model number have the optional ASME tank FonstruFtion The BTP-370 is available in natural gas only

TABLE 3. GAS AND ELECTRICAL CHARACTERISTICS

Gas Supply Pressure Model Type of Gas Minimum Maximum Gas Manifold Pressure Volts/Hz Amperes All Models Natural 45" WC (112 kPa) 14" WC (348 kPa) 35" WC (087 kPa) 120/60 <5 All Models * Propane 45" WC (112 kPa) 14" WC (348kPa) 35" WC (087 kPa) 120/60 <5

* Model BTP-370(A) is not available in Propane

9 INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER The heater must not be loFated in an area where it will be subjeFt to freezing

LoFate it near a Àoor drain The heater should be loFated CAUTION in an area where leakage from heater or FonneFtions will Property Damage Hazard not result in damage to adjaFent area or to lower Àoors of the struFture

 All water heaters eventually leak. When suFh loFations Fannot be avoided, a suitable metal drain pan should be installed under heater SuFh pans  Do not install without adequate drainage. should be fabriFated with sides at least 2´ deep, with length and width at least 2´ greater than diameter of heater and must be piped to an adequate drain Pan must not restriFt When installing the heater, Fonsideration must be given to Fombustion air Àow proper loFation LoFation seleFted should be as Flose to the staFk or Fhimney as praFtiFable, with adequate air supply and CLEARANCES as Fentralized with the piping system as possible These heaters are approved for installation on non-Fombustible flooring in an alFove when the minimum FlearanFe from Fombustion or non-Fombustible FonstruFtion are followed as indiFated in Figure 7 and Table 5

Fire or Explosion Hazard Units whiFh are to be installed on Fombustible Àooring must be supported by a full layer of hollow FonFrete bloFks, from Do not store or use gasoline or other flammable vapors and 8" to 12" liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell gas. thiFk and extending 12" (minimum) beyond the heater in all Do not expose water heater controls to excessive gas direFtions The FonFrete bloFks must provide an unbroken pressure. FonFrete surfaFe under the heater with the hollows running Fontinuously and horizontally A 3/16 inFh steel plate must Use only the gas shown on the water heater rating label. Fover the FonFrete bloFks See Figure 5 Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended periods of non-use.

Read instruction manual before installing, using or servicing water heater.

PROPER INSTALLATION ON COMBUSTIBLE FLOORING There is a risk in using fuel burning applianFes suFh as gas water FIGURE 6. heaters in rooms, garages or other areas where gasoline, other Àammable liquids or engine driven equipment or vehiFles are stored, In all installations the minimum Fombustible FlearanFes from operated or repaired Flammable vapors are heavy and travel barometriF draft Fontrol surfaFe or vent piping shall be 6´ along the Àoor and may be ignited by the heater¶s igniter or main (152mm) Vent piping passing through a Fombustible wall or burner Àames Fausing ¿re or explosion Some loFal Fodes permit Feiling must be a Fontinuous run (no joints) and retain 6´ operation of gas applianFes in suFh areas if they are installed 18´ (152mm) FlearanFe unless an approved reduFing thimble is used or more above the Àoor This may reduFe the risk if loFation in suFh an area Fannot be avoided A serviFe FlearanFe of 24´ (610mm) should be maintained from serviFeable parts, suFh as relief valves, bafÀes, thermostats, Do not install this water heater direFtly on a Farpeted Àoor A ¿re Fleanout openings or drain valves hazard may result Instead the water heater must be plaFed on a metal or wood panel extending beyond the full width and depth by at TABLE 5. INSTALLATION CLEARANCES least 3 inFhes in any direFtion If the heater is installed in a Farpeted alFove, the entire Àoor shall be Fovered by the panel Also, see the DRAINING requirements in MAINTENANCE SeFtion A B C D (RIGHT SIDE) (LEFTSIDE) (BACK) (CEILING) The heater shall be loFated or proteFted so it is not subjeFt to physiFal damage by a moving vehiFle BTP-139(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 21" (5334 Fm) Flammable items, pressurized Fontainers or any other potential BTP-199(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 21" (5334 Fm) ¿re hazardous artiFles must never be plaFed on or adjaFent to BTP-270(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 21" (5334 Fm) the heater Open Fontainers or Àammable material should not be BTP-370(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 24" (6096 Fm) stored or used in the same room with the heater 10 is to reduFe the standby heat loss enFountered with storage tank heaters The water heaters Fovered by this manual meet or exFeed the Energy PoliFy AFt standards with respeFt to insulation and standby heat loss requirements, making an insulation blanket unneFessary Should you Fhoose to apply an insulation blanket to this heater, you should follow these instruFtions See the Features and Components seFtion of this manual for identifiFation of Fomponents mentioned below Failure to follow these instruFtions Fan restriFt the air flow required for proper Fombustion, potentially resulting in fire, asphyxiation, serious personal injury or death ‡ DO NOT apply insulation to the top of the water heater, as this will interfere with safe operation of the draft Fontrol ‡ DO NOT Fover the gas Fontrol valve, thermostat or the Temperature-Pressure Relief Valve ‡ DO NOT allow insulation to Fome within 2´ (5 Fm) of the burners, to prevent bloFkage of Fombustion air Àow to the burners ‡ DO NOT Fover the instruFtion manual Keep it on the side of the water heater or nearby for future referenFe ‡ DO obtain new warning and instruFtion labels from the manufaFturer for plaFement on the blanket direFtly over the existing labels ‡ DO inspeFt the insulation blanket frequently to make Fertain it does not sag, thereby obstruFting Fombustion air Àow

HARD WATER

Where hard water Fonditions exist, water softening or the FIGURE 7. threshold type of water treatment is reFommended This will proteFt the dishwashers, Foffee urns, water heaters, water piping and other equipment INSULATION BLANKET See the MaintenanFe SeFtion in this manual for sediment and lime sFale removal proFedures

CIRCULATION PUMPS A FirFulating pump is used when a system requires a FirFulating Breathing Hazard - Carbon Monoxide Gas loop or there is a storage tank used in FonjunFtion with the water Do not obstruct water heater air intake heater See Water Piping Diagrams in this manual for installation with insulating blanket. loFation of FirFulating pumps Gas and carbon monoxide detectors See the CirFulation Pump Wiring Diagrams in this manual for are available. eleFtriFal hookup information Install in aFFordanFe with the Install water heater in accordance with Furrent edition of the National EleFtriFal Code, NFPA 70 or the the instruction manual. Canadian EleFtriFal Code, CSA C221 Breathing carbon monoxide can cause brain damage or All-bronze FirFulating pumps are reFommended for used with death. Always read and understand instruction manual. FommerFial water heaters Some FirFulating pumps are manufaFtured with sealed bearings Insulation blankets are available to the general publiF for and do not require further lubriFation Some FirFulating pumps external use on gas water heaters but are not neFessary must be periodiFally oiled Refer to the pump manufaFturer¶s with these produFts The purpose of an insulation blanket instruFtions for lubriFation requirements

11 CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION

FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK Breathing Hazard - Carbon Monoxide Gas OR CIRCULATING LOOP RETURN LINE NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT Under no circumstances should SHARE POWER WITH WATER HEATER AS THIS the input exceed the rate shown MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM on the water heater’s rating label. OPERATION. L1 HOT Overfiring could result in damage to the water heater and sooting. 120 VAC CIRC POWER PUMP Gas and carbon monoxide detectors MOTOR are available. L2 NEUTRAL Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual. FIGURE 8.

CIRCULATING PUMP WIRING DIAGRAM Installations above 2000 feet (610 meters) require DISHWASHER LOOP WITH TOGGLE SWITCH replaFement of burner orifiFes in aFFordanFe with Furrent DISHWASHER FIELD SUPPLIED TEMPERATURE edition of the National Fuel Gas Code (ANSI Z2231) For TOGGLE CONTROL INSTALLED IN THE Canadian installations Fonsult Canadian Installations Code SWITCH CIRCULATING LOOP RETURN LINE CAN/CSA B1491 Failure to replaFe orifiFes will result in

NOTE: USE SEPARATE 120 VAC POWER improper and ineffiFient operation of the water heater resulting SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH WATER HEATER AS THIS MAY in the produFtion of inFreased levels of Farbon monoxide gas CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION. in exFess of safe limits whiFh Fould result in serious personal L1 HOT injury or death You should FontaFt your gas supplier for any speFifiF Fhanges 120 VAC CIRC whiFh may be required in your area POWER PUMP MOTOR As the elevation above sea level is inFreased, there is less L2 NEUTRAL oxygen per FubiF foot of air Therefore, the heater input rate should be reduFed at high altitudes for satisfaFtory operation FIGURE 9. with the reduFed oxygen supply Failure to make t his reduFtion would result in an over firing of the heater Fausing sooting, poor Fombustion and/or unsatisfaFtory heater performanFe HIGH ALTITUDE INSTALLATIONS Ratings speFi¿ed by manufaFturers for most applianFes apply for elevations up to 2000 feet (610m) For elevations above 2000 feet (610), ratings must be reduFed at the rate of 4 Fire and Explosion Hazard for eaFh 1000 feet (305m) above sea level For example, if a heater is rated at 78,000 Btuh (229 Kwh) at sea level, to rate Under no circumstances should the the heater at 4000 feet (1219m), you subtraFt 4 (onFe for eaFh input exceed the rate shown on the thousand feet) x04 (4 input reduFtion) x 78,000 (original water heater’s rating label. rating) from the original rating Overfiring could result in fire or explosion. Therefore, to FalFulate the input rating at 4,000 feet (1219m) 4 x 04 x 78,000 12,480 Btuh (37 Kwh), 78,000 (229 Kwh) - Gas and carbon monoxide detectors are available. 12,480 (37 Kwh) 65,520 Btuh (192 Kwh) At 6000 feet (1829m) the ForreFt input rating should be 59,280 Btuh (174 Kwh)

12 INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS 4 When installing multiple water heaters in the same gas supply system it is reFommended that individual positive loFk-up gas Low pressure building gas supply systems are defined as those pressure regulators be installed at eaFh unit systems that Fannot under any FirFumstanFes exFeed 14´ WC (1/2 PSI Gauge) These systems do not require pressure POWER SUPPLY regulation Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on The water heaters Fovered in this manual require a 120 VAC, the water heater rating plate Readings should be taken with 1Ø (single phase), 60Hz, 15 amp power supply and must also all gas burning equipment off (statiF pressure) and with all gas be eleFtriFally grounded in aFFordanFe with loFal Fodes or, in the burning equipment running at maximum rate (dynamiF pressure) absenFe of loFal Fodes, with the National EleFtriFal Code, ANSI/ The gas supply pressure must be stable within 15´ WC NFPA 70 or the Canadian EleFtriFal Code, CSA C221 from statiF to dynamiF pressure to provide good performanFe Pressure drops that exFeed 15´ WC may Fause rough starting, WATER TEMPERATURE CONTROL AND MIXING VALVES noisy Fombustion or nuisanFe outages InFreases or spikes in statiF pressure during off FyFles may Fause failure to ignite or in severe Fases damage to applianFe gas valves If your Water temperature over 125°F (52°C) low pressure system does NOT meet these requirements, the can cause severe burns instantly installer is responsible for the ForreFtions resulting in severe injury or death. High Pressure building supply systems use pressures that Children, the elderly and the physically or mentally disabled are at exFeed 14´ WC (1/2 PSI Gauge) These systems must use ¿eld highest risk for scald injury. supplied regulators to lower the gas pressure to less than 14´ WC (1/2 PSI Gauge) Water heaters require gas regulators that Feel water before bathing or showering. are properly sized for the water heater input and deliver the rating Temperature limiting devices such as plate speFi¿ed pressures Gas supply systems where pressure mixing valves must be installed exFeeds 5 PSI often require multiple regulators to aFhieve desired when required by codes and to pressures Systems in exFess of 5 PSI building pressure should ensure safe temperatures at fixtures. be designed by gas delivery professionals for best performanFe Water heaters FonneFted to gas supply systems that exFeed 14´ WC (1/2 PSI Gauge) at any time must be equipped with a gas Water heated to a temperature whiFh will satisfy Flothes washing, dish supply regulator washing, and other sanitizing needs Fan sFald and Fause permanent injury upon FontaFt Short repeated heating FyFles Faused by small All models require a minimum gas supply pressure of 45" WC hot water uses Fan Fause temperatures at the point of use to exFeed for natural gas and propane gas The minimum supply pressure the water heater¶s temperature setting by up to 20ƒF (11ƒC) is measured while gas is Àowing (dynamiF pressure) The supply pressure should never fall below 45" WC for natural gas and Some people are more likely to be permanently injured by hot water propane gas The supply pressure should be measured with all than others These inFlude the elderly, Fhildren, the in¿rm and the gas ¿red applianFes FonneFted to the Fommon main ¿ring at full physiFally/mentally disabled Table 6 shows approximate time-to-burn FapaFity If the supply pressure drops more than 15´ WC as gas relationship for normal adult skin If anyone using hot water provided begins to Àow to the water heater then the supply gas system by the water heater being installed ¿ts into one of these groups or if inFluding the gas line and/or the gas regulator may be restriFted there is a loFal Fode or state law requiring a Fertain water temperature or undersized See Supply Gas Regulator seFtion and Gas at the point of use, then speFial preFautions must be taken Piping seFtion of this manual The gas valve on all models has In addition to using the lowest possible temperature setting that a maximum gas supply pressure limit of 14´ WC The maximum satis¿es the demand of the appliFation a Mixing Valve should be supply pressure is measured while gas is not Àowing (statiF installed at the water heater (see Figure 10) or at the hot water taps pressure) to further reduFe system water temperature SUPPLY GAS REGULATOR Mixing valves are available at plumbing supply stores Consult a Quali¿ed Installer or ServiFe AgenFy Follow mixing valve manufaFturer¶s The maximum allowable gas supply pressure for this water heater is instruFtions for installation of the valves 14" WC (348 kPa) Install a positive loFk-up gas pressure regulator TABLE 6. in the gas supply line if inlet gas pressure Fan exFeed 14" WC Time for Permanent Burns (348 kPa) at any time Regulators must be sized/used aFFording to Time for 1st Degree Burn Water Temperature ƒF 2nd & 3rd Degree manufaFturer¶s speFi¿Fations (Less Severe Burns) (Most Severe Burns) If a positive loFk-up regulator is required follow these instruFtions 110 (normal shower temp) 1 Positive loFk-up gas pressure regulators must be rated at or above 116 (pain threshold) the input Btu/hr rating of the water heater they supply 116 35 minutes 45 minutes 2 Positive loFk-up gas pressure regulator(s) should be installed no Floser than 3 equivalent feet (1 meter) and no farther than 8 equivalent 122 1 minute 5 minutes feet (24 meters) from water heater¶s inlet gas FonneFtion 131 5 seFonds 25 seFonds 3 After installing the positive loFk-up gas pressure regulator(s), an 140 2 seFonds 5 seFonds initial nominal supply pressure setting of 7" WC (174 kPa) while 149 1 seFond 2 seFonds water heater is operating is reFommended and will generally 154 instantaneous 1 seFond provide good water heater operation Some additional adjustment (US Government Memorandum, CPSC, Peter L Armstrong, Sept 15,1978) maybe required later to maintain a steady gas supply pressure

13 A properly sized thermal expansion tank must be installed on all Flosed systems to Fontrol the harmful effeFts of thermal HOT WATER expansion ContaFt a loFal plumbing serviFe teFhniFian to have a OUTLET thermal expansion tank installed 12” TO 15” See Water Line ConneFtions on page 19 and the Water Piping (30-38 cm) Diagrams beginning on page 35 TEMPERED WATER OUTLET TEMPERATURE-PRESSURE RELIEF VALVE

COLD CHECK WATER VALVE INLET MIXING Explosion Hazard CHECK VALVE VALVE Temperature-Pressure Relief Valve TO TANK must comply with ANSI Z21.22- INLET CSA 4.4 and ASME code.

Properly sized temperature- FIGURE 10. pressure relief valve must be installed in opening provided.

DISHWASHING MACHINES Can result in overheating and All dishwashing maFhines meeting the National Sanitation excessive tank pressure. Foundation requirements are designed to operate with water Can cause serious injury or death. flow pressures between 15 and 25 pounds per square inFh (103 kPa and 173 kPa) Flow pressures above 25 pounds per square inFh (173 kPa), or below 15 pounds per square This water heater is provided with a properly rated/sized and Ferti¿ed inFh (103 kPa), will result in improperly sanitized dishes Fombination Temperature-Pressure Relief Valve (T&P valve) by Where pressures are high, a water pressure reduFing or flow the manufaFturer The valve is Ferti¿ed by a nationally reFognized regulating Fontrol valve should be used in the 180ƒF (82ƒC) testing laboratory that maintains periodiF inspeFtion of produFtion line to the dishwashing maFhine and should be adjusted to of listed equipment of materials as meeting the requirements for deliver water pressure between these limits Pressure Relief Valves for Hot Water Supply Systems, ANSI Z2122 The National Sanitation Foundation also reFommends ‡ CSA 44, and the Fode requirements of ASME FirFulation of 180ƒF (82ƒC) water The FirFulation flow rate If replaFed, the new T&P valve must meet the requirements should be just enough to provide 180ƒF (82ƒC) water at the of loFal Fodes, but not less than a Fombination Temperature- point of take-off to the dishwashing maFhine Pressure Relief Valve rated/sized and Ferti¿ed as indiFated in Adjust flow by throttling a full port ball valve installed in the above paragraph The new valve must be marked with a the FirFulating line on the outlet side of the pump Never maximum set pressure not to exFeed the marked hydrostatiF throttle flow on the suFtion side of a pump See Water Piping working pressure of the water heater (150 psi 1,035 kPa) and Diagrams in this manual a disFharge FapaFity not less than the water heater Btu/hr or kW input rate as shown on the water heater¶s model rating label CLOSED WATER SYSTEMS NOTE In addition to the faFtory installed Temperature-Pressure Relief Valve on the water heater, eaFh remote storage tank that Water supply systems may, beFause of Fode requirements or may be installed and piped to a water heating applianFe must also suFh Fonditions as high line pressure, among others, have have its own properly sized, rated and approved Temperature- installed deviFes suFh as pressure reduFing valves, FheFk Pressure Relief Valve installed Call the toll free teFhniFal valves, and baFk flow preventers DeviFes suFh as these support phone number listed on the baFk Fover of this manual Fause the water system to be a Flosed system for teFhniFal assistanFe in sizing a Temperature-Pressure Relief Valve for remote storage tanks THERMAL EXPANSION For safe operation of the water heater, the Temperature-Pressure As water is heated, it expands (thermal expansion) In a Relief Valve must not be removed from its designated opening Flosed system the volume of water will grow when it is heated nor plugged The Temperature-Pressure Relief Valve must be As the volume of water grows there will be a Forresponding installed direFtly into the ¿tting of the water heater designed for inFrease in water pressure due to thermal expansion Thermal the pressure relief valve  Install disFharge piping so that any expansion Fan Fause premature tank failure (leakage) This disFharge will exit the pipe within 6 inFhes (152 Fm) above an type of failure is not Fovered under the limited warranty adequate Àoor drain, or external to the building In Fold Flimates Thermal expansion Fan also Fause intermittent Temperature- it is reFommended that it be terminated at an adequate drain Pressure Relief Valve operation water disFharged from the inside the building Be Fertain that no FontaFt is made with any valve due to exFessive pressure build up This Fondition is live eleFtriFal part The disFharge opening must not be bloFked not Fovered under the limited warranty The Temperature- or reduFed in size under any FirFumstanFes ExFessive length, Pressure Relief Valve is not intended for the Fonstant relief over 30 feet (914 m), or use of more than four elbows Fan Fause of thermal expansion restriFtion and reduFe the disFharge FapaFity of the valve

14 No valve or other obstruFtion is to be plaFed between the CONTAMINATED AIR Temperature-Pressure Relief Valve and the tank Do not FonneFt disFharge piping direFtly to the drain unless a 6´ (152 Fm) air gap is provided To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to disFharge water in adequate quantities should FirFumstanFes demand If Breathing Hazard - Carbon Monoxide Gas the disFharge pipe is not FonneFted to a drain or other suitable Install water heater in accordance with means, the water Àow may Fause property damage the Instruction Manual and NFPA 54 or CAN/CSA-B149.1. To avoid injury, combustion and ventilation CAUTION air must be taken from outdoors. Water Damage Hazard Do not place chemical vapor emitting products near water heater.  Temperature-Pressure Relief Valve discharge Breathing carbon monoxide can cause brain damage or pipe must terminate at adequate drain. death. Always read and understand instruction manual.

Corrosion of the Àue ways and vent system may oFFur if air for T&P Valve Discharge Pipe Requirements: Fombustion Fontains Fertain FhemiFal vapors SuFh Forrosion ‡ Shall not be smaller in size than the outlet pipe size of the may result in failure and risk of asphyxiation valve, or have any reduFing Fouplings or other restriFtions Combustion air that is Fontaminated Fan greatly diminish the life ‡ Shall not be plugged or bloFked span of the water heater and water heater Fomponents suFh as ‡ Shall not be exposed to freezing temperatures hot surfaFe igniters and burners Propellants of aerosol sprays, ‡ Shall be of material listed for hot water distribution beauty shop supplies, water softener FhemiFals and FhemiFals ‡ Shall be installed so as to allow Fomplete drainage of both used in dry Fleaning proFesses that are present in the Fombustion, the Temperature-Pressure Relief Valve and the disFharge ventilation or ambient air Fan Fause suFh damage pipe Do not store produFts of this sort near the water heater Air whiFh ‡ Must terminate a maximum of six inFhes above a Àoor is brought in FontaFt with the water heater should not Fontain any drain or external to the building In Fold Flimates, it is of these FhemiFals If neFessary, unFontaminated air should be reFommended that the disFharge pipe be terminated at an obtained from remote or outdoor sourFes The limited warranty adequate drain inside the building is voided when failure of water heater is due to a Forrosive ‡ Shall not have any valve or other obstruFtion between the atmosphere (See limited warranty for Fomplete terms and pressure relief valve and the drain Fonditions) AIR REQUIREMENTS

Burn hazard.

Hot water discharge. Breathing Hazard - Carbon Monoxide Gas Install water heater in accordance with Keep clear of Temperature- the Instruction Manual and NFPA 54 or Pressure Relief Valve CAN/CSA-B149.1. discharge outlet. To avoid injury, combustion and ventilation air must be taken from outdoors. Do not place chemical vapor emitting The Temperature-Pressure Relief Valve must be manually operated products near water heater. at least twiFe a year Caution should be taken to ensure that (1) no Breathing carbon monoxide can cause brain damage or one is in front of or around the outlet of the Temperature-Pressure death. Always read and understand instruction manual. Relief Valve disFharge line, and (2) the water manually disFharged will not Fause any bodily injury or property damage beFause For safe operation an adequate supply of fresh unFontaminated the water may be extremely hot If after manually operating the air for Fombustion and ventilation must be provided valve, it fails to Fompletely reset and Fontinues to release water, immediately Flose the Fold water inlet to the water heater, follow the An insuf¿Fient supply of air Fan Fause reFirFulation of Fombustion draining instruFtions in this manual, and replaFe the Temperature- produFts resulting in Fontamination that may be hazardous to Pressure Relief Valve with a properly rated/sized new one life SuFh a Fondition often will result in a yellow, luminous burner NOTE: The purpose of a Temperature-Pressure Relief Valve is to Àame, Fausing sooting of the Fombustion Fhamber, burners and prevent exFessive temperatures and pressures in the storage tank Àue tubes and Freates a risk of asphyxiation The T&P valve is not intended for the Fonstant relief of thermal Do not install the water heater in a Fon¿ned spaFe unless an expansion A properly sized thermal expansion tank must be adequate supply of air for Fombustion and ventilation is brought installed on all Flosed systems to Fontrol thermal expansion, see in to that spaFe using the methods desFribed in the Con¿ned Closed Water Systems and Thermal Expansion on page 14 SpaFe seFtion that follows If you do not understand these instruFtions or have any questions Never obstruFt the Àow of ventilation air If you have any doubts regarding the Temperature-Pressure Relief Valve Fall the toll or questions at all, Fall your gas supplier Failure to provide the free number listed on the baFk Fover of this manual for teFhniFal proper amount of Fombustion air Fan result in a ¿re or explosion assistanFe and Fause property damage, serious bodily injury or death 15 UNCONFINED SPACE DIRECT VENT APPLIANCES An UnFon¿ned SpaFe is one whose volume IS NOT LESS THAN ApplianFes installed in a DireFt Vent Fon¿guration that derive all 50 FubiF feet per 1,000 Btu/hr (48 FubiF meters per kW) of the air for Fombustion from the outdoor atmosphere through sealed total input rating of all applianFes installed in the spaFe Rooms intake air piping are not faFtored in the total applianFe input Btu/ FommuniFating direFtly with the spaFe, in whiFh the applianFes hr FalFulations used to determine the size of openings providing are installed, through openings not furnished with doors, are fresh air into Fon¿ned spaFes Fonsidered a part of the unFon¿ned spaFe EXHAUST FANS Makeup air requirements for the operation of exhaust fans, Where exhaust fans are installed, additional air shall be provided kitFhen ventilation systems, Flothes dryers and ¿replaFes shall to replaFe the exhausted air When an exhaust fan is installed also be Fonsidered in determining the adequaFy of a spaFe to in the same spaFe with a water heater, suf¿Fient openings to provide Fombustion, ventilation and dilution air provide fresh air must be provided that aFFommodate the requirements for all applianFes in the room and the exhaust fan UNUSUALLY TIGHT CONSTRUCTION Undersized openings will Fause air to be drawn into the room In unFon¿ned spaFes in buildings, in¿ltration may be adequate through the water heater¶s vent system Fausing poor Fombustion to provide air for Fombustion, ventilation and dilution of Àue Sooting, serious damage to the water heater and the risk of ¿re gases However, in buildings of unusually tight FonstruFtion (for or explosion may result It Fan also Freate a risk of asphyxiation example, weather stripping, heavily insulated, Faulked, vapor LOUVERS AND GRILLES barrier, etF) additional air must be provided using the methods desFribed in the Con¿ned SpaFe seFtion that follows The free areas of the fresh air openings in the instruFtions that follow do not take in to aFFount the presenFe of louvers, grilles or CONFINED SPACE sFreens in the openings The required size of openings for Fombustion, ventilation and A Con¿ned SpaFe is one whose volume is less than 50 FubiF dilution air shall be based on the ³net free area´ of eaFh opening feet per 1,000 Btu/hr (48 FubiF meters per kW) of the total input Where the free area through a design of louver or grille or sFreen rating of all applianFes installed in the spaFe is known, it shall be used in FalFulating the size of opening Openings must be installed to provide fresh air for Fombustion, required to provide the free area speFi¿ed Where the louver and ventilation and dilution in Fon¿ned spaFes The required size for grille design and free area are not known, it shall be assumed the openings is dependent on the method used to provide fresh that wood louvers will have 25 free area and metal louvers and air to the Fon¿ned spaFe and the total Btu/hr input rating of all grilles will have 75 free area Non motorized louvers and grilles applianFes installed in the spaFe shall be ¿xed in the open position

VENTING INSTALLATION

VENTING to faFe in direFtion needed The assembly must be ¿tted to the jaFket Fover suFh that it is plumb and level to the ground Fasten THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST the draft Fontrol assembly to the top Fover using sheet metal BE FOLLOWED TO AVOID CHOKED COMBUSTION OR sFrews at three loFations, or more, as required RECIRCULATION OF FLUE GASES SUCH CONDITIONS Dampers or other obstruFtions must not be installed between the CAUSE SOOTING OR RISKS OF FIRE AND ASPHY;IATION heater and the barometriF draft Fontrol assembly Heater must be proteFted from freezing downdrafts Do not adjust settings on gate Counterweight washers are faFtory Remove all soot or other obstruFtions from the Fhimney that will adjusted and should result in breeFhing pressure measurements retard a free draft at the Fombustion test hole (Figure 11) within the range shown Type B venting is reFommended with these heaters in Table 10 This water heater must be vented in FomplianFe with all loFal NOTE: A negative draft must be maintained in the vent piping Fodes, the Furrent revision of the National Fuel Gas Code When installed, the damper gate must pivot freely in the ring (ANSI-Z2231) and with the Category I Venting Tables guides This gate will automatiFally adjust to regulate the Fhimney draft imposed on the heater If any part of the vent system is exposed to ambient temperatures below 40ƒF (44ƒC) it must be insulated to prevent Fondensation ‡ Do not FonneFt the heater to a Fommon vent or Fhimney with solid fuel burning equipment This praFtiFe is prohibited by many loFal building Fodes as is the praFtiFe of venting gas ¿red equipment to the duFt work of ventilation systems ‡ Where a separate vent FonneFtion is not available and the vent pipe from the heater must be FonneFted to a Fommon vent with an oil burning furnaFe, the vent pipe should enter the smaller Fommon vent or Fhimney at a point above the large vent pipe

BAROMETRIC DRAFT CONTROL ASSEMBLY

A double-aFting barometriF draft Fontrol assembly is provided with eaFh unit The draft Fontrol assembly must be installed without alteration This assembly is faFtory adjusted for horizontal PROPER DRAFT CONTROLLER AND appliFation only and must be attaFhed to the heater as shown in VENT PIPE INSTALLATION Figure 11 The outlet of the draft Fontrol assembly may be rotated FIGURE 11.

16 FRESH AIR OPENINGS FOR CONFINED SPACES Alternatively a single permanent opening, FommenFing within 12 inFhes (300 mm) of the top of the enFlosure, The following instruFtions shall be used to FalFulate the size, shall be provided See Figure 12 The water heater shall number and plaFement of openings providing fresh air for have FlearanFes of at least 1 inFh (25 mm) from the sides Fombustion, ventilation and dilution in Fon¿ned spaFes The and baFk and 6 inFhes (l50 mm) from the front of the illustrations shown in this seFtion of the manual are a referenFe water heater The opening shall direFtly FommuniFate for the openings that provide fresh air into Fon¿ned spaFes with the outdoors or shall FommuniFate through a vertiFal only DO NOT refer to these illustrations for the purpose of vent or horizontal duFt to the outdoors or spaFes that freely installation See Venting Installation on page 16 for Fomplete FommuniFate with the outdoors and shall have a minimum venting installation instruFtions free area of the following

2 OUTDOOR AIR THROUGH TWO OPENINGS 1 1 square inFh per 3000 Btu/hr (733 mm per kW) of the total input rating of all applianFes loFated in the enFlosure, and

2 Not less than the sum of the areas of all vent FonneFtors in the spaFe

OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS

FIGURE 12.

The Fon¿ned spaFe shall be provided with two permanent openings, one FommenFing within 12 inFhes (300 mm) of the top and one FommenFing within 12 inFhes (300 mm) of the bottom of the enFlosure The openings shall FommuniFate direFtly with the outdoors See Figure 12 EaFh opening shall have a minimum free area of 1 square inFh 2 per 4,000 Btu/hr (550 mm per kW) of the aggregate input rating FIGURE 14. of all applianFes installed in the enFlosure EaFh opening shall not be less than 100 square inFhes (645 Fm2) The Fonfined spaFe shall be provided with two permanent OUTDOOR AIR THROUGH ONE OPENING horizontal duFts, one FommenFing within 12 inFhes (300 mm) of the top and one FommenFing within 12 inFhes (300 mm) of the bottom of the enFlosure The horizontal duFts shall FommuniFate direFtly with the outdoors See Figure 14

EaFh duFt opening shall have a minimum free area of 1 square inFh per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of all applianFes installed in the enFlosure

When duFts are used, they shall be of the same Fross seFtional area as the free area of the openings to whiFh they FonneFt The minimum dimension of reFtangular air duFts shall be not less than 3 inFhes

FIGURE 13.

17 OUTDOOR AIR THROUGH TWO VERTICAL DUCTS When duFts are used, they shall be of the same Fross seFtional area as the free area of the openings to whiFh they FonneFt The illustrations shown in this seFtion of the manual are a referenFe for the openings that provide fresh air into Fon¿ned The minimum dimension of reFtangular air duFts shall be not less spaFes only than 3" (762 mm) DO NOT refer to these illustrations for the purpose of vent AIR FROM OTHER INDOOR SPACES installation See Venting Installation on page 14 for Fomplete venting installation instruFtions

FIGURE 16. The Fon¿ned spaFe shall be provided with two permanent FIGURE 15. openings, one FommenFing within 12 inFhes (300 mm) of the top and one FommenFing within 12 inFhes (300 mm) of the bottom of The Fon¿ned spaFe shall be provided with two permanent vertiFal the enFlosure See Figure 16 duFts, one FommenFing within 12 inFhes (300 mm) of the top and EaFh opening shall FommuniFate direFtly with an additional one FommenFing within 12 inFhes (300 mm) of the bottom of the room(s) of suf¿Fient volume so that the Fombined volume of all enFlosure The vertiFal duFts shall FommuniFate direFtly with the spaFes meets the Friteria for an UnFon¿ned SpaFe outdoors See Figure 15 EaFh opening shall have a minimum free area of 1 square inFh EaFh duFt opening shall have a minimum free area of 1 square per 1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating inFh per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input of all applianFes installed in the enFlosure EaFh opening shall rating of all applianFes installed in the enFlosure not be less than 100 square inFhes (645 Fm2)

18 VENT CONNECTION Where an existing Fhimney or vent is to be used, be sure that the Fhimney or vent has adequate FapaFity for the Vent FonneFtions must be made to an adequate staFk number and sizes of gas applianFes being vented through or Fhimney Refer to the National Fuel Gas Code (Furrent it InspeFt the Fhimney or vent and remove all soot or other edition) or to the vent pipe manufaFturer¶s gas vent and obstruFtions whiFh will retard free draft Fhimney sizing table to properly design and size the venting system Refer to Table 7 for the vent pipe size required for Vent FonneFtor s making hor izont al r uns must have a minimum installation to the barometriF draft Fontrol assembly outlet upward slope toward the Fhimney or vent of 1/4 inFh per foot TABLE 7. BAROMETRIC DRAFT CONTROL Vent FonneFtor length should be kept as short as possible ASSEMBLY OUTLET SIZE Be sure that the vent pipe does not extend beyond the inside wall of a Fhimney DRAFT CONTROL MODEL OUTLET DIAMETER In venting systems where a Fontinuous or intermittent BTP-139/A 6´ baFk (positive) draft is found to exist, the Fause must BTP-199/A 6´ be determined and ForreFted In some Fases, a speFial BTP-270/A 8´ vent Fap may be required Do not install this unit on the positive draft side of a venting system being served by a BTP-370/A 8´ power exhauster

WATER HEATER INSTALLATION

WATER LINE CONNECTIONS WATER PIPING DIAGRAMS This manual provides detailed water piping diagrams for typiFal The water piping installation must Fonform to these instruFtions methods of appliFation for the water heaters, see Water Piping and to all loFal Fode authority having jurisdiFtion Good praFtiFe Diagrams beginning on page 35 requires that all heavy piping be supported The water heater may be installed by itself, or with a separate Read and observe all requirements in the following seFtions storage tank When used with a separate storage tank, the before installation of the water piping begins FirFulation may be either by gravity or by means of FirFulating 1 Water Temperature Control and Mixing Valves on page 13 pump Adjust Àow by throttling a full port ball valve installed in the FirFulating line on the outlet side of the pump Never throttle Àow 2 Dishwashing MaFhines on page 14 on the suFtion side of a pump See the Water Piping Diagrams 3 Temperature-Pressure Relief Valve on page 14-15 beginning on page 35 4 Closed Systems and Thermal Expansion on page 14 NOTE: In addition to the faFtory installed Temperature-Pressure 5 For multiple water heater installations see Water Piping Relief Valve (T&P valve) on the water heater, eaFh remote Diagrams beginning on page 35 storage tank that may be installed and piped to a water heating applianFe must also have its own properly sized, rated and WATER (POTABLE) HEATING AND SPACE HEATING approved Temperature-Pressure Relief Valve installed Call the toll free teFhniFal support phone number listed on the 1 All piping Fomponents FonneFted to this unit for spaFe baFk Fover of this manual for further assistanFe in sizing a T&P heating appliFations shall be suitable for use with potable valve for remote storage tanks water 2 ToxiF FhemiFals, suFh as those used for boiler treatment, T&P VALVE DISCHARGE PIPE shall NEVER be introduFed into this system 3 This unit may NEVER be FonneFted to any existing heating system or Fomponent(s) previously used with a non-potable water heating applianFe Explosion Hazard 4 When the system requires water for spaFe heating at temperatures higher than required for domestiF water Temperature-Pressure Relief Valve purposes, a tempering valve must be installed Please must comply with ANSI Z21.22- refer to installation diagrams beginning on page 35 of this CSA 4.4 and ASME code. manual for suggested piping arrangements 5 These water heaters Fannot be used in spaFe heating Properly sized temperature- appliFations only pressure relief valve must be installed in opening provided. THERMOMETERS (NOT SUPPLIED) Can result in overheating and Thermometers should be obtained and ¿eld installed as shown excessive tank pressure. in the installation diagrams Thermometers are installed in the system as a means of Can cause serious injury or death. deteFting the temperature of the outlet water supply

19 This water heater is provided with a properly rated/sized and TUBE INLET INSTALLATION Ferti¿ed Fombination temperature - pressure (T&P) relief valve by the manufaFturer See Temperature-Pressure Relief Valve on pages 14-15 for information on replaFement and other requirements CAUTION Water Damage Hazard

 Temperature-Pressure Relief Valve discharge FIGURE 17. pipe must terminate at adequate drain. BURNER INSTALLATION Remove the faFtory-installed insulation Fovering the Fombustion Install a disFharge pipe between the T&P valve disFharge Fhamber opening (A utility knife is useful for Futting out the opening and a suitable Àoor drain Do not FonneFt disFharge insulation) Cut the insulation baFk even with the jaFket opening piping direFtly to the drain unless a 6´ (152 Fm) air gap is Install the Àange gasket (whiFh is usually taped to the heater jaFket) provided To prevent bodily injury, hazard to life, or property over the three bolts protruding from the tank at the Fombustion damage, the relief valve must be allowed to disFharge water Fhamber opening in adequate quantities should FirFumstanFes demand If the Remove hardware (3 hex nuts, 3 Àat washers, and 3 loFk washers) disFharge pipe is not FonneFted to a drain or other suitable from the shipping bag attaFhed to the heater¶s eleFtriFal Fonduit means, the water Àow may Fause property damage Begin assembling the power burner to the tank by plaFing the power T&P VALVE DISCHARGE PIPE REQUIREMENTS: burner nozzle in the Fombustion Fhamber opening Slide the nozzle into the tank and rotate the mounting Àange to engage the mounting ‡ Shall not be smaller in size than the outlet pipe size of the bolts, refer to Figure 18 Then, plaFe the Àat washers followed by valve, or have any reduFing Fouplings or other restriFtions the loFk washers, and ¿nally the hex nuts on the mounting bolts ‡ Shall not be plugged or bloFked Hand tighten the nuts Then gradually tighten eaFh nut alternating between the 3 mounting bolts Do not over tighten as damage to ‡ Shall not be exposed to freezing temperatures the Àange gasket or to the tank may result Refer to Figure 18 ‡ Shall be of material listed for hot water distribution ‡ Shall be installed so as to allow Fomplete drainage of both Temperature-Pressure Relief Valve and the disFharge pipe ‡ Must terminate a maximum of six inFhes above a Àoor drain or external to the building In Fold Flimates, it is reFommended that the disFharge pipe be terminated at an adequate drain inside the building ‡ Shall not have any valve or other obstruFtion between the relief valve and the drain

INSTALLATION DIAGRAMS - TOP INLET/OUTLET USAGE Use of the top inlet water FonneFtion requires an inlet dip tube (refer to Figure 17) The tube is supplied in the heater Follow Faution labels if applying heat to this ¿tting Do not allow pipe POWER BURNER INSTALLATION dope to FontaFt the plastiF tube during installation FIGURE 18.

20 HEATER WIRING

All eleFtriFal work must be installed in aFFordanFe with the Furrent edition of the National EleFtriFal Code ANSI/NFPA No 70 or Canadian EleFtriFal Code CSA C221 and must Fonform to all loFal Fode authority having jurisdiFtion AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION If any of the original wire as supplied with the water heater must be replaFed, use only type 105ƒC thermoplastiF or equivalent 2500C type F must be used for the Àame sensor and igniter leads The Fontrols of this water heater are polarity sensitive Be Fertain to properly wire the hot and neutral FonneFtions

FIGURE 19.

21 GAS PIPING Apply joint Fompounds (pipe dope) sparingly and only to the male threads of pipe joints Do not apply Fompounds to the ¿rst two threads ContaFt your loFal gas serviFe Fompany to ensure that adequate Use Fompounds resistant to the aFtion of lique¿ed petroleum gases gas serviFe is available and to review appliFable installation Fodes GAS METER SIZE – NATURAL GASES ONLY for your area Be sure the gas meter has suf¿Fient FapaFity to supply the full rated Size the main gas line in aFFordanFe with Table 8 The ¿gures shown gas input of the water heater as well as the requirements of all other are for straight lengths of pipe at 05 in WC pressure drop, whiFh is gas ¿red equipment supplied by the meter If gas meter is too small, ask Fonsidered normal for low pressure systems Note Fittings suFh as the gas Fompany to install a larger meter having adequate FapaFity elbows, tees and line regulators will add to the pipe pressure drop Also refer to the latest version of the National Fuel Gas Code GAS PIPING AND SEDIMENT TRAP INSTALLATION SFhedule 40 Steel or Wrought Iron Pipe is the preferred material for the gas line of this water heater It is imperative to follow the sizing reFommendations in the latest version of the National Fuel Gas Code if Corrugated Stainless Steel Tubing (CSST) is used as the gas line for this water heater The heater is not intended for operation at higher than 140" WC- natural gas, (1/2 pound per square inFh gage) supply gas pressure Exposure to higher supply pressure may Fause damage to the gas valve whiFh Fould result in ¿re or explosion If overpressure has oFFurred suFh as through improper testing of gas lines or emergenFy malfunFtion of the supply system, the gas valve must be FheFked for safe operation Make sure that the outside vents on the supply regulators and the safety vent valves are proteFted against bloFkage These are parts of the gas supply system, not the heater Vent bloFkage may oFFur during iFe storms FIGURE 20. TABLE 8. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR GAS LINE LEAK TESTING (Based upon a Pressure Drop of 05 inFh Water Column and 06 SpeFi¿F Gravity Gas and max gas pressure of 5 psig)

LENGTH NOMINAL IRON PIPE SIZE (INCHES) IN FEET 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 Fire and Explosion Hazard 10 175 360 680 1,400 2,100 3,950 6,300 11,000 23,000 Use joint compound or Teflon tape 20 120 250 465 950 1,460 2,750 4,350 7,700 15,800 compatible with propane gas. 30 97 200 375 770 1,180 2,200 3,520 6250 12800 Leak test before placing the water 40 82 170 320 660 990 1,900 3,000 5,300 10,900 heater in operation. 50 73 151 285 580 900 1,680 2,650 4,750 9,700 Disconnect gas piping and main gas shutoff valve before leak testing. 60 66 138 260 530 810 1,520 2,400 4,300 8,800 Install sediment trap in accordance 70 61 125 240 490 750 1,400 2,250 3,900 8,100 with NFPA 54. 80 57 118 220 460 690 1,300 2,050 3,700 7,500 Any time work is done on the gas supply system perform a leak test 90 53 110 205 430 650 1,220 1,950 3,450 7,200 to avoid the possibility of ¿re or explosion 100 50 103 195 400 620 1,150 1,850 3,250 6,700 1 For test pressures exFeeding 1/2 psi (345 kPa) disFonneFt the 125 44 93 175 360 550 1,020 1,650 2,950 6,000 water heater and its Main Gas Shutoff Valve from the gas supply 150 40 84 160 325 500 950 1,500 2,650 5,500 piping system during testing, see Figure 20 The gas supply line 175 37 77 145 300 460 850 1,370 2,450 5,000 must be Fapped when disFonneFted from the water heater 200 35 72 135 280 430 800 1,280 2,280 4,600 2 For test pressures of 1/2 psi (345 kpa) or less, the water heater need not be disFonneFted, but must be isolated from the supply It is important to guard against gas valve fouling from Fontaminants in gas line by Flosing the Main Gas Shutoff Valve during testing gas ways SuFh fouling may Fause improper operation, ¿re or explosion 3 Coat all supply gas line joints and FonneFtions upstream of the If Fopper supply lines are used they must be internally tinned and water heater with a non-Forrosive soap and water solution to Ferti¿ed for gas serviFe Before attaFhing the gas line, be sure that test for leaks Bubbles indiFate a gas leak Do not use matFhes, Fandles, Àame or other sourFes of ignition for this purpose all gas pipe is Flean on the inside 4 Repair any leaks before plaFing the water heater in operation To trap any dirt or foreign material in the gas supply line, a sediment trap must be inForporated in the piping (see Figure 20) The sediment trap must be readily aFFessible and not subjeFt to freezing Fonditions PURGING Install in aFFordanFe with reFommendations of serving gas suppliers Gas line purging is required with new piping or systems in whiFh air Refer to the latest version of the National Fuel Gas Code has entered To prevent damage, Fare must be taken not to apply too muFh torque Purging should be performed per the Furrent edition of NFPA 54 the when attaFhing gas supply pipe to gas valve inlet National Fuel Gas Code

22 START-UP AND OPERATION

‡ AttaFh a gas pressure gauge or manometer to upstream side of main gas FoFk and a gas pressure gauge or manometer to the manifold pressure tapping Fire or Explosion Hazard ‡ CheFk voltage at disFonneFt switFh to make Fertain that it matFhes that shown on the burner label ‡ Apply a few drops of No 20 SAE non-detergent oil to the Gas line purging is required with new piping or systems in motor bearings which air has entered. ‡ Drill max 5/16" hole in breeFhing as Flose as possible to Àue To avoid risk of fire or explosion purge discharge must not FonneFtion on heater to install staFk thermometer and enter into confined areas or spaces where ignition can occur. Fombustion analyzing equipment (See Figure 11) ‡ You are now ready to begin the burner start up proFedure The area must be well ventilated and all sources of ignition must be deactivated or removed. Installation and start up of this water heater requires abilities and skills equivalent to that of a liFensed tradesman in the ¿eld involved, see Quali¿Fations on page 6

Read instruction manual before Do not plaFe the water heater in operation if any part has been under installing, using or servicing water Immediately Fall a quali¿ed serviFe teFhniFian to inspeFt the water heater. water heater and to replaFe any part of the Fontrol system and any gas Fontrol whiFh has been under water Light the water heater in aFFordanFe with the Lighting and Operation PRIOR TO START UP InstruFtion label on the water heater and in this manual on pages 25 Before attempting start up, thoroughly study and know the exaFt This produFt requires a formal Start-Up by an authorized serviFe/ SequenFe Of Operation See written SequenFe Of Operation on start-up provider that has been approved by the manufaFturer for page 23 and SequenFe Of Operation Flow Chart on page 24 this speFi¿F produFt Call 1-800-527-1953 to loFate the nearest authorized start-up provider and arrange a faFtory start-up Please Be Fertain that the water heater is full of water, that air is purged from provide as muFh notiFe as possible, preferably 2 weeks Please the gas and water lines and that there are no leaks in the gas and have the model and serial number ready when you Fall water lines Ensure all inlet water valves are open This start-up is required to aFtivate the warranty and ensure safe, FILLING THE WATER HEATER ef¿Fient operation Follow these steps to ¿ll the water heater prior to start up Warranty on this produFt is limited and Fould be void in the event the unit is not installed per the instruFtions in this manual and/or not 1 Close the heater drain valve started up by an authorized faFtory trained serviFe/start-up provider 2 Open a nearby hot water fauFet to permit air in system to esFape The following test equipment should be on hand (all test equipment 3 Fully open the Fold water inlet valve allowing the piping and must be aFFlimated to ambient temperature before Falibration and use) water heater to ¿ll with water 1 CO2 indiFator (Fyrite or similar) or O2 analyzer 4 Close hot water fauFet opened in Step 2 as water starts to Àow 2 CO indiFator (Monoxor or similar) Read SEQUENCE OF OPERATION seFtion of this manual prior 3 StaFk thermometer to lighting and operating this water heater 4 Draft Gauge or inFlined manometer 5 Two U-tube manometers or Falibrated 0-10" and 0-35" wF With above Fonditions satis¿ed, start the unit in aFFordanFe with the pressure gauges instruFtions on the operating label attaFhed to the heater For your 6 Combination volt/ammeter FonvenienFe a Fopy of the instruFtions are shown on pages 25

SEQUENCE OF OPERATION

The following information will desFribe the SequenFe of Operation 7 If the Ignition Control does not sense the Àame during the for this water heater 4 seFond ignition trial period, the Ignition Control shuts the Gas Valve and turns off the Spark Igniter The Fontrol is loFked out, 1 SwitFh power on to unit the power to the unit must be FyFled to restart the Ignition 2 Thermostat Falls for heat Control 3 On a Fall for heat, 24V is applied to motor start relay and air 8 If the ignition Fontrol senses Àame during the 4 seFonds trial for switFh OnFe the fan motor reaFhes operating rpm Fombustion ignition period, the gas Fontrol remains open and the burner on air pressure is sensed by the air proving switFh and Floses the until the Fall for heat ends switFh FontaFts energizing the S89 ignition module The ignition 9 The Ignition Control monitors the Flame Sensor during the module performs diagnostiF self FheFk on system Fomponents heating FyFle If the flame signal is lost, the Ignition Control shuts 4 The Ignition Control begins the trial for ignition after 30 seFonds the Main Gas Valve and re-starts the ignition proFess at prepurge is Fompleted step 4 5 The Ignition Control turns on the Spark Igniter and opens the Pilot 10 OnFe the unit is satis¿ed, the Ignition Control will shut off the Gas Valve Main Gas Valve and the unit will be in standby mode until another Fall for heat is initiated by the thermostat 6 The Ignition Control monitors the Flame Sensor during the ignition trial period See the Àow Fhart on page 26 for more information

23 SEQUENCE OF OPERATION FLOW CHART DesFription of this Àow Fhart Fan be found in the ³SEQUENCE OF OPERATION´ seFtion found on page 25

START

THERMOSTAT CALLS FOR HEAT.

POWER INTERUPTION. SYSTEM SHUTS OFF. RESTARTS SAFE WHEN POWER IS RESTORED. START CHECK SAFE START CHECK IF FLAME SIMULATION CONDITION IS PRESENT, SYSTEM WILL NOT START.

VALVE-ON DELAY VALVE-ON DELAY (S89F ONLY) 30S PREPURGE COMBUSTION AIR BLOWER STARTS.

TRIAL FOR SPARK GENERATOR IGNITION POWERED, IGNITION IF NO SPARK, S89 LOCKS OUT BEGINS AND GAS AND SHUTS DOWN SYSTEM. CONTROL OPENS. MUST BE RESET.

BURNER LIGHTS. IF FLAME CURRENT IS ABSENT, IGNITION STOPS WEAK, OR UNSTEADY, S89 AND FLAME LOCKS OUT AND SHUTS DOWN CURRENT IS SYSTEM. MUST BE RESET. SENSED.

BURNER OPERATION BURNER RUNS IF FLAME IS LOST, S89 CLOSES S89 MONITORS GAS CONTROL, THEN RESTARTS FLAME CURRENT. SAFE START CHECK AND TRIAL FOR IGNITION.

THERMOSTAT SATISFIED. GAS CONTROL CLOSES, BURNER GOES OFF. END

FLOWCHART 1.

24 LIGHTING & OPERATION LABEL

FIGURE 21. LABEL FOR NATURAL AND LP GAS MODELS 25 ADJUSTMENTS time required for the heater to Fonsume 5 FubiF feet of gas The aFtual rate may then be estimated by using the formula below 1 CheFk gas line pressure and manifold pressure (table 10) and adjust as required (3600/T) x H Btuh

2 CheFk barometriF damper for proper operation Parts must T Time in seFonds to burn one FubiF foot of gas move freely 3 Allow the unit to operate for 15 minutes Drain hot water from H Btu¶s per FubiF foot of gas the heater or storage tank to Fontinue main burner operation Btuh AFtual heater input 4 Determine heat input rate (see CHECKING THE INPUT seFtion below) Example

CHECKING VENTING T 151 seFonds

The following steps shall be followed with eaFh applianFe H 1050 Btu FonneFted to the venting system plaFed in operation, while any other applianFes FonneFted to the venting system are Btuh " not in operation (3600/151) x 1050 250,000 1 Seal any unused openings in the venting system 2 InspeFt the venting system for proper size and horizontal pitFh, as required in the National Fuel Gas Code, ANSI The input may be adjusted by adjusting the pressure regulator Z2231or the CAN/CGA B149 Installation Codes and Remove the top Fap to expose the adjustment sFrew Turning these instruFtions Determine that there is no bloFkage or the sFrew in inFreases the gas pressure and baFking the restriFtion, leakage, Forrosion and other defiFienFies whiFh sFrew out deFreases the pressure Do not turn the adjusting Fould Fause an unsafe Fondition sFrew in past the point where no further inFrease in pressure is noted 3 So far as is praFtiFal, Flose all building doors and windows and all doors between the spaFe in whiFh the water The manifold pressure is measured at the manifold pressure heater(s) FonneFted to the venting system are loFated and tap, see figure 7, and should be used as a referenFe point other spaFes of the building Turn on all applianFes not for making pressure regulator adjustments Table 6 gives the FonneFted to the venting system Turn on all exhaust fans, design manifold pressures for eaFh model InFrease or reduFe suFh as range hoods and bathroom exhausts, so they shall the pressure as required to obtain the rated input operate at maximum speed Close fireplaFe dampers If an aFFeptable rate Fannot be aFhieved by adjusting the 4 Follow the lighting instruFtion PlaFe the water heater in pressure regulator (manifold pressure), first FheFk to be operation Adjust thermostat so water heater shall operate Fertain that the gas supply pressure to the unit is adequate Fontinuously If the supply pressure is inadequate, a different burner orifiFe 5 After it has been determined that eaFh applianFe FonneFted may be required Obtain from the utility the heating value and to the venting system properly vents when tested as outlined speFifiF gravity of the gas at the site Provide this information above, return doors, windows, exhaust fans, fireplaFe and the altitude of the site to obtain a larger orifiFe size dampers and any other gas burning applianFe to their UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT previous Fonditions of use EXCEED THE INPUT SHOWN ON THE HEATER MODEL AND 6 If improper venting is observed during any of the above RATING PLATE OVERFIRING COULD RESULT IN DAMAGE tests, the venting system must be ForreFted OR SOOTING OF THE HEATER FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR TABLE 9. CONTAMINATION AND UNSAFE CONDITIONS APPROXIMATE TIME REQUIRED TO CONSUME ‡ If the baFk draft Fannot be ForreFted by the normal method 1 CU. FT. OF GAS AT FULL CAPACITY or if a suitable draft Fannot be obtained, a blower type flue gas exhauster must be employed to assure proper venting INPUT BTUH TIMES TIMES and ForreFt Fombustion RATE INPUT PER (for Natural (for LP gas (BTUH) CU. FT. gas in Sec.) in Sec.) CHECKING THE INPUT 1050 BTP-139 139000 27 2647 2500 For installation loFations with elevations above 2000 feet, refer 1050 to HIGH ALTITUDE INSTALLATIONS seFtion of this manual BTP-199 199000 190452 for input reduFtion proFedure 2500 1050 The input rate Fan be estimated by timing the meter, if no other BTP-270 270000 140333 applianFes are operating 2500 1050 With a stopwatFh, or a wristwatFh, whiFh Fan display the time BTP-370 370000 102 243 in seFonds, read the gas meter and measure the amount of 2500

26 SETTING BURNER OPERATION TABLE 10. NOMINAL START-UP SPECIFICATIONS Make Fombustion measurements and Forresponding air BTP BTP BTP BTP MODEL 139/A 199/A 270/A 370/A shutter adjustments per table 10 Combustion results from Max Gas Line Press(WC) Nat Gas - 105´ WC/Prop Gas -130´ table 10 are for natural gas models Manifold Press (WC) Natural Gas 35353535 ‡ ProFeed with CO2 test of the Àue gases with an Orsat or Propane Gas 35353535 Ori¿Fe other similar Fombustion test equipment If the CO2 Fontent Natural Gas 024 0308 0386 0532 is within range (see table 6) no adjustment of the air shutter Propane Gas 0209 0257 0302 0368 is required Flue gas temperature and CO2 measurements Air Shutter Setting No should be repeated 3 times to ensure aFFurate readings Natural Gas 25575 4 3 Propane Gas 45104 85 ‡ CheFk the Àue gas temperature ahead of the barometriF CO 92 98 75 80 damper See table 10 (net temp gross temp ambient temp) CO Parts Per Million <200 <200 <200 <200 Gross StaFk Temp (ƒF) 305 338 405 488 BreeFhing Press(inFhes WC) Ranges from - 0.02 to - 0.07 Inches Water Column ‡ CheFk breeFhing pressure and the barometriF damper Fontrol to make sure it operates freely and there is no disFharge of Àue produFts into the room

‡ CheFk main burner operation by FyFling on and off the thermostat dial several times Wait 1 minute between FyFles for regulators and sequenFing to reset

When all adjustments are satisfaFtory

‡ Fill in part no 196793 ³Start-up´ form

‡ Adjust thermostat temperature dial to deliver desired water temperature at point of use ‡ For subsequent normal starting and shutoff proFedure, see LIGHTING and OPERATION LABEL on page 25 FIGURE 22.

27 MAINTENANCE

VENTING SYSTEM AND BAROMETRIC DRAFT CONTROL heater where the thermostat senses the drop in water temperature and aFtivates main burner operation of the water heater The heater is equipped with a double aFting barometriF draft Fontrol This Fontrol assembly is faFtory adjusted to automatiFally If the storage tank temperature Fontrol is out of Falibration, replaFe regulate the Fhimney draft imposed on the unit The damper gate with new Fontrol must pivot freely in the ring guides See Figure 23 SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE Water heater TEMPERATURE-PRESSURE RELIEF VALVE TEST

Burn hazard

Hot water disFharge

BAROMETRIC DRAFT CONTROL Keep Flear of Temperature- FIGURE 23. Pressure Relief Valve Examine the venting system every six months for obstruFtions disFharge outlet and/or deterioration of the vent piping

Remove all soot or other obstruFtions from Fhimney whiFh will It is reFommended that the Temperature-Pressure Relief Valve should retard free draft be FheFked to ensure that it is in operating Fondition every 6 months GENERAL When FheFking the Temperature-Pressure Relief Valve operation, make sure that (1) no one is in front of or around outlet of Temperature- Water heater maintenanFe inFludes periodiF tank Àushing and Pressure Relief Valve disFharge line, and (2) that water disFharge Fleaning, and removal of lime sFale The power burner should be will not Fause any property damage, as water may be extremely hot inspeFted and adjusted to maintain proper Fombustion Refer to Use Fare when operating valve as valve may be hot Table 10 A periodiF inspeFtion of the venting system and barometriF To FheFk the pressure relief valve, lift lever at the end of valve several damper should be made Where used, the water heating system times, see Figure 24 The valve should seat properly and operate freely FirFulating pump should be oiled per manufaFturer s instruFtions If after manually operating the valve, it fails to Fompletely reset and Following are the instruFtions for performing some of the Fontinues to release water, immediately Flose the Fold water inlet to reFommended maintenanFe Power burner inspeFtion and the water heater and drain the water heater, see Draining And Flushing adjustment should be performed by a Fompetent teFhniFian on page 32 ReplaFe the Temperature-Pressure Relief TABLE 11. Valve with a properly rated/sized new one, see Temperature-Pressure RECOMMENDED MAINTENANCE SCHEDULE Relief Valve on pages 12-13 for instruFtions on replaFement FOR THE BTP HEATER

COMPONENTS OPERATION INTERNAL REQUIRED Flushing Monthly Sediments Semi-Annually Tank Removal Lime SFale Un»l_ime As Required Removal Delimer Relief Valve InspeFt Semi-Annually CirFulating Pump SAE No 20 and Power Oiling Quarterly Non-Detergent Burner Motor(1) Motor Oil FIGURE 24. Power Burner Combustion Test InspeFtion and Ignition Semi-Annually Kit and Test If the Temperature-Pressure Relief Valve on water heater weeps and Adjustment DeviFe (2) SpeFi¿Fations or disFharges periodiFally, this may be due to thermal expansion Main Burner InspeFt Semi-Annually NOTE ExFessive water pressure is the most Fommon Fause of Vent System and Temperature-Pressure Relief Valve leakage ExFessive water system BarometriF InspeFt Semi-Annually Draft Gauge pressure is most often Faused by "thermal expansion" in a "Flosed Damper system" See Closed Water Systems and Thermal Expansion on Anode(s) InspeFt Annually page 12 The Temperature-Pressure Relief Valve is not intended for the Fonstant relief of thermal expansion REMOTE STORAGE TANK TEMPERATURE CONTROL Temperature-Pressure Relief Valve leakage due to pressure build Water temperature in remote storage tank (if used) is Fontrolled by the up in a Flosed system that does not have a thermal expansion storage tank temperature Fontrol The sensing element is mounted tank installed is not Fovered under the limited warranty Thermal in the hot water storage tank, see Water Piping Diagram seFtion expansion tanks must be installed on all Flosed water systems A Fhange in water temperature in the storage tank lower than the DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF tank temperature Fontrol setting will Fause the sensor to aFtivate the VALVE OPENING THIS CAN CAUSE PROPERTY DAMAGE, FirFulating pump The pump then FirFulates the water through the SERIOUS INJURY OR DEATH 28 It is reFommended that the water heater storage tank be drained and Àushed every 6 months to reduFe sediment buildup The water heater should be drained if being shut down during freezing temperatures See Features And Components in this manual for Explosion Hazard the loFation of the water heater Fomponents desFribed below Temperature-Pressure Relief Valve TO DRAIN THE WATER HEATER STORAGE TANK: must comply with ANSI Z21.22- 1 Turn off the eleFtriFal supply to the water heater CSA 4.4 and ASME code. 2 Turn off the gas supply at the Main Gas Shutoff Valve if the Properly sized temperature- water heater is going to be shut down for an extended period pressure relief valve must be 3 Ensure the Fold water inlet valve is open installed in opening provided. 4 Open a nearby hot water fauFet and let the water run until the water is no longer hot Can result in overheating and 5 Close the Fold water inlet valve to the water heater excessive tank pressure. 6 ConneFt a hose to the water heater drain valve and terminate it to an adequate drain Can cause serious injury or death. 7 Open the water heater drain valve and allow all the water to drain from the storage tank 8 Close the water heater drain valve when all water in the ANODE ROD INSPECTION storage tank has drained 9 Close the hot water fauFet opened in Step 4 10 If the water heater is going to be shut down for an extended CAUTION period, the drain valve should be left open Property Damage Hazard TO FLUSH THE WATER HEATER STORAGE TANK:  Avoid water heater damage. 1 Turn off the eleFtriFal supply to the water heater 2 Ensure the Fold water inlet valve is open  Inspection and replacement of anode rod required. 3 Open a nearby hot water fauFet and let the water run until the water is no longer hot Then Flose the hot water fauFet The anode rod is used to proteFt the tank from Forrosion Most 4 ConneFt a hose to the drain valve and terminate it to an hot water tanks are equipped with an anode rod The submerged adequate drain rod saFri¿Fes itself to proteFt the tank Instead of Forroding tank, 5 Ensure the drain hose is seFured before and during the entire water ions attaFk and eat away the anode rod This does not affeFt Àushing proFedure Flushing is performed with system water water¶s taste or Folor The rod must be maintained to keep tank in pressure applied to the water heater operating Fondition 6 Open the water heater drain valve to Àush the storage tank Anode rod deterioration depends on water FonduFtivity, not 7 Flush the water heater storage tank to remove sediment and neFessarily water Fondition A Forroded or pitted anode rod indiFates allow the water to Àow until it runs Flean high water FonduFtivity and should be FheFked and/or replaFed more 8 Close the water heater drain valve when Àushing is Fompleted often than an anode rod that appears to be intaFt ReplaFement 9 Remove the drain hose of a depleted anode rod Fan extend the life of your water heater 10 Fill the water heater - see Filling The Water Heater in this manual InspeFtion should be FonduFted by a quali¿ed teFhniFian, and at a 11 Turn on eleFtriFal supply to plaFe water heater baFk in operation minimum should be FheFked annually after warranty period 12 Allow the water heater to Fomplete several heating FyFles to ensure it is operating properly Arti¿Fially softened water is exFeedingly Forrosive beFause the proFess substitutes sodium ions for magnesium and FalFium ions Use of a water softener may deFrease the life of water heater tank RECOMMENDED PROCEDURE FOR PERIODIC REMOVAL OF LIME DEPOSITS FROM TANK TYPE The anode rod should be inspeFted after a maximum of three COMMERCIAL WATER HEATERS years and annually thereafter until Fondition of anode rod diFtates its replaFement Anode replaFement is not Fovered by warranty The amount of FalFium Farbonate (lime) released from water is NOTE arti¿Fially softened water requires the anode rod to be in direFt proportion to water temperature and usage, see Fhart inspeFted annually The higher the water temperature or water usage, the more lime deposits are dropped out of the water This is the lime sFale whiFh forms in pipes, heaters and on Fooking utensils Lime aFFumulation not only reduFes the life of equipment but also reduFes ef¿FienFy of the heater and inFreases fuel Fonsumption The usage of water softening equipment greatly reduFes the hardness of the water However, this equipment does not always remove all of the hardness (lime) For this reason it is reFommended that a regular sFhedule for deliming be maintained The time between Fleaning will vary from weeks to months depending upon water Fonditions and usage DRAINING AND FLUSHING The depth of lime buildup should be measured periodiFally Heaters equipped with Fleanouts will have about 2" of lime buildup when the level of lime has reaFhed the bottom of the Fleanout opening A sFhedule for deliming should then be set up,based on the amount Burn harzard. of time it would take for a 1" buildup of lime It is reFommended that the water heater initially be inspeFted after 6 months Hot water discharge. Example 1: Initial inspeFtion after 6 months shows 1/2" of lime aFFumulation Keep hands clear of drain Therefore, the heater should be delimed onFe a year valve discharge. Example 2: Initial inspeFtion after 6 months shows 2" of lime aFFumulation Therefore, the heater should be delimed every 3 months

29 Prepare the Water Heater To delime the water heater using the Flo-Jug method, ¿rst prepare the heater for deliming

Explosion Hazard

Flammable hydrogen gases may be present.

Keep all ignition sources away from faucet when turning on hot water.

Do not smoke or have open Àame or sparks in viFinity of heater Do not mix UN‡LIME with other FhemiFals Do not allow FontaFt with magnesium, aluminum or galvanized metals

FIGURE 25. Chemical Hazard DELIMING SOLVENTS UN‡LIME is reFommended for deliming UN‡LIME is a patented food grade aFid whiFh is safe to handle and does not Freate the ‡ 3roduct contains phosphoric acid. harmful fumes whiFh are assoFiated with other produFts ‡ .eep out of reach of children. UN‡LIME may be obtained from your dealer, distributor or ‡ Use rubber or neoprene gloves. water heater manufaFturer Order Part Number 9005416105, 1 gallon, paFked 4 gallons per Fase or Part Number 9005417105, 5 gallon Fontainer Contains phosphoriF aFid In Fase of external FontaFt, Àush with NOTE Un‡Lime is not available for use in Canada Fool water If irritation persists, get mediFal attention If swallowed, give 1 or 2 glasses of water or milk and Fall physiFian HydroFhloriF base aFids are not reFommended for use on glass lined tanks Get immediate mediFal attention for eyes Keep out of reaFh of Fhildren Observe handling instruFtions on label of produFt being used NOTE: THE USE OF RUBBER OR NEOPRENE GLOVES IS TANK CLEANOUT PROCEDURE RECOMMENDED, ESPECIALLY IF YOU HAVE ANY OPEN The following praFtiFes will ensure longer life and enable the SORES OR CUTS TO AVOID UNNECESSARY IRRITATION OR unit to operate at its designed ef¿FienFy DISCOMFORT. 1 OnFe a month the heater should be Àushed Open drain valve 1 Turn off fuel and/or power supply to heater Also, turn off power and allow two gallons of water to drain from heater Inlet water to any eleFtriFal deviFe or equipment, whiFh is attaFhed, or part valve should remain open to maintain pressure in tank of the system 2 A Fleanout opening is provided for periodiF Fleaning of the tank 2 Open hot water side of fauFet Flosest to heater and allow water Gas must be shut off and heater drained before opening Fleanout to run until it is Fool enough to handle safely To Flean heater through Fleanout opening, proFeed as follows 3 Close Fold water inlet valve to heater 3 Drain heater 4 ConneFt hose to drain valve at bottom of heater and start draining 4 Remove outer Fover plate from lower side of heater jaFket heater into suitable Àoor drain area 5 Remove six (6) hex head sFrews seFuring tank Fleanout plate 5 Remove pressure relief valve while heater is draining NOTE and remove plate Do not replaFe pressure relief valve until deliming is Fompleted 6 Remove lime, sFale, or sediment using Fare not to damage Pressure relief valve opening will also aFt as a vent in Fase of the glass lining possible FontaFt between the delimer and the anode rod(s), 7 InspeFt Fleanout plate gasket, if new gasket is required, whiFh may produFe Àammable hydrogen-air mixtures replaFe with part no 9004099215 6 If pressure relief valve appears to be limed-up, plaFe it in a Flean 8 Install Fleanout plate Be sure to draw plate up tight by glass or plastiF Fontainer adequate in size so that you Fan pour tightening sFrews seFurely enough UN‡LIMEŠ into Fontainer to Fover the valve and allow 9 ReplaFe outer jaFket Fover plate spaFe for foaming When foaming stops, run fresh Fool water into the Fontainer and rinse the pressure relief valve for a few minutes In some water areas the sediment might not be removed by this 7 If heater does not drain Fompletely after a reasonable length method and may result in the water heater making rumbling or of time, turn off the main water supply valve to stop water from boiling noises To dissolve and remove these more stubborn entering the tank due to a by-pass problem or defeFtive Fold mineral deposits, UN‡LIME Professional Delimer should be used water inlet valve Also, FheFk for Flogged drain valve opening DELIMING USING FLO-JUG METHOD Heater must be Fompletely drained before introduFing UN‡LIME 8 Remove the Fleanout Fover and plaFe a Flean plastiF buFket UN‡LIME in the 5 gallon size is reFommended for deliming of all next to the Fleanout opening models ContaFt your loFal dealer, distributor or, water heater Partially open the Fold water inlet valve to allow time to manufaFturer aFFomplish the following and then Flose the valve 30 While the water is being run through the tank, insert a Normally, lime removal will be Fompleted within one hour stiff wire, Fopper tube Àattened at one end or an opened Severe build-up of lime may take longer than an hour to Fomplete wire Foat hanger through the Fleanout opening and desFaling sFrape out any loose deposits of sFale or sediment This Note To FheFk UN‡LIME for Fontinued use, plaFe some sFale is an eFonomiFal way to avoid unneFessary usage of the or white Fhalk in a glass with a small amount of UN‡LIME If deliming solution the material is vigorously dissolved by the UN‡LIME, it Fan be Repeat the opening and Flosing of the Fold water inlet valve reused if not, the UN‡LIME should be replaFed as neFessary but be sure the heater is Fompletely drained when ready to introduFe the UN‡LIME Upon Fompletion, reinstall the Fleanout Fover and use a new Fleanout Fover gasket (part number 9004099215) Remove the drain valve 9 Install the long plastiF male adapter insert ¿tting into the drain valve opening of heater after applying TeÀon tape or paste to threads Tighten ¿rmly by hand and use wrenFh or adjustable pliers to FheFk for seFure FonneFtion Do not over tighten to avoid damage to threads and ¿ttings

Prepare the Up-N-Down Transfer Kit The next step is the preparation on the Up-N-Down Transfer Kit, if you have not already done so 1 With the 5 gallon Up-N-Down Fontainer in the vertiFal position, unsFrew the plastiF vent Fap in the handle and FIGURE 26. pierFe the plastiF membrane over the vent boss under the Fap to allow the Fontainer to vent POWER BURNER Note: If your Fontainer does not have the vent Fap and vent Keep the area around the burner Flear and free of Fombustible boss, drill a 3/16´ hole in the handle When you have ¿nished materials, gasoline or other Àammable liquids or vapors Do not obstruFt burner air openings or ventilation grilles for deliming you will be able to plug this drilled vent with the Fombustion air stainless steel sFrew that is supplied with the kit 2 Remove the Fontainer¶s Fap and Fut the plastiF membrane loFated in the 3/4´ IPT opening in the Fap Take Fare to not damage the threads 3 Find the 3/4´ male adapter, apply teÀon tape to the threaded end and sFrew it into the 3/4´ IPT opening in the Fap 4 Put Fap with male adapter baFk on the Fontainer and slide 3/4´ hose over end of male adapter and fasten in plaFe using hose Flamp provided

Delime using Flo-Jug Method

5 Slide the hose Flamp over end of hose and slide hose over TYPICAL MAIN BURNER FLAME the male adapter in the water heater drain opening and FIGURE 27. seFure in plaFe using hose Flamp The main burner Àames (Figure 27) should be visually FheFked 6 Lift Fontainer to the ³Pour´ Position, see Figure 26, being onFe a year for proper operation This Fan be observed through Fareful to keep the vent in the handle above the liquid level the observation port on the burner housing Burner Àame should and pour the UN‡LIME into the heater be blue DO NOT use the observation port on the side of the tank 7 Lower Fontainer, you may have to plaFe the Fontainer on its to inspeFt the burner Àame empty Farton to prevent the UN‡LIME from Àowing baFk into 1 Add a few drops of no 20 non-detergent oil (BTP-139/A thru - the Fontainer 370/A) into the oil tubes onFe every three months 8 Let UN‡LIME remain in the heater for 5 minutes and then 2 At least annually, FontaFt a quali¿ed serviFe teFhniFian for lower the Fontainer to the ³Drain´ Position, see Figure 26 a burner readjustment, Fleaning and other than routine maintenanFeShould the main burner or burner air openings 9 Deliming aFtivity is indiFated by foaming on the surfaFe of the require Fleaning, remove the burner and Flean with a soft UN‡LIME If there is deliming aFtivity, repeat steps 6 thru 8 brush Clean main burner ori¿Fe with a suitable soft material

31 GAS CONTROL VALVE

Figure 30 shows the Fombination gas Fontrol valves used on these heaters

If gas Fontrol valve beFomes defeFtive, repairs should not be attempted A new valve should be installed in plaFe of defeFtive one FIGURE 30.

SERVICE

The installer may be able to observe and ForreFt Fertain problems ELECTRICAL SERVICING whiFh may arise when the unit is put into operation HOWEVER, it is reFommended that only a quali¿ed serviFe teFhniFian or LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING quali¿ed agenFies, using appropriate test equipment, be allowed to serviFe the heater CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION As preliminary step, FheFk wiring against diagram, FheFk for grounded, broken or loose wires CheFk all wire ends to be sure VERIFY PROPER OPERATION AFTER SERVICING that they are making good FontaFt

32 TROUBLESHOOTING CHECKLIST

REMEDY COMPLAINT CAUSE USER QUALIFIED SERVICE AGENCY Set thermostat dial to a higher Thermostat set too low temperature Water not hot enough CheFk Fontinuity and resistanFe Upper and/or lower temperature (Ohms) of upper and lower Call quali¿ed serviFe agenFy probe out of Falibration thermostat probes ReplaFe probes if out of speFi¿Fation Set thermostat dial to a higher Thermostat set too low temperature CheFk Fontinuity and resistanFe Insuf¿Fient hot water Upper and/or lower temperature (Ohms) of upper and lower Call quali¿ed serviFe agenFy probe out of Falibration thermostat probes ReplaFe probes if out of speFi¿Fation Main manual gas shutoff valve Open main manual gas shutoff partially Flosed valve to fullest extent

SpaFe usage to give heater time Heater too small for demand to restore water temperature

CheFk gas input If inForreFt, adjust Heater reFovery is slower Call quali¿ed serviFe agenFy gas pressure or replaFe main burner ori¿Fe

Water temperature too hot Thermostat set too high Set thermostat to a lower setting

Condensation on outside of Heater makes sounds sizzling tank - normal

Drain a quantity of water through Sediment aFFumulation on Rumbling drain valve If rumbling persists, Delime heater bottom of tank Fall a quali¿ed serviFe agenFy

Expansion and FontraFtion- TiFking or metalliF sounds normal Drain piping system and re¿ll Air Fhambers in piping have Heater must be off while this beFome waterlogged Thermal Follow the manufaFturer s is being done CheFk thermal Pounding / water hammer expansion tank damaged, instruFtions for proper Fharging expansion tank Fharge pressure improperly Fharged, or of the thermal expansion tank when the water system pressure improperly sized is zero Too muFh primary air Call quali¿ed serviFe agenFy Combustion noises Overtired heater InForreFt burners or ori¿Fe for types of Call quali¿ed serviFe agenFy CheFk and ForreFt as neFessary gas used If drain valve Fannot be Flosed Drain valve not Flosed tightly tightly, replaFe Water leaks If leakage sourFe Fannot be Shut off gas supply to heater Repair or in Fase of suspeFted tank ForreFted or identi¿ed, Fall and Flose Fold water inlet valve to leakage, be Fertain to Fon¿rm before quali¿ed serviFe agenFy heater replaFing heater CheFk for sooted Àue passage CheFk for obstruFted vent line Gas odors Shut off gas supply to heater and Heater is over ¿red CheFk baFkdraft or laFk of draft Fall quali¿ed serviFe agenFy Draft hood may be improperly installed or not sized properly

Shut off gas supply to heater and Possible gas leaks Fall gas Fompany at onFe

33 FOR YOUR INFORMATION

START UP CONDITIONS F A sulfate reduFing baFteria whiFh has aFFumulated within the water heater (this harmless baFteria is SMOKE/ODOR nontoxiF to humans) It is not unFommon to experienFe a small amount of smoke and d An exFess of aFtive hydrogen in the tank This is Faused odor during the initial start-up This is due to burning off of oil by the Forrosion proteFtive aFtion of the anode rod from metal parts, and will disappear in a short while Smelly water may be eliminated or reduFed in some water heater models by replaFing the anode rod(s) with one of less STRANGE SOUNDS aFtive material, and then Fhlorinating water heater tank and all Possible noises due to expansion and FontraFtion of some metal water lines parts during periods of heat-up and Fool-down do not neFessarily ContaFt the loFal water heater supplier or serviFe agenFy for represent harmful or dangerous Fonditions further information FonFerning an Anode Rod ReplaFement Kit Condensation Fauses sizzling and popping within the burner area and this Fhlorination treatment during heating and Fooling periods and should be Fonsidered If smelly water persists after anode rod replaFement and Fhlorination normal See ³Condensation" seFtion in this manual treatment, we Fan only suggest that Fhlorination or aeration of the CONDENSATION water supply be Fonsidered to eliminate the water problem Whenever the water heater is ¿lled with Fold water, some Do not remove the anode rod leaving the tank unproteFted By Fondensate will form while the burner is on A water heater may doing so, all warranty on the water heater tank is voided appear to be leaking when in faFt the water is Fondensation This usually happens when “AIR” IN HOT WATER FAUCETS a A new water heater is ¿lled with Fold water for the ¿rst time HYDROGEN GAS Hydrogen gas Fan be produFed in a hot water system that has not been used for a long period of time b Burning gas produFes water vapor in water heaters, (generally two weeks or more) Hydrogen gas is extremely partiFularly high ef¿FienFy models where Àue temperatures Àammable and explosive To prevent the possibility of injury under are lower these Fonditions, we reFommend the hot water fauFet, loFated F Large amounts of hot water are used in a short time and the farthest away, be opened for several minutes before any eleFtriFal re¿ll water in the tank is very Fold applianFes whiFh are FonneFted to the hot water system are Moisture from the produFts of Fombustion Fondense on the Fooler used (suFh as a dishwasher or washing maFhine) If hydrogen tank surfaFes and form drops of water whiFh may fall onto the gas is present, there will probably be an unusual sound similar to burner or other hot surfaFes to produFe a ³sizzling´ or ³frying´ noise air esFaping through the pipe as the hot water fauFet is opened There must be no smoking or open Àame near the fauFet at the OPERATIONAL CONDITIONS time it is open

HOT WATER ODOR HIGH WATER TEMPERATURE SHUT OFF SYSTEM In eaFh water heater there is installed at least one anode rod for This water heater is equipped with a manual reset type high limit (Energy Cutout) switFh The high limit switFh interrupts the main Forrosion proteFtion of the tank Certain water Fonditions will burner gas Àow should water temperature reaFh 203ƒF (95ƒC) Fause a reaFtion between this rod and the water The most Fommon Fomplaint assoFiated with the anode rod is one of a ³rotten egg smell´ in the hot water The smell is a result of four In the event of high limit switFh operation, the water heater faFtors whiFh must all be present for the odor to develop Fannot be restarted unless the water temperature is reduFed to approximately 120F (49C) The high limit reset button on the a A FonFentration of sulfate in the supply water front of the thermostat then needs to be depressed See Figure 2 b Little or no dissolved oxygen in the water for the loFation of the reset button

34 WATER PIPING DIAGRAMS FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER FROM FIXTURES HOT WATER RETURN HOT WATER LEGEND COLD WATER SUPPLY EXPANSION TANK TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN ALT. COLD WATER CONNECTION TO FIXTURES TO HOT WATER HOT PIPE T&P TO OPEN DRAIN FINISHED FLOOR - (1 UNIT) WITH VERTICAL STORAGE TANK STORAGE - (1 UNIT) WITH VERTICAL WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the 35 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER HOT WATER RETURN FROM FIXTURES COLD WATER SUPPLY EXPANSION TANK CIRCULATING PUMP LEGEND TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN ALTERNATE LOCATION HOT WATER TO FIXTURES TO WATER HOT - (1 UNIT) WITH HORIZONTAL STORAGE TANK STORAGE - (1 UNIT) WITH HORIZONTAL PIPE T&P TO OPEN DRAIN FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

36 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER LEGEND PIPE T&P TO OPEN DRAIN TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN HOT COLD HOT WATER OUTLET WATER OUTLET TEMPERED HOT WATER RETURN WATER RETURN TEMPERED EXPANSION TANK COLD WATER SUPPLY - (1 UNIT) WITH MIXING VALVE TWO TEMPERATURE TWO - (1 UNIT) WITH MIXING VALVE WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The

37 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER HOT WATER RETURN LEGEND COLD WATER SUPPLY EXPANSION TANK TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN PIPE T&P TO OPEN DRAIN HOT WATER HOT PIPE T&P TO OPEN DRAIN TO FIXTURES TO - (2 UNITS) WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The

38 HOT WATER RETURN FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER COLD WATER SUPPLY EXPANSION TANK LEGEND ALTERNATE CONNECTION COLD WATER HOT WATER TO FIXTURES TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN PIPE T&P TO OPEN DRAIN - (2 UNITS) WITH VERTICAL STORAGE TANK STORAGE - (2 UNITS) WITH VERTICAL FINISHED FLOOR PIPE T&P TO OPEN DRAIN WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

39 HOT WATER RETURN FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER COLD WATER SUPPLY EXPANSION TANK LEGEND ALTERNATE CONNECTION COLD WATER HOT WATER TO FIXTURES TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN PIPE T&P TO OPEN DRAIN - (2 UNITS) WITH VERTICAL STORAGE TANK STORAGE - (2 UNITS) WITH VERTICAL FINISHED FLOOR PIPE T&P TO OPEN DRAIN WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

40 HOT WATER RETURN FROM FIXTURES FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER EXPANSION TANK COLD WATER SUPPLY LEGEND TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN ALTERNATE LOCATION HOT WATER TO FIXTURES TO WATER HOT PIPE T&P TO OPEN DRAIN - (2 UNITS) WITH HORIZONTAL STORAGE TANK STORAGE - (2 UNITS) WITH HORIZONTAL FINISHED FLOOR PIPE T&P TO OPEN DRAIN WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

41 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER LEGEND BOOSTER WATER RETURN TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN HEATER BOOSTER BOOSTER WATER TO FIXTURES PRE-HEATED WATER TO BOOSTER COLD WATER SUPPLY HOT WATER RETURN HOT WATER TO FIXTURES EXPANSION TANK 1st HEATER WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE (2 UNITS) TWO TEMPERATURE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However,

42 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER HOT WATER RETURN COLD WATER SUPPLY EXPANSION TANK LEGEND BOOSTER RETURN (IF USED) TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN HOT OUTLET AT STORED TEMPERATURE BOOSTED WATER OUTLET TYPICAL BOOSTER HEATER PIPE T&P TO OPEN DRAIN PRE-HEATER PIPE T&P TO OPEN DRAIN MUST BE IDENTICAL HEATERS PRE-HEATER PIPE T&P TO OPEN DRAIN FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE (2 UNITS) WITH BOOSTER TWO TEMPERATURE TEMPERATURE (2 UNITS) WITH BOOSTER TWO FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However,

43 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER HOT WATER RETURN LEGEND COLD WATER SUPPLY EXPANSION TANK TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN HOT WATER TO FIXTURES PIPE T&P TO OPEN DRAIN WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI-FLUE (3 UNITS) MULTI-FLUE 3. local codes shall govern their usage. Service valves are shown for servicing unit. However,

44 HOT WATER RETURN FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER EXPANSION TANK COLD WATER SUPPLY LEGEND ALT. COLD WATER CONNECTION TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN TO FIXTURES

AOS STORAGE TANK HOT WATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI-FLUE (3 UNITS) WITH VERTICAL STORAGE TANK (3 UNITS) WITH VERTICAL STORAGE MULTI-FLUE 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

45 HOT WATER RETURN FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER COLD WATER SUPPLY EXPANSION TANK LEGEND ALTERNATE LOCATION PIPE T&P TO OPEN DRAIN TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN AOS STORAGE TANK HOT WATER TO FIXTURES HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI-FLUE (3 UNITS) WITH HORIZONTAL STORAGE TANK STORAGE (3 UNITS) WITH HORIZONTAL MULTI-FLUE 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

46 HOT WATER RETURN FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER COLD WATER SUPPLY EXPANSION TANK LEGEND TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN PIPE T&P TO OPEN DRAIN HOT WATER TO FIXTURES FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI FLUE FLUE (4 UNITS) FLUE FLUE MULTI 3. local codes shall govern their usage. Service valves are shown for servicing unit. However,

47 FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER COLD WATER SUPPLY EXPANSION TANK HOT WATER RETURN LEGEND ALT. COLD WATER CONNECTION HOT WATER TO FIXTURES TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN

AOS STORAGE TANK PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI-FLUE (4 UNITS) WITH VERTICAL STORAGE TANK (4 UNITS) WITH VERTICAL STORAGE MULTI-FLUE 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

48 COLD WATER SUPPLY EXPANSION TANK HOT WATER RETURN FULL PORT BALL VALVE BALL PORT FULL CHECK VALVE GAGE TEMPERATURE FLOW SWITCH WATER LEGEND ALTERNATE LOCATION PIPE T&P TO OPEN DRAIN TEMPERATURE & PRESSURE TEMPERATURE RELIEF VALVE PRESSURE RELIEF VALVE PUMP CIRCULATING CONTROL TEMPERATURE TANK DRAIN AOS STORAGE TANK HOT WATER TO FIXTURES HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN HEATER PIPE T&P TO OPEN DRAIN FINISHED FLOOR WARNING: THIS DRAWING SHOWS SUGGESTED THIS DRAWING WARNING: AND OTHER DEVICES; PIPING CONFIGURATION CHECK WITH LOCAL CODES AND ORDINANCES CODES CHECK WITH LOCAL FOR ADDITIONAL REQUIREMENTS. NOTES: diagram. piping 1. Preferred 2. The temperature and pressure relief valve setting shall not exceed rating of any component in the system. MULTI-FLUE (4 UNITS) WITH HORIZONTAL STORAGE TANK STORAGE (4 UNITS) WITH HORIZONTAL MULTI-FLUE 3. local codes shall govern their usage. Service valves are shown for servicing unit. However, 4. Control should be wired to and control the pump between water heater(s) storage tank(s). Temperature Tank The 5. Control. Temperature The water heater’sTank operating thermostat should be set 5 degrees F higher than the

49 MANIFOLD KITS

Dimensions shown are for minimum spaFe oFFupied by the water heaters assemblies

SpaFe for the barometriF draft Fontrol assemblies, Fombustion FlearanFes and serviFing must be added PRIOR TO START UP IMPORTANT

FaFtory Start-Up is required for aFtivating warranty and assuring maximum operating performanFe ContaFt your loFal sales representatives or Authorized Start-Up Agent to arrange a FREE Certi¿ed Start-Up

50 COMMERCIAL GAS Glass Lined Tank Type Water Heater REPLACEMENT PARTS LIST MAIN BURNER ORIFICE CHART Natural Gas Propane Gas Burner Wayne C.S. Wayne C.S. Models Number Part No. (Decimal) Part No. (Decimal) BTP-139 HSG-200 62459-001 024 62459-001 0209 BTP-199 HSG-200 62459-001 038 62459-001 0257 BTP-270(A) HSG-400 62459-002 0368 62459-002 0302 BTP-370(A) HSG-400 62459-002 0532 62459-002 0386

51 Item Description BTP-139 BTP-199 BTP-270, 270A BTP-370, 370A 1  Anode 9003892005(2)  9003892005(2) 9003892005(2) 9003892005(2) 2  BafÀe, Flue 9005293205(7)  9005293205(7) 9005293205(7) 9005293205(7) 3  BarometriF Draft Control w Tee Assy 9500007199  9500007199 9500007200 9500007200 Cleanout Assembly: 4  Gasket 9004099215  9004099215 9004099215 9004099215 5  Pressure Plate 9005797205  9005797205 9005797205 9005797205 6  SFrew, Self Tapping (Req¶d) 9004100215  9004100215 9004100215 9004100215 7  Cover, Cleanout Opening 181260  181260 181260 181260 8  Thermostat with ECO 9004529005  9004529005 9004529005 9004529005 9  Valve, Drain9003906015  9003906015 9003906015 9003906015 10  Valve, T & P 9005903205  9005903205 9005903205 9005903205 11  ReduFer, Flue 76707-0  76707-0 76707-4 76707-4

*Items not illustrated ( ) ReÀeFts quantities All information suFh as model and series number, type of gas and speFi¿Fations must tobe supplied to State Water Heaters

52 NOTES

53 NOTES

54 COMMERCIAL WATER HEATER LIMITED WARRANTY

EFFECTIVE WHAT'S NOT COVERED For 3 Years, in the event of a tank leak, we will repair or, at our ‡ Problems Faused by improper gas supply line sizing, gas type, disFretion, replaFe the defeFtive water heater venting, FonneFtions, Fombustion air, voltage, wiring, or fusing For 1 Year, in the event of part failure, we will repair or, at our ‡ Failure to follow appliFable Fodes disFretion, replaFe the defeFtive part ‡ Failure to follow printed instruFtions We warrant this produFt against defeFts in materials or ‡ Abuse, misuse, aFFident, ¿re, Àood, AFts of God workmanship as desFribed in this doFument if installed within ‡ Improper installation, sizing, delivery, or maintenanFe the United States or Canada and provided the produFt remains at its original plaFe of installation ‡ Claims related to rust, noise, smell, or taste of water Warranty Foverage begins the date of installation OR the date of ‡ Failure to FonduFt authorized faFtory start up if required manufaFture if installation Fannot be veri¿ed ‡ Alterations to the water heater ‡ Non-outdoor heaters installed outdoors WHAT'S COVERED ‡ Damages due to a failure to allow for thermal expansion SubjeFt to these terms, in the event of defeFt in materials and/ ‡ Heat exFhanger failure due to laFk of adequate / proper supply or workmanship resulting in a tank leak during the ¿rst three of water years, we will ‡ ReplaFe the water heater should the tank leak ‡ Heaters moved from their original loFation SubjeFt to these terms, in the event of a defeFt in materials and/or ‡ ServiFe trips to explain proper installation, use, or maintenanFe workmanship appearing during the ¿rst year, we will of the produFt/unit or to desFribe FomplianFe requirements ‡ Repair or, at our disFretion, replaFe any part of the water under appliFable Fodes and regulations heater Fovered under this limited warranty exFluding parts ‡ Charges related to aFFessing your heater inFluding but not subjeFt to normal maintenanFe (Example non-eleFtroniF limited to door/wall removal, equipment rental, etF anode rod, ¿lter, etF) ‡ ReplaFement parts after expiration of this warranty Service/labor, shipping, delivery, installation, handling or any other costs are not covered at any time under this warranty. LIMITATIONS Any replaFement part or produFt will be warranted only for NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY, the unexpired portion of the original water heater¶s limited THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY warranty period ALL OTHER WARRANTIES INCLUDING A WARRANTY If an identiFal model is no longer available due to a Fhange in law, OF MERCHANTABILITY OR FITNESS FOR PARTICULAR regulation, or standard, we will replaFe the produFt with one having PURPOSE ARE EXPRESSLY DISCLAIMED SELLER SHALL Fomparable FapaFity and input In these instanFes, the owner will NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, have the option of paying the differenFe between what was paid for SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES TOTAL the original model and the new model with the additional features, LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE or reFeiving a refund of the portion of the purFhase priFe, on a PURCHASE PRICE PAID WHETHER BASED ON CONTRACT, pro-rata basis alloFable to the unexpired portion of the warranty TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY

SERVICE INQUIRIES: For service inquiries call the telephone number listed below. Be prepared to provide the following information name, address, and telephone number the model and serial number of the water heater proof of installation and a Flear desFription of the problem For your reFords, fill in the produFt Serial ______Model ______US Customers Canadian Customers A. O. Smith Corporation P. O. Box 310 – 768 Erie Street 500 Tennessee Waltz Parkway Stratford (Ontario) N5A 6T3 Ashland City, Tennessee 37015 800-265-8520 800-527-1953 www.hotwater.com

55 500 Tennessee Waltz Parkway, Ashland City, TN 37015 TeFhniFal Support 800-527-1953 ‡ Parts 800-433-2545 www.hotwater.com

Copyright ‹ 2014 A O Smith, All rights reserved