A.O. Smith 104 Series User manual

Brand: A.O. Smith

Model: 104 Series

Category: Water heaters & boilers

Type: User manual

COMMERCIAL GAS WATER HEATERS

Instruction Manual

PRINTED 0814 194186-003

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

MODELS BTP 139(A) Thru 370(A)

SERIES 104/105

INSTALLATION - OPERATION - SERVICE

- MAINTENANCE - LIMITED WARRANTY

Read and understand this instruction

manual and the safety messages

herein before installing, operating or

servicing this water heater.

Failure to follow these instructions and

safety messages could result in death

or serious injury.

This manual must remain with the

water heater.

500 Tennessee Waltz Parkway

Ashland City, TN 37015

Low Lead Content

Thank yRX IRr EXyinJ this enerJy eI¿Fient water heater

We aSSreFiate yRXr FRn¿denFe in RXr SrRdXFts

WARNING: If the information in these

instructions is not followed exactly, a fire

or explosion may result causing property

damage, personal injury or death.

Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

Do not touch any electrical switch; do

not use any phone in your building.

Immediately call your gas supplier

from a neighbor’s phone. Follow the

gas supplier’s instructions.

If you cannot reach your gas supplier,

call the fire department.

Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.



Air )rRP 2ther IndRRr 6SaFes  18

9ent CRnneFtiRn  19

WATER HEATER INSTALLATION 19-22

Water Line CRnneFtiRns  19

TP 9alYe DisFharJe PiSe  19

Installation Diagrams - Top Inlet/Outlet Usage  20

Burner Installation  20

Heater Wiring  21

Gas Piping  22

Gas Line Leak Testing  22

Purging  22

STARTUP AND OPERATION  23

Prior to Start Up  23

SEQUENCE OF OPERATION 23-27

SeTuenFe oI Operation Flow Chart  24

Lighting & Operation Label  25

Adjustments

 26

CheFking 9enting  26

CheFking the Input  26

Setting Burner Operation  27

MAINTENANCE 28-32

9enting System and BarometriF DraIt Control  28

General  28

Remote Storage Tank Temperature Control  28

Temperature-Pressure Relief Valve Test  28

Anode Rod InspeFtion 29

Draining and Flushing  29

ReFommended ProFedure for PeriodiF Removal or Lime Deposits

from the Tank Type CommerFial Water Heaters  29

DeLiming Solvents  30

Tank Cleanout ProFedure  30

Deliming Using Flo-Jug Method 30-31

Power Burner 31-32

Gas Control Valve  32

SERVICE  32

EleFtriFal ServiFing  32

TROUBLESHOOTING CHECKLIST 

FOR YOUR INFORMATION  34

Start up Conditions  34

Operational Conditions  34

WATER PIPING DIAGRAMS 35-49

MANIFOLD KITS  50

REPLACEMENT PARTS LIST  51- 52

NOTES 53-54

WARRANTY  55

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE  3

APPROVALS  3

GENERAL SAFETY INFORMATION 4-5

PreFautions  5

Grounding InstruFtions  5

Hydrogen Gas Flammable  5

INTRODUCTION  6

Abbreviations Used  6

Quali¿Fations  6

Start Up Requirements  6

Preparing for the Installation  6

FEATURES AND COMPONENTS  7

High Limit SwitFh  7

EleFtroniF Ignition Control  7

BarometriF Draft Control  7

Combustion Chamber Observation Port  7

UnFrating  7

INSTALLATION CONSIDERATIONS  8-12

Rough In Dimensions  8

LoFating The Water Heater  10

ClearanFes  10

Insulation Blanket 11

Hard Water 11

CirFulation Pumps 11-12

High Altitude Installations  12

INSTALLATION REQUIREMENTS  13-16

Gas Supply Systems  13

Supply Gas Regulator  13

Power Supply  13

Water Temperature Control and Mixing Valves  13

Dishwashing MaFhines  14

Closed Water Systems  14

Thermal Expansion  14

Temperature-Pressure Relief Valve 14-15

Contaminated Air  15

Air Requirements  15

UnFon¿ned SpaFe  16

Con¿ned SpaFe  16

VENTING INSTALLATION  16-19

Venting  16

BarometriF Draft Control Assembly  16

Fresh Air Opening for Con¿ned SpaFes  17

Outdoor Air Through Two Openings  17

Outdoor Air Through One Opening  17

Outdoor Air Through Two Horizontal DuF

ts  17

Outdoor Air Through Two VertiFal DuFts  18

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

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

DANGER

WARNING

CAUTION

DANGER indicates an imminently

hazardous situation which, if not avoided,

will result in injury or death.

This is the safety alert symbol. It is used to alert you to

potential personal injury hazards. Obey all safety

messages that follow this symbol to avoid possible

injury or death.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result

in injury or death.

CAUTION indicates a potentially hazardous

situation which, if not avoided, could result in

minor or moderate injury.

CAUTION used without the safety alert

symbol indicates a potentially hazardous

situation which, if not avoided, could result in

property damage.

APPROVALS

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

Low Lead Content

GENERAL SAFETY INFORMATION

Fire or Explosion Hazard

Read instruction manual before

installing, using or servicing

water heater.

Avoid all ignition sources if you smell gas.

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

Use only the gas shown on the water heater rating label.

Keep ignition sources away from faucets after extended

periods of non-use.

Maintain required clearances to combustibles.

Do not expose water heater controls to excessive gas

pressure.

Property Damage Hazard

All water heaters eventually leak.



Do not install without adequate drainage.



CAUTION

Fire and Explosion Hazard

Leak test before placing the

water heater in operation.

Disconnect gas piping and main

gas shutoff valve before leak

testing.

Install sediment trap in

accordance with NFPA 54.

Use joint compound or Teflon tape

compatible with propane gas.

Turn off power to the water heater

before performing any service.

Electrical Shock Hazard



Label all wires prior to disconnecting

when performing service. Wiring errors

can cause improper and dangerous

operation.



Verify proper operation after servicing.



Failure to follow these instructions can

result in personal injury or death.



Fire Hazard

For continued protection against

risk of fire:



Do not install water heater on

carpeted floor.



Do not operate water heater if

any part has been exposed to

flooding or water damage.

Fire and Explosion Hazard

Turn off gas lines during installation.

Contact a qualified installer or service

technician for installation and service.

Excessive gas pressure to gas valve can

cause serious injury or death.

Do not use water heater with any gas

other than the gas shown on the rating

label.

Jumping out control circuits or components can

result in property damage, personal injury or death.

Service should only be performed by a qualified service

technician using proper test equipment.



Altering the water heater controls and/or wiring in any way

could result in permanent damage to the controls or water

heater and is not covered under the limited warranty.



Any bypass or alteration of the water

heater controls and/or wiring will result

in voiding the water heater warranty.

Altering the water heater controls and/or wiring in any way

could result in altering the ignition sequence allowing gas to

flow to the main burner before the hot surface igniter is at

ignition temperature causing delayed ignition which can

cause a fire or explosion.



PRECAUTIONS

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

should be taken next

If the unit is exposed to the following, do not operate heater

until all ForreFtive steps have been made by a qualified

serviFe teFhniFian

1 External ¿re

2 Damage

3 Firing without water

GROUNDING INSTRUCTIONS

This water heater must be grounded in aFFordanFe with the

National EleFtriFal Code and/or loFal Fodes These must be

followed in all Fases

This water heater must be FonneFted to a grounded, permanent

wiring system or an equipment grounding FonduFtor must be

run with the FirFuit FonduFtors and FonneFted to the equipment

grounding terminal or lead on the water heater, see Figure 19

HYDROGEN GAS FLAMMABLE

Explosion Hazard

Flammable hydrogen gases

may be present.

Keep all ignition sources away

from faucet when turning on

hot water.

Hydrogen gas Fan be produFed in a hot water system served

by this water heater that has not been used for a long period of

time generally two weeks or more Hydrogen gas is extremely

Àammable To re du Fe the risk of injury under these Fonditions,

it is reFommended that a hot water fauFet served by this water

heater be opened for several minutes before using any eleFtriFal

applianFe FonneFted to the hot water system If hydrogen is

present there will probably be an unusual sound suFh as air

esFaping through the pipe as the water begins to Àow THERE

SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE

FAUCET AT THE TIME IT IS OPEN

GENERAL SAFETY INFORMATION

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

Read and understand this instruction

manual and the safety messages

herein before installing, operating or

servicing this water heater.

Failure to follow these instructions and

safety messages could result in death

or serious injury.

This manual must remain with the

water heater.

Water temperature over 125°F (52°C)

can cause severe burns instantly

resulting in severe injury or death.

Children, the elderly and the

physically or mentally disabled are at

highest risk for scald injury.

Feel water before bathing or

showering.

Temperature limiting devices such as

mixing valves must be installed

when required by codes and to

ensure safe temperatures at fixtures.

Explosion Hazard

Overheated water can cause

water tank explosion.

Properly sized temperature and

pressure relief valve must be

installed in the opening provided.

GENERAL SAFETY INFORMATION

Improper installation, use and service may result

in property damage.



Do not operate water heater if any part has been exposed

to flooding or water damage.



Inspect anode rods regularly, replace if damaged.



Install in location with drainage.



Fill tank with water before operation.



Properly sized thermal expansion tanks are required on all

closed water systems.

Refer to this manual for installation and service.

CAUTION

INTRODUCTION

Thank You for purFhasing this water heater Properly installed

and maintained, it should give you years of trouble free serviFe

ABBREVIATIONS USED

Abbreviations found in this InstruFtion Manual inFlude 

 ANSI - AmeriFan National Standards Institute

 ASME - AmeriFan SoFiety of MeFhaniFal Engineers

 AHRI - Air-Conditioning, Heating and Refrigeration Institute

 NEC - National EleFtriFal Code

 NFPA - National Fire ProteFtion AssoFiation

 UL - Underwriters Laboratory

 CSA - Canadian Standards AssoFiation

QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and serviFe of this water heater requires ability

equivalent to that of a Quali¿ed AgenFy as de¿ned by ANSI

below in the ¿eld involved Installation skills suFh as plumbing,

air supply, venting, gas supply and eleFtriFal supply are required

in addition to eleFtriFal testing skills when performing serviFe

ANSI Z223.1 2006 Sec. 3.3.83: ³Quali¿ed AgenFy´ - ³Any

individual, ¿rm, Forporation or Fompany that either in person or

through a representative is engaged in and is responsible for (a)

the installation, testing or replaFement of gas piping or (b) the

FonneFtion, installation, testing, repair or serviFing of applianFes

and equipment that is experienFed in suFh work that is familiar

with all preFautions required and that has Fomplied with all the

requirements of the authority having jurisdiFtion´

If you are not quali¿ed (as de¿ned by ANSI above) and liFensed

or Ferti¿ed as required by the authority having jurisdiFtion

to perform a given task do not attempt to perform any of the

proF

edures desFribed in this manual If you do not understand

the instruFtions given in this manual do not attempt to perform

any proFedures outlined in this manual

START UP REQUIREMENTS

This produFt requires a formal Start-Up by an authorized

serviFe/

start-up provider that has been approved by the manufaFturer

for this speFi¿F produFt Call 1-800-527-1953 to loFate the

nearest authorized start-up provider and arrange a faFtory

start-up Please provide as muFh notiFe as possible, preferably

2 weeks Please have the model and serial number ready when

you Fall

This start-up is required to aFtivate the warranty and ensure

safe, ef¿Fient operation

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 started up by an authorized faFtory trained serviFe/

start-up provider

PREPARING FOR THE INSTALLATION

1 Read the ³General Safety´ seFtion, page 4-5 of this manual

first and then the entire manual Farefully If you don¶t follow

the safety rules, the water heater will not operate properly

It Fould Fause DEATH, SERIOUS BODILY INJURY AND/OR

PROPERTY DAMAGE

This manual Fontains instruFtions for the installation, operation,

and maintenanFe of the gas-¿red water heater It also Fontains

warnings throughout the manual that you must read and be

aware of All warnings and all instruFtions are essential to the

proper operation of the water heater and your safety SinFe we

Fannot put everything on the ¿rst few pages, READ THE ENTIRE

MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE

THE WATER HEATER

2 The installation must Fonform with these instruFtions and the

loFal Fode authority having jurisdiFtion In the absenFe of loFal

Fodes, the installation must Fomply with the Furrent editions

of the National Fuel Gas Code, ANSI =2231/NFPA 54 or CAN/

CSA-B1491 the Natural Gas and Propane Installation Code

All doFuments are available from the Canadian Standards

AssoFiation, 8501 East Pleasant Valley Road, Cleveland, OH

44131 NFPA doFuments are also available from the National

Fire ProteFtion AssoFiation, 1 BatterymarFh Park, QuinFy, MA

02269

3 If after reading this manual you have any questions or do

not understand any portion of the instruFtions, Fall the loFal

gas utility or the manufaFturer whose name appears on the

rating plate

4 Carefully plan the plaFe where you are going to put the

water heater CorreFt Fombustion, vent aFtion, and vent pipe

installation are very important in preventing death from possible

Farbon monoxide poisoning and ¿res

Examine the loFation to ensure the water heater Fomplies with

the ³LoFating the New Water Heater´ seFtion in this manual

5 For California installation this water heater must be braFed,

anFhored, or strapped to avoid falling or moving during

an earthquake See instruFtions for ForreFt installation

proFedures InstruFtions may be obtained from California

OffiFe of the State ArFhiteFt, 400 P Street, SaFramento,

CA 95814

6 MassaFhusetts Code requires this water heater to be installed in

aFFordanFe with MassaFhusetts 248-CMR 200 State Plumbing

Code and 248-CMR 500

HIGH LIMIT SWITCH

The dual bulb Fontroller (¿g 1) Fontains the high limit (energy Futoff)

sensor The high limit switFh interrupts main burner gas Àow should

the water temperature reaFh 205F (96C)

In the event of high limit switFh operation, the applianFe Fannot be

restarted unless the water temperature is reduFed by at least 20F

(11C) and the high limit reset button on front of limit Fontrol (¿g1)

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

operation oFFurs

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

sequenFe and gas Fontrol operation of the water heater

IGNITION MODULE

FIGURE 2.

BAROMETRIC DRAFT CONTROL

The heater is equipped with a double aFting barometriF draft

Fontrol This Fontrol assembly is faFtory adjusted to automatiFally

regulate the Fhimney draft imposed on the unit

BAROMETRIC DRAFT CONTROL

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 inser ted into the Fombustion Fhamber wall

This plug should not be removed exFept, in rare Fases, when

the Fombustion Fhamber requires Fleaning or replaFement

FIGURE 4.

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

DisFard the shipping Frate and paFkaging Fartons in an

appropriate manner

FEATURES AND COMPONENTS

ROUGH IN DIMENSIONS

INSTALLATION CONSIDERATIONS

FIGURE 5.

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

MODELS A B

DE G

JGAS

APPROX. SHIP. WT.

(LBS.)

IN OUT

ASME STD.

BTP-139/A 74 3/4"

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"

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"

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"

26 3/4

" 8" 21 3/8"

27 3/4

" 38" 85 1/4" 3/4 731 634 1 1/2" 1 1/2"

TABLE 2. HEATER PERFORMANCE DATA BTP MODELS

MODELS

STORAGE

CAPACITY

U.S. GALLONS

IMPUT RATING BTU/HR.

RECOVERY RATE

GPH@100°F RISE

RECOVERY RATE

GPH@140°F RISE

MAXIMUM

AMPERES

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

Model Type of Gas

Gas Supply Pressure

Gas Manifold Pressure Volts/Hz AmperesMinimum Maximum

All Models Natural 45" WC (112 kPa) 14" WC (348 kPa) 35" WC (087 kPa) 120/60 <5

All Models * Propane 45" WC (112 kPa) 14" WC (348kPa) 35" WC (087 kPa) 120/60 <5

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

INSTALLATION CONSIDERATIONS

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

in an area where leakage from heater or FonneFtions will

not result in damage to adjaFent area or to lower Àoors of

the struFture

When suFh loFations Fannot be avoided, a suitable metal

drain pan should be installed under heater SuFh pans

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

Fombustion air Àow

CLEARANCES

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

Units whiFh are to be installed on Fombustible Àooring must

be supported by a full layer of hollow FonFrete bloFks, from

8" to 12"

thiFk and extending 12" (minimum) beyond the heater in all

direFtions The FonFrete bloFks must provide an unbroken

FonFrete surfaFe under the heater with the hollows running

Fontinuously and horizontally A 3/16 inFh steel plate must

Fover the FonFrete bloFks See Figure 5

PROPER INSTALLATION ON COMBUSTIBLE FLOORING

FIGURE 6.

In all installations the minimum Fombustible FlearanFes from

barometriF draft Fontrol surfaFe or vent piping shall be 6´

(152mm) Vent piping passing through a Fombustible wall or

Feiling must be a Fontinuous run (no joints) and retain 6´

(152mm) FlearanFe unless an approved reduFing thimble is used

A serviFe FlearanFe of 24´ (610mm) should be maintained from

serviFeable parts, suFh as relief valves, bafÀes, thermostats,

Fleanout openings or drain valves

TABLE 5. INSTALLATION CLEARANCES

(RIGHT SIDE)

(LEFTSIDE)

(BACK)

(CEILING)

BTP-139(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 21" (5334 Fm)

BTP-199(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 21" (5334 Fm)

BTP-270(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 21" (5334 Fm)

BTP-370(A) 6" (1524 Fm) 6" (1524 Fm) 6" (1524 Fm) 24" (6096 Fm)

LOCATING THE WATER HEATER

Property Damage Hazard

All water heaters eventually leak.



Do not install without adequate drainage.



CAUTION

When installing the heater, Fonsideration must be given to

proper loFation LoFation seleFted should be as Flose to the

staFk or Fhimney as praFtiFable, with adequate air supply and

as Fentralized with the piping system as possible

Fire or Explosion Hazard

Read instruction manual before

installing, using or servicing

water heater.

Avoid all ignition sources if you smell gas.

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

Use only the gas shown on the water heater rating label.

Keep ignition sources away from faucets after extended

periods of non-use.

Maintain required clearances to combustibles.

Do not expose water heater controls to excessive gas

pressure.

There is a risk in using fuel burning applianFes suFh as gas water

heaters in rooms, garages or other areas where gasoline, other

Àammable liquids or engine driven equipment or vehiFles are stored,

operated or repaired Flammable vapors are heavy and travel

along the Àoor and may be ignited by the heater¶s igniter or main

burner Àames Fausing ¿re or explosion Some loFal Fodes permit

operation of gas applianFes in suFh areas if they are installed 18´

or more above the Àoor This may reduFe the risk if loFation in

suFh an area Fannot be avoided

Do not install this water heater direFtly on a Farpeted Àoor A ¿re

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

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

The heater shall be loFated or proteFted so it is not subjeFt to physiFal

damage by a moving vehiF

le

Flammable items, pressurized Fontainers or any other potential

¿re hazardous artiFles must never be plaFed on or adjaFent to

the heater Open Fontainers or Àammable material should not be

stored or used in the same room with the heater

INSTALLATION CONSIDERATIONS

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

threshold type of water treatment is reFommended This will

proteFt the dishwashers, Foffee urns, water heaters, water piping

and other equipment

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

loop or there is a storage tank used in FonjunFtion with the water

heater See Water Piping Diagrams in this manual for installation

loFation of FirFulating pumps

See the CirFulation Pump Wiring Diagrams in this manual for

eleFtriFal hookup information Install in aFFordanFe with the

Furrent edition of the National EleFtriFal Code, NFPA 70 or the

Canadian EleFtriFal Code, CSA C221

All-bronze FirFulating pumps are reFommended for used with

FommerFial water heaters

Some FirFulating pumps are manufaFtured with sealed bearings

and do not require further lubriFation Some FirFulating pumps

must be periodiFally oiled Refer to the pump manufaFturer¶s

instruFtions for lubriFation requirements

FIGURE 7.

INSULATION BLANKET

Do not obstruct water heater air intake

with insulating blanket.

Gas and carbon monoxide detectors

are available.

Install water heater in accordance with

the instruction manual.

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

Breathing Hazard - Carbon Monoxide Gas

Insulation blankets are available to the general publiF for

external use on gas water heaters but are not neFessary

with these produFts The purpose of an insulation blanket

Breathing Hazard - Carbon Monoxide Gas

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

Under no circumstances should

the input exceed the rate shown

on the water heater’s rating label.

Overfiring could result in damage to

the water heater and sooting.

Gas and carbon monoxide detectors

are available.

Installations above 2000 feet (610 meters) require

replaFement of burner orifiFes in aFFordanFe with Furrent

edition of the National Fuel Gas Code (ANSI Z2231) For

Canadian installations Fonsult Canadian Installations Code

CAN/CSA B1491 Failure to replaFe orifiFes will result in

improper and ineffiFient operation of the water heater resulting

in the produFtion of inFreased levels of Farbon monoxide gas

in exFess of safe limits whiFh Fould result in serious personal

injury or death

You should FontaFt your gas supplier for any speFifiF Fhanges

whiFh may be required in your area

As the elevation above sea level is inFreased, there is less

oxygen per FubiF foot of air Therefore, the heater input rate

should be reduFed at high altitudes for satisfaFtory operation

with the reduFed oxygen supply Fa il u re to ma ke t h i s r e du Ftion

would result in an over firing of the heater Fausing sooting,

poor Fombustion and/or unsatisfaFtory heater performanFe

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

for eaFh 1000 feet (305m) above sea level For example, if a

heater is rated at 78,000 Btuh (229 Kwh) at sea level, to rate

the heater at 4000 feet (1219m), you subtraFt 4 (onFe for eaFh

thousand feet) x04 (4 input reduFtion) x 78,000 (original

rating) from the original rating

Therefore, to FalFulate the input rating at 4,000 feet (1219m)

4 x 04 x 78,000 12,480 Btuh (37 Kwh), 78,000 (229 Kwh) -

12,480 (37 Kwh) 65,520 Btuh (192 Kwh) At 6000 feet (1829m)

the ForreFt input rating should be 59,280 Btuh (174 Kwh)

CIRCULATING PUMP WIRING DIAGRAM

STORAGE TANK OR BUILDING RECIRCULATION

FIELD SUPPLIED TEMPERATURE CONTROL

INSTALLED IN THE STORAGE TANK

OR CIRCULATING LOOP RETURN LINE

CIRC

PUMP

MOTOR

L1 HOT

L2 NEUTRAL

120 VAC

POWER

NOTE: USE SEPARATE 120 VAC POWER

SUPPLY FOR PUMP CIRCUIT. DO NOT

SHARE POWER WITH WATER HEATER AS THIS

MAY CAUSE ELECTRICAL LINE NOISE AND

LEAD TO ERRATIC CONTROL SYSTEM

OPERATION.

FIGURE 8.

CIRCULATING PUMP WIRING DIAGRAM

DISHWASHER LOOP WITH TOGGLE SWITCH

FIELD SUPPLIED TEMPERATURE

CONTROL INSTALLED IN THE

CIRCULATING LOOP RETURN LINE

DISHWASHER

TOGGLE

SWITCH

CIRC

PUMP

MOTOR

L1 HOT

L2 NEUTRAL

120 VAC

POWER

NOTE: USE SEPARATE 120 VAC POWER

SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE

POWER WITH WATER HEATER AS THIS MAY

CAUSE ELECTRICAL LINE NOISE AND LEAD

TO ERRATIC CONTROL SYSTEM OPERATION.

FIGURE 9.

HIGH ALTITUDE INSTALLATIONS

Fire and Explosion Hazard

Gas and carbon monoxide detectors are

available.

Overfiring could result in fire or

explosion.

Under no circumstances should the

input exceed the rate shown on the

water heater’s rating label.

4 When installing multiple water heaters in the same gas supply

system it is reFommended that individual positive loFk-up gas

pressure regulators be installed at eaFh unit

POWER SUPPLY

The water heaters Fovered in this manual require a 120 VAC,

1Ø (single phase), 60Hz, 15 amp power supply and must also

be eleFtriFally grounded in aFFordanFe with loFal Fodes or, in the

absenFe of loFal Fodes, with the National EleFtriFal Code, ANSI/

NFPA 70 or the Canadian EleFtriFal Code, CSA C221

WATER TEMPERATURE CONTROL AND MIXING VALVES

Water temperature over 125°F (52°C)

can cause severe burns instantly

resulting in severe injury or death.

Children, the elderly and the

physically or mentally disabled are at

highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting devices such as

mixing valves must be installed

when required by codes and to

ensure safe temperatures at fixtures.

Water heated to a temperature whiFh will satisfy Flothes washing, dish

washing, and other sanitizing needs Fan sFald and Fause permanent

injury upon FontaFt Short repeated heating FyFles Faused by small

hot water uses Fan Fause temperatures at the point of use to exFeed

the water heater¶s temperature setting by up to 20F (11C)

Some people are more likely to be permanently injured by hot water

than others These inFlude the elderly, Fhildren, the in¿rm and the

physiFally/mentally disabled Table 6 shows approximate time-to-burn

relationship for normal adult skin If anyone using hot water provided

by the water heater being installed ¿ts into one of these groups or if

there is a loFal Fode or state law requiring a Fertain water temperature

at the point of use, then speFial preFautions must be taken

In addition to using the lowest possible temperature setting that

satis¿es the demand of the appliFation a Mixing Valve should be

installed at the water heater (see Figure 10) or at the hot water taps

to further reduFe system water temperature

Mixing valves are available at plumbing supply stores Consult a

Quali¿ed Installer or ServiFe AgenFy Follow mixing valve manufaFturer¶s

instruFtions for installation of the valves

TABLE 6.

Water Temperature F

Time for 1st Degree Burn

(Less Severe Burns)

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

110

(normal shower temp)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seFonds 25 seFonds

140 2 seFonds 5 seFonds

149 1 seFond 2 seFonds

154 instantaneous 1 seFond

(US Government Memorandum, CPSC, Peter L Armstrong, Sept 15,1978)

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are defined as those

systems that Fannot under any FirFumstanFes exFeed 14´

WC (1/2 PSI Gauge) These systems do not require pressure

regulation Measurements should be taken to insure that gas

pressures are stable and fall within the requirements stated on

the water heater rating plate Readings should be taken with

all gas burning equipment off (statiF pressure) and with all gas

burning equipment running at maximum rate (dynamiF pressure)

The gas supply pressure must be stable within 15´ WC

from statiF to dynamiF pressure to provide good performanFe

Pressure drops that exFeed 15´ WC may Fause rough starting,

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

low pressure system does NOT meet these requirements, the

installer is responsible for the ForreFtions

High Pressure building supply systems use pressures that

Feed 14´ WC (1/2 PSI Gauge) These systems must use ¿eld

supplied regulators to lower the gas pressure to less than 14´

WC (1/2 PSI Gauge) Water heaters require gas regulators that

are properly sized for the water heater input and deliver the rating

plate speFi¿ed pressures Gas supply systems where pressure

exFeeds 5 PSI often require multiple regulators to aFhieve desired

pressures Systems in exFess of 5 PSI building pressure should

be designed by gas delivery professionals for best performanFe

Water heaters FonneFted to gas supply systems that exFeed 14´

WC (1/2 PSI Gauge) at any time must be equipped with a gas

supply regulator

All models require a minimum gas supply pressure of 45" WC

for natural gas and propane gas The minimum supply pressure

is measured while gas is Àowing (dynamiF pressure) The supply

pressure should never fall below 45" WC for natural gas and

propane gas The supply pressure should be measured with all

gas ¿red applianFes FonneFted to the Fommon main

¿ring at full

FapaFity If the supply pressure drops more than 15´ WC as gas

begins to Àow to the water heater then the supply gas system

inFluding the gas line and/or the gas regulator may be restriFted

or undersized See Supply Gas Regulator seFtion and Gas

Piping seFtion of this manual The gas valve on all models has

a maximum gas supply pressure limit of 14´ WC The maximum

supply pressure is measured while gas is not Àowing (statiF

pressure)

SUPPLY GAS REGULATOR

The maximum allowable gas supply pressure for this water heater is

14" WC (348 kPa) Install a positive loFk-up gas pressure regulator

in the gas supply line if inlet gas pressure Fan exFeed 14" WC

(348 kPa) at any time Regulators must be sized/used aFFording to

manufaFturer¶s speFi¿Fations

If a positive loFk-up regulator is required follow these instruFtions

1 Positive loFk-up gas pressure regulators must be rated at or above

the input Btu/hr rating of the water heater they supply

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

feet (24 meters) from water heater¶s inlet gas FonneFtion

3 After installing the positive loFk-up gas pressure regulator(s), an

initial nominal supply pressure setting of 7" WC (174 kPa) while

water heater is operating is reFommended and will generally

provide good water heater operation Some additional adjustment

maybe required later to maintain a steady gas supply pressure

INSTALLATION REQUIREMENTS

HOT WATER

OUTLET

TO TANK

INLET

CHECK

VALVE

MIXING

VALVE

COLD

WATER

INLET

TEMPERED WATER

OUTLET

12” TO 15”

(30-38 cm)

CHECK

VALVE

FIGURE 10.

DISHWASHING MACHINES

All dishwashing maFhines meeting the National Sanitation

Foundation requirements are designed to operate with water

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

inFh (103 kPa), will result in improperly sanitized dishes

Where pressures are high, a water pressure reduFing or flow

regulating Fontrol valve should be used in the 180F (82C)

line to the dishwashing maFhine and should be adjusted to

deliver water pressure between these limits

The National Sanitation Foundation also reFommends

FirFulation of 180F (82C) water The FirFulation flow rate

should be just enough to provide 180F (82C) water at the

point of take-off to the dishwashing maFhine

Adjust flow by throttling a full port ball valve installed in

the FirFulating line on the outlet side of the pump Never

throttle flow on the suFtion side of a pump See Water Piping

Diagrams in this manual

CLOSED WATER SYSTEMS

Water supply systems may, beFause of Fode requirements or

suFh Fonditions as high line pressure, among others, have

installed deviFes suFh as pressure reduFing valves, FheFk

valves, and baFk flow preventers DeviFes suFh as these

Fause the water system to be a Flosed system

THERMAL EXPANSION

As water is heated, it expands (thermal expansion) In a

Flosed system the vo lume of water will grow when it is heated

As the volume of water grows there will be a Forresponding

inFrease in water pressure due to thermal expansion Thermal

expansion Fan Fause premature tank failure (leakage) This

type of failure is not Fovered under the limited warranty

Thermal expansion Fan also Fause intermittent Temperature-

Pressure Relief Valve operation water disFharged from the

valve due to exFessive pressure build up This Fondition is

not Fovered under the limited warranty The Temperature-

Pressure Relief Valve is not intended for the Fonstant relief

of thermal expansion

A properly sized thermal expansion tank must be installed on

all Flosed systems to Fontrol the harmful effeFts of thermal

expansion ContaFt a loFal plumbing serviFe teFhniFian to have a

thermal expansion tank installed

See Water Line ConneFtions on page 19 and the Water Piping

Diagrams beginning on page 35

TEMPERATURE-PRESSURE RELIEF VALVE

Explosion Hazard

Temperature-Pressure Relief Valve

must comply with ANSI Z21.22-

CSA 4.4 and ASME code.

Properly sized temperature-

pressure relief valve must be

installed in opening provided.

Can result in overheating and

excessive tank pressure.

Can cause serious injury or death.

This water heater is provided with a properly rated/sized and Ferti¿ed

Fombination Temperature-Pressure Relief Valve (T&P valve) by

the manufaFturer The valve is Ferti¿ed by a nationally reFognized

testing laboratory that maintains periodiF inspeFtion of produFtion

of listed equipment of materials as meeting the requirements for

Pressure Relief Valves for Hot Water Supply Systems, ANSI Z2122

 CSA 44, and the Fode requirements of ASME

If replaFed, the new T&P valve must meet the requirements

of loFal Fodes, but not less than a Fombination Temperature-

Pressure Relief Valve rated/sized and Ferti¿ed as indiFated in

the above paragraph The new valve must be marked with a

maximum set pressure not to exFeed the marked hydrostatiF

working pressure of the water heater (150 psi 1,035 kPa) and

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

NOTE In addition to the faFtory installed Temperature-Pressure

Relief Valve on the water heater, eaFh remote storage tank that

may be installed and piped to a water heating applianFe must also

have its own properly sized, rated and approved Temperature-

Pressure Relief Valve installed Call the toll free teFhniFal

support phone number listed on the baFk Fover of this manual

for teFhniF

al assistanFe in sizing a Temperature-Pressure Relief

Valve for remote storage tanks

For safe operation of the water heater, the Temperature-Pressure

Relief Valve must not be removed from its designated opening

nor plugged The Temperature-Pressure Relief Valve must be

installed direFtly into the ¿tting of the water heater designed for

the pressure relief valve  Install disFharge piping so that any

disFharge will exit the pipe within 6 inFhes (152 Fm) above an

adequate Àoor drain, or external to the building In Fold Flimates

it is reFommended that it be terminated at an adequate drain

inside the building Be Fertain that no FontaFt is made with any

live eleFtriFal part The disFharge opening must not be bloFked

or reduFed in size under any FirFumstanFes ExFessive length,

over 30 feet (914 m), or use of more than four elbows Fan Fause

restriFtion and reduFe the disFharge FapaFity of the valve

No valve or other obstruFtion is to be plaFed between the

Temperature-Pressure Relief Valve and the tank Do not FonneFt

disFharge piping direFtly to the drain unless a 6´ (152 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

the disFharge pipe is not FonneFted to a drain or other suitable

means, the water Àow may Fause property damage

Water Damage Hazard

Temperature-Pressure Relief Valve discharge

pipe must terminate at adequate drain.



CAUTION

T&P Valve Discharge Pipe Requirements:

 Shall not be smaller in size than the outlet pipe size of the

valve, or have any reduFing Fouplings or other restriFtions

 Shall not be plugged or bloFked

 Shall not be exposed to freezing temperatures

 Shall be of material listed for hot water distribution

 Shall be installed so as to allow Fomplete drainage of both

the 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

pressure relief valve and the drain

Burn hazard.

Hot water discharge.

Keep clear of Temperature-

Pressure Relief Valve

discharge outlet.

The Temperature-Pressure Relief Valve must be manually operated

at least twiFe a year Caution should be taken to ensure that (1) no

one is in front of or around the outlet of the Temperature-Pressure

Relief Valve disFharge line, and (2) the water manually disFharged

will not Fause any bodily injury or property damage beFause

the water may be extremely hot If after manually operating the

valve, it fails to Fompletely reset and Fontinues to release water,

immediately Flose the Fold water inlet to the water heater, follow the

draining instruFtions in this manual, and replaFe the Temperature-

Pressure Relief Valve with a properly rated/sized new one

NOTE: The purpose of a Temperature-Pressure Relief Valve is to

prevent exFessive temperatures and pressures in the storage tank

The T&P valve is not intended for the Fonstant relief of thermal

expansion A properly sized thermal expansion tank must be

installed on all Flosed systems to Fontrol thermal expansion, see

Closed Water Systems and Thermal Expansion on page 14

If you do not understand these instruFtions or have any questions

regarding the Temperature-Pressure Relief Valve Fall the toll

free number listed on the baFk Fover of this manual for teFhniFal

assistanFe

CONTAMINATED AIR

Breathing Hazard - Carbon Monoxide Gas

Install water heater in accordance with

the Instruction Manual and NFPA 54 or

CAN/CSA-B149.1.

To avoid injury, combustion and ventilation

air must be taken from outdoors.

Do not place chemical vapor emitting

products near water heater.

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

Corrosion of the Àue ways and vent system may oFFur if air for

Fombustion Fontains Fertain FhemiFal vapors SuFh Forrosion

may result in failure and risk of asphyxiation

Combustion air that is Fontaminated Fan greatly diminish the life

span of the water heater and water heater Fomponents suFh as

hot surfaFe igniters and burners Propellants of aerosol sprays,

beauty shop supplies, water softener FhemiFals and FhemiFals

used in dry Fleaning proFesses that are present in the Fombustion,

ventilation or ambient air Fan Fause suFh damage

Do not store produFts of this sort near the water heater Air whiFh

is brought in FontaFt with the water heater should not Fontain any

of these FhemiFals If neFessary, unFontaminated air should be

obtained from remote or outdoor sourFes The limited warranty

is voided when failure of water heater is due to a Forrosive

atmosphere (See limited warranty for Fomplete terms and

onditions)

AIR REQUIREMENTS

Breathing Hazard - Carbon Monoxide Gas

Install water heater in accordance with

the Instruction Manual and NFPA 54 or

CAN/CSA-B149.1.

To avoid injury, combustion and ventilation

air must be taken from outdoors.

Do not place chemical vapor emitting

products near water heater.

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

For safe operation an adequate supply of fresh unFontaminated

air for Fombustion and ventilation must be provided

An insuf¿Fient supply of air Fan Fause reFirFulation of Fombustion

produFts resulting in Fontamination that may be hazardous to

life SuFh a Fondition often will result in a yellow, luminous burner

Àame, Fausing sooting of the Fombustion Fhamber, burners and

Àue tubes and Freates a risk of asphyxiation

Do not install the water heater in a Fon¿ned spaFe unless an

adequate supply of air for Fombustion and ventilation is brought

in to that spaFe using the methods desFribed in the Con¿ned

SpaFe seFtion that follows

Never obstruFt the Àow of ventilation air If you have any doubts

or questions at all, Fall your gas supplier Failure to provide the

proper amount of Fombustion air Fan result in a ¿re or explosion

and Fause property damage, serious bodily injury or death

DIRECT VENT APPLIANCES

ApplianFes installed in a DireFt Vent Fon¿guration that derive all

air for Fombustion from the outdoor atmosphere through sealed

intake air piping are not faFtored in the total applianFe input Btu/

hr FalFulations used to determine the size of openings providing

fresh air into Fon¿ned spaFes

EXHAUST FANS

Where exhaust fans are installed, additional air shall be provided

to replaFe the exhausted air When an exhaust fan is installed

in the same spaFe with a water heater, suf¿Fient openings to

provide fresh air must be provided that aFFommodate the

requirements for all applianFes in the room and the exhaust fan

Undersized openings will Fause air to be drawn into the room

through the water heater¶s vent system Fausing poor Fombustion

Sooting, serious damage to the water heater and the risk of ¿re

or explosion may result It Fan also Freate a risk of asphyxiation

LOUVERS AND GRILLES

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

sFreens in the openings

The required size of openings for Fombustion, ventilation and

dilution air shall be based on the ³net free area´ of eaFh opening

Where the free area through a design of louver or grille or sF

reen

is known, it shall be used in FalFulating the size of opening

required to provide the free area speFi¿ed Where the louver and

grille design and free area are not known, it shall be assumed

that wood louvers will have 25 free area and metal louvers and

grilles will have 75 free area Non motorized louvers and grilles

shall be ¿xed in the open position

UNCONFINED SPACE

An UnFon¿ned SpaFe is one whose volume IS NOT LESS THAN

50 FubiF feet per 1,000 Btu/hr (48 FubiF meters per kW) of the

total input rating of all applianFes installed in the spaFe Rooms

FommuniFating direFtly with the spaFe, in whiFh the applianFes

are installed, through openings not furnished with doors, are

Fonsidered a part of the unFon¿ned spaFe

Makeup air requirements for the operation of exhaust fans,

kitFhen ventilation systems, Flothes dryers and ¿replaFes shall

also be Fonsidered in determining the adequaFy of a spaFe to

provide Fombustion, ventilation and dilution air

UNUSUALLY TIGHT CONSTRUCTION

In unFon¿ned spaFes in buildings, in¿ltration may be adequate

to provide air for Fombustion, ventilation and dilution of Àue

gases However, in buildings of unusually tight FonstruFtion (for

example, weather stripping, heavily insulated, Faulked, vapor

barrier, etF) additional air must be provided using the methods

desFribed in the Con¿ned SpaF

e seFtion that follows

CONFINED SPACE

A Con¿ned SpaFe is one whose volume is less than 50 FubiF

feet per 1,000 Btu/hr (48 FubiF meters per kW) of the total input

rating of all applianFes installed in the spaFe

Openings must be installed to provide fresh air for Fombustion,

ventilation and dilution in Fon¿ned spaFes The required size for

the openings is dependent on the method used to provide fresh

air to the Fon¿ned spaFe and the total Btu/hr input rating of all

applianFes installed in the spaFe

VENTING INSTALLATION

VENTING

THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST

BE FOLLOWED TO AVOID CHOKED COMBUSTION OR

RECIRCULATION OF FLUE GASES SUCH CONDITIONS

CAUSE SOOTING OR RISKS OF FIRE AND ASPHY;IATION

Heater must be proteFted from freezing downdrafts

Remove all soot or other obstruFtions from the Fhimney that will

retard a free draft

Type B venting is reFommended with these heaters

This water heater must be vented in FomplianFe with all loFal

Fodes, the Furrent revision of the National Fuel Gas Code

(ANSI-Z2231) and with the Category I Venting Tables

If any part of the vent system is exposed to ambient temperatures

below 40F (44C) it must be insulated to prevent 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

appliFation only and must be attaFhed to the heater as shown in

Figure 11 The outlet of the draft Fontrol assembly may be rotated

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 draft Fontrol assembly to the top Fover using sheet metal

sFrews at three loFations, or more, as required

Dampers or other obstruFtions must not be installed between the

heater and the barometriF draft Fontrol assembly

Do not adjust settings on gate Counterweight washers are faFtory

adjusted and should result in breeFhing pressure measurements

at the Fombustion test hole (Figure 11) within the range shown

in Table 10

NOTE: A negative draft must be maintained in the vent piping

When installed, the damper gate must pivot freely in the ring

guides This gate will automatiFally adjust to regulate the Fhimney

draft imposed on the heater

PROPER DRAFT CONTROLLER AND

VENT PIPE INSTALLATION

FIGURE 11.

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instruFtions shall be used to FalFulate the size,

number and plaFement of openings providing fresh air for

Fombustion, ventilation and dilution in Fon¿ned spaFes The

illustrations shown in this seFtion of the manual are a referenFe

for the openings that provide fresh air into Fon¿ned spaFes

only DO NOT refer to these illustrations for the purpose of vent

installation See Venting Installation on page 16 for Fomplete

venting installation instruFtions

OUTDOOR AIR THROUGH TWO OPENINGS

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

per 4,000 Btu/hr (550 mm

per kW) of the aggregate input rating

of all applianFes installed in the enFlosure EaFh opening shall

not be less than 100 square inFhes (645 Fm

)

OUTDOOR AIR THROUGH ONE OPENING

FIGURE 13.

Alternatively a single permanent opening, FommenFing

within 12 inFhes (300 mm) of the top of the enFlosure,

shall be provided See Figure 12 The water heater shall

have FlearanFes of at least 1 inFh (25 mm) from the sides

and baFk and 6 inFhes (l50 mm) from the front of the

water heater The opening shall direFtly FommuniFate

with the outdoors or shall FommuniFate through a vertiFal

or horizontal duFt to the outdoors or spaFes that freely

FommuniFate with the outdoors and shall have a minimum

free area of the following

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 14.

The Fonfined spaFe shall be provided with two permanent

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

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" (762 mm)

AIR FROM OTHER INDOOR SPACES

FIGURE 16.

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 See Figure 16

EaFh opening shall FommuniFate direFtly with an additional

room(s) of suf¿Fient volume so that the Fombined volume of all

spaFes meets the Friteria for an UnFon¿ned SpaFe

EaFh opening shall have a minimum free area of 1 square inFh

per 1,000 Btu/hr (2200 mm

per kW) of the aggregate input rating

of all applianFes installed in the enFlosure EaFh opening shall

not be less than 100 square inFhes (645 Fm

)

OUTDOOR AIR THROUGH TWO VERTICAL DUCTS

The illustrations shown in this seFtion of the manual are a

referenFe for the openings that provide fresh air into Fon¿ned

spaFes only

DO NOT refer to these illustrations for the purpose of vent

installation See Venting Installation on page 14 for Fomplete

venting installation instruFtions

FIGURE 15.

The Fon¿ned spaFe shall be provided with two permanent vertiFal

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 vertiFal duFts shall FommuniFate direFtly with the

outdoors See Figure 15

EaFh duFt opening shall have a minimum free area of 1 square

inFh per 4,000 Btu/hr (550 mm

per kW) of the aggregate input

rating of all applianFes installed in the enFlosure

Where an existing Fhimney or vent is to be used, be sure

that the Fhimney or vent has adequate FapaFity for the

number and sizes of gas applianFes being vented through

it InspeFt the Fhimney or vent and remove all soot or other

obstruFtions whiFh will retard free draft

Vent FonneFt o r s m ak i n g ho r iz o n t al r un s m us t h av e a mi ni mu m

upward slope toward the Fhimney or vent of 1/4 inFh per foot

Vent FonneFtor length should be kept as short as possible

Be sure that the vent pipe does not extend beyond the inside

wall of a Fhimney

In venting systems where a Fontinuous or intermittent

baFk (positive) draft is found to exist, the Fause must

be determined and ForreFted In some Fases, a speFial

vent Fap may be required Do not install this unit on the

positive draft side of a venting system being served by a

power exhauster

WATER HEATER INSTALLATION

VENT CONNECTION

Vent FonneFtions must be made to an adequate staFk

or Fhimney Refer to the National Fuel Gas Code (Furrent

edition) or to the vent pipe manufaFturer¶s gas vent and

Fhimney sizing table to properly design and size the venting

system Refer to Table 7 for the vent pipe size required for

installation to the barometriF draft Fontrol assembly outlet

TABLE 7. BAROMETRIC DRAFT CONTROL

ASSEMBLY OUTLET SIZE

MODEL

DRAFT CONTROL

OUTLET DIAMETER

BTP-139/A

BTP-199/A

BTP-270/A

BTP-370/A

6´

8´

WATER PIPING DIAGRAMS

This manual provides detailed water piping diagrams for typiFal

methods of appliFation for the water heaters, see Water Piping

Diagrams beginning on page 35

The water heater may be installed by itself, or with a separate

storage tank When used with a separate storage tank, the

FirFulation may be either by gravity or by means of FirFulating

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

on the suFtion side of a pump See the Water Piping Diagrams

beginning on page 35

NOTE: In addition to the faFtory installed Temperature-Pressure

Relief Valve (T&P valve) on the water heater, eaFh remote

storage tank that may be installed and piped to a water heating

applianFe must also have its own properly sized, rated and

approved Temperature-Pressure Relief Valve installed

Call the toll free teFhniFal support phone number listed on the

baFk Fover of this manual for further assistanFe in sizing a T&P

valve for remote storage tanks

T&P VALVE DISCHARGE PIPE

Explosion Hazard

Temperature-Pressure Relief Valve

must comply with ANSI Z21.22-

CSA 4.4 and ASME code.

Properly sized temperature-

pressure relief valve must be

installed in opening provided.

Can result in overheating and

excessive tank pressure.

Can cause serious injury or death.

WATER LINE CONNECTIONS

The water piping installation must Fonform to these instruFtions

and to all loFal Fode authority having jurisdiFtion Good praFtiFe

requires that all heavy piping be supported

Read and observe all requirements in the following seFtions

before installation of the water piping begins

1 Water Temperature Control and Mixing Valves on page 13

2 Dishwashing MaFhines on page 14

3 Temperature-Pressure Relief Valve on page 14-15

4 Closed Systems and Thermal Expansion on page 14

5 For multiple water heater installations see Water Piping

Diagrams beginning on page 35

WATER (POTABLE) HEATING AND SPACE HEATING

1 All piping Fomponents FonneFted to this unit for spaFe

heating appliFations shall be suitable for use with potable

water

2 ToxiF FhemiFals, suFh as those used for boiler treatment,

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

4 When the system requires water for spaFe heating at

temperatures higher than required for domestiF

water

purposes, a tempering valve must be installed Please

refer to installation diagrams beginning on page 35 of this

manual for suggested piping arrangements

5 These water heaters Fannot be used in spaFe heating

appliFations only

THERMOMETERS (NOT SUPPLIED)

Thermometers should be obtained and ¿eld installed as shown

in the installation diagrams

Thermometers are installed in the system as a means of

deteFting the temperature of the outlet water supply

This water heater is provided with a properly rated/sized and

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

Water Damage Hazard

Temperature-Pressure Relief Valve discharge

pipe must terminate at adequate drain.



CAUTION

Install a disFharge pipe between the T&P valve disFharge

opening and a suitable Àoor drain Do not FonneFt disFharge

piping direFtly to the drain unless a 6´ (152 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 the

disFharge pipe is not FonneFted to a drain or other suitable

means, the water Àow may Fause property damage

T&P VALVE DISCHARGE PIPE REQUIREMENTS:

 Shall not be smaller in size than the outlet pipe size of the

valve, or have any reduFing Fouplings or other restriFtions

 Shall not be plugged or bloFked

 Shall not be exposed to freezing temperatures

 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

dope to FontaFt the plastiF tube during installation

TUBE INLET INSTALLATION

FIGURE 17.

BURNER INSTALLATION

Remove the faFtory-installed insulation Fovering the Fombustion

Fhamber opening (A utility knife is useful for Futting out the

insulation) Cut the insulation baFk even with the jaFket opening

Install the Àange gasket (whiFh is usually taped to the heater jaFket)

over the three bolts protruding from the tank at the Fombustion

Fhamber opening

Remove hardware (3 hex nuts, 3 Àat washers, and 3 loFk washers)

from the shipping bag attaFhed to the heater¶s eleFtriFal Fonduit

Begin assembling the power burner to the tank by plaFing the power

burner nozzle in the Fombustion Fhamber opening Slide the nozzle

into the tank and rotate the mounting Àange to engage the mounting

bolts, refer to Figure 18 Then, plaFe the Àat washers followed by

the loFk washers, and ¿nally the hex nuts on the mounting bolts

Hand tighten the nuts Then gradually tighten eaFh nut alternating

between the 3 mounting bolts Do not over tighten as damage to

the Àange gasket or to the tank may result Refer to Figure 18

POWER BURNER INSTALLATION

FIGURE 18.

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A.O. Smith 104 Series User manual

Brand: A.O. Smith

Model: 104 Series

Category: Water heaters & boilers

Type: User manual

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A.O. Smith 104 Series User manual

A.O. Smith 104 Series User manual

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