Hydro-Smart 115 User manual

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‐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electricswitch,donot
useanyphoneinyourbuilding.
Immediatelycallyourgassupplierfroma
neighbor'sphone.Followthegas
supplier'sinstructions.
Ifyoucannotreachyourgassupplier,call
thefiredepartment.
‐Installationandservicemustbeperformed
byaqualifiedinstaller,serviceagencyorthe
gassupplier.
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Hydro‐Smart115
“MicroBoiler”forRadiantHeating
InstallationManualandOwner’sGuide
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H
y
dro‐Smart115
Ifyouhaveanyquestions,please
callorwriteto:
Hydro‐SmartInc.
10725165thAveNW,
Elk River, MN 55330
WARNING
Iftheinformationinthese
instructionsisnotfollowed
exactly,afireorexplosion
mayresultcausing
propertydamage,personalinjuryordeath.
PleasemakesurethepropergaspressureguidelinesandrecommendationfromHydro‐
Smartfailuretodosocancauseafireorexplosionandmayresult,causingproperty
damage,personalinjury,ordeath.
ANSI Z21.10.3 andCSA4.3

Contents
2│Page
CONTENTS
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SPECIFICATIONS…………………………………………………………………………………………..………………………...
INTRODUCTION…………………………………………………………………………………………………..………………….
SAFETYGUIDELINES…………….………………………………………………………………………………………..………..
INSTALLATION………………………………………………………………………………………………..…………………..….
General………………………………………………………………………………………………………………………..…..…
Clearances…………………………………………………………………………………………………………………………..
IncludedAccessories…………….………………………………………………………………………………………..…..
OptionalItems…………………………………………………………………………………………………………………….
WarningforInstallations…………………………………………………………………………………………………….
High‐AltitudeInstallations…………………………………………………………………………………………………..
VentingInstructions…………………………………………………………………………………………………………...
GasSupplyandGasPipeSizing………........................................................................................
WaterConnections……………..………………………………………………………………………………………………
ElectricalConnections……………………………………………………………………..…………………………….......
RemoteControllerConnections……..……………………………………………………………………….………..…
APPLICATIONS...………………………………………………………………………………………………………………..……
INITIALOPERATION..………………………………………………………………………………………………………….……
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OPERATINGSAFETY…………………………………………………………………………………………………………………
NORMALOPERATION…………………………………………………………………………………………………………..…
General………..……….………….…………………………………………………………………………………………………
Operation……………………………………………………………………………………………………………………….....
TemperatureSettings.…….……..……………………………………………………………………………………………
Flow…………………………………………………………………………………………………………………………………….
FreezeProtectionSystem…….…………………………………………………………………………………………..…
MaintenanceandService………………………………………………………………………………………………….…
UnitDraining…………………………………………….…………………………………………………………………………
TROUBLESHOOTING……..……………………………………………………………………………………………………..…
General………..……….………….…………………………………………………………………………………………………
ErrorCodes.…………………….…..………………………………………………………………………………………………
COMPONENTSDIAGRAM……………………………………………………………………………………………………..…
PARTSLIST………………….………………………………………………………………………………………………..…………
OUTPUTTEMPERATURECHART…………………………………………………………………………………………...…
LIMITEDWARRANTY…………………………………………………………....…………………………………………….….
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InstallationManual
Owner’sGuide

Specifications
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SPECIFICATIONS
ModelHydro‐Smart115
NaturalGasInput
(OperatingRange)
Min:19,500Btu/h
Max:140,000Btu/h
PropaneInput
(OperatingRange)
Min:19,500Btu/h
Max:140,000Btu/h
GasConnection¾”NPT
WaterConnections¾”NPT
WaterPressure15‐150psi*
NaturalGas
InletPressure
Min.5.0”WC
Max.10.5”WC
Propane
InletPressure
Min.8.0”WC
Max.14.0”WC
Manifold
Pressure**
Natural2.0”WC
Propane2.5”WC
Weight33lbs.
DimensionsH20.5”xW13.8”xD6.7”
IgnitionElectricIgnition
Electric
Supply120VAC/60Hz
Consumption
Operation73.1W/0.61A
Standby6.2W/0.05A
Freeze‐
Protection111W/0.93A
*40psioraboveisrecommendedformaximumflow.
**TheManifoldPressureisthefactorysettingandgenerallyshouldnotneedadjustment.
NOTE:
Checktheratingplatetoensurethisproductmatchesyourspecifications.
InaccordancewithANSIZ21.10.3,COemissiondoesnotexceed400PPMfor
normalinput.
Hydro‐Smartreservestherighttodiscontinue,orchangeatanytime,
specificationsordesignswithoutnoticeandwithoutincurringobligations.
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Introduction
4│Page
INTRODUCTION
Thismanualprovidesinformationnecessaryfortheinstallation,operation,and
maintenanceofthewaterheater.
Themodeldescriptionislistedontheratingplatewhichisattachedtothefrontpanel
ofthewaterheater.
Pleasereadallinstallationinstructionscompletelybeforeinstallingthisproduct.
Ifyouhaveanyproblemsorquestionsregardingthisequipment,consultwithHydro‐
Smart.
Hydro‐Smart115isawaterheaterdesignedtobeusedwithradiantheatingina
combinationHydroPanel.
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1. Ahotwatertapisturnedon.
2. Waterenterstheheater.
3. Thewaterflowsensordetectsthewaterflow.
4. Thecomputerinitiatesthefanmotorandsendsasignaltotheignitertocreateanignition
spark.
5. Thegasignitesandflamesappearwithintheburnerchamber.
6. Watercirculatesthroughtheheatexchangerandthengetshot.
7. Usingthermistorstomeasuretemperaturesthroughoutthewaterheater,thecomputer
modulatesthegasandwatervalvestoensureproperoutputwatertemperature.
8. Whentheta
p
isturnedoff
,
theunitshutsdown.
Theprinciplebehindtanklesswaterheatersissimple:
Pleasereadallinstallationinstructionscompletelybeforeinstallingthisproduct.
ThisproductisonlytobeusedwithHydro‐SmartHeatingPanels,“Integrator”.
*Thisdiagram
illustratestankless
waterheaterdesign
conceptsonlyand
doesnotaccurately
representtothewater
heater’sphysical
description.
Watersupply
Heatingpanel“Integrator” Strainer
Gasvalve
Thermistor
Burner
Hydro‐Smart115
GAS
Airvent
Expansiontank
Flowsensor
Watercontrolvalve
Pumpcontroller
Primarypump
Secondarypump
Radiantheating
Checkvalve

SafetyGuidelines
5│Page
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Watertemperaturesover125°F (52
°
C) cancausesevereburnsinstantlyordeath
fromscalding.Thewatertemperatureissetat122°F(50°C)fromthefactoryto
minimizeanyscaldingrisk.Beforebathingorshoweringalwayscheckthewater
temperature.
Donotstoreorusegasolineorotherflammables,vapors,orliquidsinthevicinity
ofthisappliance.
Donotreversethewaterand/orgasconnectionsasthiswilldamagethegas
valvesandcancausesevereinjuryordeath.Followthediagramonp.20when
installingyourwaterheater.
Donotusethisapplianceifanyparthasbeenincontactwithorbeenimmersed
inwater.Immediatelycallalicensedplumber,alicensedgasfitter,ora
professionalservicetechniciantoinspectand/orservicetheunitifnecessary.
Donotdisconnecttheelectricalsupplyiftheambienttemperaturewilldrop
belowfreezing.TheFreezePreventionSystemonlyworksiftheunithaselectrical
power.Thewarrantywillnotbecoverediftheheatexchangerisdamageddueto
freezing.RefertothesectionontheFreezePreventionSystemonp.30formore
information.
SAFETYGUIDELINES
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SAFETYDEFINITIONS
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultin
deathorseriousinjury.
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
indeathorseriousinjury.
Indicatesanimminentlyhazardoussituationwhich,ifnotavoided,couldresult
inminorormoderateinjury.
GENERAL
1. Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecenteditionofthe
NationalFuelGasCode:ANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1NaturalGas,Propane
InstallationCodeinCanada.
2. Properlygroundtheunitinaccordancewithalllocalcodesorintheabsenceoflocalcodes,with
theNationalElectricalCodes:ANSI/NFPA70intheUSAorCSAstandardC22.1CanadaElectrical
CodePart1inCanada.
3. Carefullyplanwhereyouintendtoinstallthewaterheater.Pleaseensure:
Yourwaterheaterwillhaveenoughcombustibleairandproperventilation.
Locateyourheaterwherewaterleakagewillnotdamagesurroundingareas(pleaserefer
top.7).
4. ChecktheratingplateforthecorrectGASTYPE,GASPRESSURE,WATERPRESSUREandELECTRIC
RATING.
*Ifthisunitdoesnotmatchyourrequirements,donotinstallandconsultwithHydro‐Smart.
5. Ifanyproblemshouldoccur,turnoffallhotwatertapsandturnoffthegas.Thencallatrained
technicianortheGasCompanyorHydro‐Smart.
WARNING
CAUTION
DANGER
WARNING

Installation
6│Page
INSTALLATION
GENERAL
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1. Followalllocalcodes,orintheabsenceoflocalcodes,followthemostrecenteditionofthe
NationalFuelGasCode:ANSIZ223.1/NFPA54intheUSAorCAN/CSAB149.1NaturalGas,
PropaneInstallationCodeinCanada.
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2. Allgaswaterheatersrequirecarefulandcorrectinstallationtoensuresafeandefficient
operation.Thismanualmustbefollowedexactly.Readthe“SafetyGuidelines”section.

3. Themanifoldgaspressureispresetatthefactory.Itiscomputercontrolledandshouldnot
needadjustment.

4. Maintainproperspaceforservicing.Installtheunitsothatitcanbeconnectedorremoved
easily.RefertotheClearancesSectiononp.8forproperclearances.
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5. Thewaterheatermustbeinstalledinalocationwheretheproperamountofcombustibleair
willbeavailabletoitatalltimeswithoutobstructions.
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6. Theelectricalconnectionrequiresameansofdisconnection,toterminatepowertothewater
heaterforservicingandsafetypurposes.
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7. Donotinstalltheunitwheretheexhaustventispointingintoanyopeninginabuildingorwhere
thenoisemaydisturbyourneighbors.Makesuretheventterminationmeetstherequired
distancebylocalcodefromanydoorwayoropeningtopreventexhaustfromenteringabuilding
(refertop.15).
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8. Particlesfromflour,aerosols,andothercontaminantsmayclogtheairventorreducethe
functionsoftherotatingfanandcauseimproperburningofthegas.Regularlyensurethatthe
areaaroundtheunitisdust‐ordebris‐free;regularmaintenanceisrecommendedforthese
typesofenvironment.
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9. Ifyouwillbeinstallingthewaterheaterinacontaminatedareawithahighlevelofdust,sand,
flour,aerosolsorothercontaminants/chemicals,theycanbecomeairborneandenterandbuild
upwithinthefanandburnercausingdamagetothewaterheater.
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10. FortheHydro‐Smart115:
Theseunitsmaybeconvertedtoadirect‐vent(sealedcombustion)appliancebyinstallinga
direct‐ventconversionkitPartNo.9007667005(TK‐TV10)whichwillbringinallrequired
combustibleairfromoutsidethebuilding.Wheninstallingthedirect‐ventconversionkit,
pleasefollowallinstructionsincludedwiththekit.
Ifthewaterheaterisusedasadirect‐ventappliance,theunitrequiresa3”combustibleair
supplypipe.Theintakepipemustbesealedairtight.AirsupplypipecanbemadeofABS,
PVC,galvanizedsteel,corrugatedaluminum,corrugatedstainlesssteelorCategoryIII
stainlesssteel.
Terminatingtheventingthroughasidewallisrecommendedforthedirect‐ventsystem.
Runningtheexhaustventandtheintakepipeparallelisrecommended.
Terminatingtheexhaustandintakeonthesamewall/surfaceisrecommended.
Terminatinginthesamepressurezoneallowsforpressurebalancing,whichprevents
nuisanceshutdowns.


Installation
7│Page
Installationandservicemustbeperformedbyaqualifiedinstaller(for
example,alicensedplumberorgasfitter),otherwisethewarrantybyHydro‐
Smartwillbevoid.
Theinstaller(licensedprofessional)isresponsibleforthecorrectinstallation
ofthewaterheaterandforcompliancewithallnational,state/provincial,
andlocalcodes.
Hydro‐Smartdoesnotrecommendinstallingthewaterheaterinapitor
locationwheregasandwatercanaccumulate.
Donothavetheventterminalpointingtowardanyoperatingwindow,door,or
openingintoabuilding.
Donotinstallnexttoanysourceofairbornedebris,suchasaclothesdryer,
thatcancausedebristobetrappedinsidethecombustionchamber,unless
thesystemisdirect‐vented.
Hydro‐Smartdoesnotrecommendinstallingthewaterheaterinanatticdue
tosafetyissues.Ifyouinstallthewaterheaterinanattic:
Makesuretheunitwillhaveenoughcombustionairandproperventilation.
Keeptheareaaroundthewaterheaterclean.Whendustcollectsonthe
flamesensor,thewaterheaterwillshutdownonanerrorcode.
Iftheaboveconditionscannotbemet,usethedirectventconversionkit
PartNo.9007667005(TK‐TV10).
Placetheunitforeasyaccessforserviceandmaintenance.
Adrainpan,orothermeansofprotectionagainstwaterdamage,is
re
q
uiredtobeinstalledunderthewaterheaterincaseofleaks.
Thewarrantywillnotcoverdamagecausedbywaterquality.
Onlypotablewaterorpotablewater/glycolmixturescanbeusedwiththis
waterheater.Donotintroducepoolorspawater,oranychemically
treatedwaterintothewaterheater.
Waterhardnesslevelsmustnotexceed7grainspergallon(120ppm)for
singlefamilydomesticapplicationsormorethan4grainspergallon(70
ppm)forallothertypesofapplications.Waterhardnessleadstoscale
formationandmayaffect/damagethewaterheater.Hardwaterscaling
mustbeavoidedorcontrolledbyproperwatertreatment.
WaterpHlevelsmustbebetween6.5and8.5
Wellwatermustbetreated.
Donotinstalltheunitwherewater,debris,orflammablevaporsmaygetinto
theflueterminal.
Hydro‐Smartrecommendsusingthedirectventkitwhenthewaterheateris
installedinabeautysalon.Somechemicalsusedinabeautysalonmayaffect
theflamesensor.Waterheatermaynotworkproperly.
Althoughthewaterheaterisdesignedtooperatewithminimalsound,Hydro‐
Smartdoesnotrecommendinstallingtheunitonawalladjacenttoa
bedroom,oraroomthatisintendedforquietstudyormeditation,etc.
Locateyourheaterclosetoadrainwherewaterleakagewillnotdodamageto
surroundingareas.Aswithanywaterheatingappliance,thepotentialfor
leakageatsometimeinthelifeoftheproductdoesexist.Hydro‐Smartwill
notberesponsibleforanywaterdamagethatmayoccur.Ifyouinstalladrain
panundertheunit,ensurethatitwillnotrestrictthecombustionairflow.




CAUTION
WARNING

Installation
8│Page


CLEARANCES













ModelTopBottomFrontBackSides
Hydro‐Smart115*12”12”24”1”2“
*Standardindoorinstallationsanddirect‐ventindoorinstallationshavethesameclearances.





INCLUDEDACCESSORIES

Checkthattheseitemsbelowareincludedwiththewaterheater.

1.InstallationManualand
Owner’sGuide

2. ProductRegistrationCard 3.Remotecontroller
900766605(TK‐RE02)





OPTIONALITEMS
ModelHydro‐Smart115
9007678005(TK‐BF01) ✔
9007667005(TK‐TV10) ✔
9007671005(TK‐PCJr2) ✔
9007608005(TK‐KPWL4)
9007609005(TK‐KPWH4) ✔
9007680005(TK‐KPCT43) ✔


Bottom
Side
Top
Side
Front
Back
Maintainallclearancesaround
thewaterheater.
Qty:1Qty:1Qty:1

Installation
9│Page


1.BackflowPreventer:9007678005(TK‐BF01)
TheBackflowpreventerprevents
thebackflowofairthroughthe
exhaustvent.Thishelpsprevent
harmfulexhaustgasesfrom
enteringthehome,aswellas
helpingtopreventtheunitfrom
freezinginareaswherecoldaircanbeblown
ordrawnintotheexhaustsystem.Installthis
ventdamperinaccordancewiththe
installationinstructionsandanyapplicable
codes.
2.Direct‐VentConversionKit:9007667005
(TK‐TV10)
Thiskitcanbeusedto
convertthewater
heaterfromastandard
ventsystemtoa
direct‐vent(orsealed
combustion)system.
Installthisconversionkitinaccordancewith
theinstallationinstructionsandanyapplicable
codes.
3.PipeCovers:9007671005(TK‐PCJr2)
Thepipecoverprotectstheplumbingpipestothewaterheaterfromunexpected
adjustments.Thispipecoverisfixedtothebottomofthewaterheater,whichhides
theplumbingandimprovesthevisualaspectsofthewholeinstallationforthewater
heater.
4.T‐VentWallThimblewithTermination:9007608005(TK‐KPWL4)and9007609005(TK‐KPWH4)

Theseterminationsareusedwhenventingoutthroughthewall
andarecompatiblewiththeT‐Ventpipesystem.
Theseterminationsarespecialstainlesssteelventsforgas
appliancesandareULlistedasCategoryII,IIIandIV.Thereare
twotypesofterminations:theLouverterminationandtheHood
termination.Fordifferentwallthicknesses,therearetworanges
oflengthsavailable(refertotheventingbrochurefordetails).
Installtheseventterminationsinaccordancewiththeir
installationinstructionsandanyapplicablelocalcodes.

5.Direct‐VentConcentricTermination:9007680005(TK‐KPCT43)

Usedwhenterminatingdirect‐vent(sealed‐combustion)systems,
withdirect‐ventmodelsthatrequirea3”intakeanda4”exhaust.
Thisconcentricterminationprovidestheconvenienceofonly
havingtomakeonepenetrationthroughasidewallinsteadoftwo
separatepenetrationsfortheintakeandexhaustpiping.The
terminationincludesabirdscreen,restrictingsmallanimals,
pests,andforeignobjectsfromenteringintotheventsystem.
Thissidewallterminationisavailableinthreedifferentsizes,to
coverallrangesofwallthicknesses.
Direct‐ventConcentricTermination
Part#Coveringwallthickness
9007680005(TK‐KPCT43‐1)3.9”–7.1”
9007772005(TK‐KPCT43‐2)6.9”–10.1”
9007773005(TK‐KPCT43‐3)9.8”–13.0”
Louver
Termination
9007608005
(TK‐KPWL4)
Hood
Termination
9007609005
(TK‐KPWH4)

Installation
10│Page

WARNINGFORINSTALLATIONS
FORYOURSAFETY,READBEFOREINSTALLATION:
DonotinstalltheHydro‐Smart115wherewater,
debrisorflammablevaporsmaygetintotheflue
terminal.ThismaycausedamagetotheHydro‐
Smart115andvoidthewarranty.


Donotinstallnexttoadryeroranysourceof
airbornedebristhatcanbetrappedinsidethe
combustionchamber,unlessthesystemisdirect
vented.
Hydro‐Smart115isprohibitedandnot
recommendstobeinstalledinanatticdueto
safetyissues.


FORYOURSAFETY,READBEFOREINSTALLATION:
Prohibited
Prohibited

Installation
11│Page
HIGH‐ALTITUDEINSTALLATIONS

Checktheelevationwhereyourwaterheaterisinstalled.Setdipswitchesshowninthetablebelow
dependingonthealtitude.

Altitude0to2,000ft
(DEFAULT)2,000to4,000ft 4,000to6,000ft Over6,000ft
SwitchNo.3OFFON OFF
Consult
Hydro‐Smart
at763‐
331‐3066
SwitchNo.4OFFOFFON

OFF
ON12345678
OFF
ON12345678
OFF
ON12345678

WARNING
Thedarksquaresindicatethe
directionthedipswitchesshould
besetto.
Dipswitches

Installation
12│Page
Improperventingofthisappliancecanresultinexcessivelevelsofcarbon
monoxidewhichcanresultinseverepersonalinjuryordeath.

Improperinstallationcancausenauseaorasphyxiation,severeinjuryordeathfrom
carbonmonoxideandfluegasespoisoning.Improperinstallationwillvoidproduct
warranty.
Wheninstallingtheventsystem,allapplicablenationalandlocalcodesmustbe
followed.Ifyouinstallthimbles,firestopsorotherprotectivedevicesandthey
penetrateanycombustibleornoncombustibleconstruction,besuretofollowall
applicablenationalandlocalcodes.
VENTINGINSTRUCTIONS
‐General‐
Thewaterheatermustbeventedinaccordancewiththesection“VentingofEquipment"ofthelatest
editionoftheNationalFuelGasCode:ANSIZ223.1/NFPA54intheUnitedStatesand/orSection7ofthe
CAN/CSAB149.1NaturalGasandPropaneInstallationCodeinCanada,aswellasapplicablelocal
buildingcodes.
Hydro‐Smartrecommendsthe“T‐Vent”linemanufacturedbyTAKAGI(Referto“T‐Vent”brochurefor
details).However,thefollowingarealsoULlistedmanufacturers:ProTechSystemsInc.(FasNSeal),Flex‐
LInc.,Z‐FlexInc.(Z‐VentIII),Metal‐FabInc.,andHeat‐FabInc.(Saf‐TVent).


Generalrulesforventingwaterheatersare:
Placethewaterheaterascloseaspossibletotheventterminator.
Theventcollarofthewaterheatermustbefasteneddirectlytoanunobstructedventpipe.
Donotweldtheventpipetothewaterheater’sventcollar.
Donotcuttheventcollaroftheunit.
Theventmustbeeasilyremovablefromthetopofthewaterheaterfornormalserviceand
inspectionoftheunit.
Thewaterheaterventmustnotbeconnectedtoanyothergasapplianceorventstack.
Avoidusinganoversizedventpipeorusingextremelylongrunsofthepipe.
Forrooftopventing,araincaporotherformofterminationthatpreventsrainwaterfrom
enteringintothewaterheatermustbeinstalled.
Donotcommonventorconnectanyventfromotherappliancestothewaterheatervent.

Generalrulesforventterminations:
Avoidlocatingthewaterheaterventterminatornearanyairintakedevices.Thesefanscan
pickuptheexhaustflueproductsfromthewaterheaterandreturnthemtothebuilding.
Thiscancreateahealthhazard.
Locatetheventterminatorsothatitcannotbeblockedbyanydebris,atanytime.Most
codesrequirethattheterminatorbeatleast12inchesabovegrade,buttheinstallermay
determineifitshouldbehigherdependingonthejobsiteconditionandapplicablecodes.
Apropersidewallterminatorisrecommendedwhenthewaterheaterisventedthrougha
sidewall.
Regardingtheclearancesfromtheexhaustterminatortotheairinletoropening,referto
thenextfewpages.
CAUTION
DANGER

Installation
13│Page
‐Exhaustventing‐
ThisisaCategoryIIIapplianceandmustbeventedaccordingly.Theventsystemmustbesealedairtight.
AllseamsandjointswithoutgasketsmustbesealedwithhighheatresistantsiliconesealantorULlisted
aluminumadhesivetapehavingaminimumtemperatureratingof350°F.Forbestresults,aventsystem
shouldbeasshortandstraightaspossible.
ThiswaterheaterisaCategoryIIIapplianceandmustbeventedaccordinglywithany4”vent
approvedforusewithCategoryIIIorSpecialBHtypegasvent.
Followtheventpipemanufacturer’sinstructionswheninstallingtheventpipe.
Donotcommonventthisappliancewithanyotherventedappliance(Donotterminatevent
intoachimney.Iftheventmustgothroughthechimney,theventmustrunalltheway
throughthechimneywithCategoryIIIapprovedorSpecialBHventpipe).
Whenthehorizontalventrunexceeds5ft.,supporttheventrunat3ft.intervalswith
overheadhangars.
Themaximumlengthofexhaustventpipingmustnotexceed50ft.(deducting5ft.foreach
elbowusedintheventingsystem).Donotusemorethan5elbows.
DiameterMax.No.ofElbowMax.VerticalandHorizontal(Total)VentLength
4”550ft.
*Foreachelbowadded,deduct5ft.frommax.Ventlength.
No.ofElbowsMax.VerticalorHorizontalLength
050ft.
145ft.
240ft.
525ft.

‐VentingIllustrations‐
HorizontalInstallationDiagramVerticalInstallationDiagram
SidewallVent
Terminator
Wall
BackflowPreventer*
VerticalCondensationDrain**
Fordetailsoftheoptionalitems,refertotheInstallationmanualforeachOptionalitem.
Roo
f
VerticalCondensation
Drain**
RoofFlashing
RainCap
BackflowPreventer*

Installation
14│Page

*BackflowPreventer (Recommendedforfreezingweatherconditions:36
°
Fandbelow)
**VerticalCondensationDrainmustbeinstalledaccordancewithlocalcodes.
HorizontalInstallationDiagram
WithDirect‐VentConcentric
Termination
HorizontalInstallationDiagram
(Withdirect‐venting)
VerticalInstallationDiagram
(Withdirect‐venting)
Thewaterheater
Intakeportof
Direct‐Vent
ConversionKit

InstallationDiagramofDirect‐Vent
ConversionKitwithwaterheater
Wall
Direct‐vent
Concentric
Termination
PlateofDirect‐VentConversionKit

Seethepicturebelowfordetailedconnection
instructionstotheDirect‐VentConversionKit.
VerticalCondensationDrain**

Backflow
Preventer*
Wall
Sidewall
Vent
Terminator
RoofFlashing
Vertical
Condensation
Drain**
Backflow
Preventer*
RainCap
Roo
f
Firestop

Installation
15│Page

‐Ventterminationclearances‐


Canada U.S.A
Directventand
otherthanDirect
Vent
Directvent OtherthanDirectVent
AClearanceabovegrade,veranda,porch,deck,
orbalcony.1foot1foot1foot
BClearancetowindowordoorthatmaybe
opened.3feet1foot
4feetfrombeloworside
opening.1footfrom
aboveopening.
CClearancetopermanentlyclosedwindow * * *
D
Verticalclearancetoventilatedsoffitlocated
abovetheventterminatorwithinahorizontal
distanceof2feet(61cm)fromthecenterline
oftheterminator.
***
EClearancetounventilatedsoffit* * *
FClearancetooutsidecorner* * *
GClearancetoinsidecorner* * *
HClearancetoeachsideofcenterlineextended
abovemeter/regulatorassembly3feet**
IClearancetoserviceregulatorventoutlet. 3feet * *
J
Clearancetonon‐mechanicalairsupplyinlet
tobuildingorthecombustionairinlettoany
otherapplication.
3feet1foot
4feetfrombeloworside
opening.1footfrom
aboveopening.
KClearancetomechanicalairsupplyinlet. 6feet 3feet 3feet
LClearanceabovepavedsidewalkorpaved
drivewaylocatedonpublicproperty.7feet*7feet
MClearanceunderveranda,porchdeck,or
balcony.1foot**
*ForclearancesnotspecifiedinANSIZ223.1/NFPA54orCAN/CSA‐B149.1,pleaseuseclearancesinaccordancewith
localinstallationcodesandtherequirementsofthegassupplier.

Installation
16│Page
Pleasefollowalllocalandnationalcodesinregardstoproperterminationclearances.
Intheabsenceofsuchcodes,thefollowingclearancescanbeusedasguidelines.Local
codessupersedetheseguidelines.



Forsidewallterminations

Exhausttermination
1ft.
1ft.2ft.
Inside
corner
Formultiplesidewallexhaust
terminations(e.g.multi‐unit
systems),anexhausttermination
mustbeatleast1ft.awayfrom
anotherexhausttermination.An
exhaustterminationmustalsobe
atleast2ft.awayfromaninside
corner(iftheadjacentwallisless
than2ft.oflength,theminimum
requireddistanceawayfromthe
insidecornerwillbeequaltothe
lengthofthatadjacentwall).
Fordirect‐ventsidewall
terminationsthatusetwo
separatepenetrationsforthe
intakeandexhaust,distance
theintakeandexhaust
terminationsatleast3ft.away
fromeachother,nomatterthe
orientation.
Formultiple‐unit,direct‐ventsidewall
terminationsthatcombinetheintake
andexhaustintoasinglepenetration,
spaceeachdirect‐ventterminationat
least1ft.awayfromeachother,no
mattertheorientation.Adirect‐vent
terminationmustalsobeatleast2ft.
awayfromaninsidecorner(ifthe
adjacentwallislessthan2ft.of
length,theminimumrequired
distanceawayfromtheinsidecorner
willbeequaltothelengthofthat
adjacentwall).
Formultiple‐unitrooftopterminations(whetherforstandardindooror
direct‐ventinstallations)spaceallexhaustandintaketerminationsin
accordancewithlocalcodes.Anexhaustterminationmustbespacedfrom
awallorsurfaceinaccordancewithlocalcodesaswell.Intheabsenceof
suchacode,anexhaustterminationmustbeahorizontaldistanceofat
least2ft.awayfromawallorsurface.
A:Inaccordancewithlocalcodes
Forrooftopterminations
Airintake
Exhausttermination
A
A
A
A
A
2ft.
Airintake
Exhaust
termination
Exhaustand/ordirect‐vent
sidewallterminationsshould
beatleast2ft.awayfroman
oppositesurface/wall.Do
notplacethetermination
directlyinfrontofan
openingintoabuilding.
2ft.
Exhaust
termination
Airsupplyinlet
3ft.
3ft.
3ft.
Directventtermination
1ft.
1ft.
Inside
corner
2ft.
CAUTION

Installation
17│Page
Sizethegaspipeappropriatelytosupplythenecessaryvolumeofgasrequiredfor
thewaterheaterusingANSI233.1/NFPA54intheUSAorCAN/CSAB149.1inCanada
orlocalcodes.Otherwise,flowcapabilitiesandoutputtemperatureswillbelimited.
Checkthatthetypeofgasmatchestheratingplatefirst.
Ensurethatanyandallgasregulatorsusedareoperatingproperlyand
providinggaspressureswithinthespecifiedrangeshownbelow.Excessgas
inletpressuremaycauseseriousaccidents.
Conversionofthisunitfromnaturalgastopropaneorviseversawillvoidall
warranty.Contactyourlocaldistributortogetthecorrectunitforyourgas
type.Themanufacturerisnotliableforanypropertyand/orpersonal
damageresultingfromgasconversions.

GASSUPPLYANDGASPIPESIZING
‐General‐

Theminimumandmaximuminletgaspressuresare:
GastypeInletgaspressure
NaturalGasMin.5.0”WC–Max.10.5”WC
PropaneMin.8.0”WC–Max.14.0”WC
Gaspressureabovethisspecifiedrangeforthewaterheaterand/orinsufficientgasvolumewill
adverselyaffectperformance.Thesepressuresaremeasuredwhenthewaterheaterisinfull
operation.
Inletgaspressuremustnotexceedtheabovemaximumvalues;gaspressureabovethespecified
rangewillcausedangerousoperatingconditionsanddamagetotheunit.
Untiltestingofthemaingaslinesupplypressureiscompleted,ensurethegaslinetothewater
heaterisdisconnectedtoavoidanydamagetothewaterheater.



‐Gasconnections‐
1. Installamanualgasshut‐offvalvebetweenthewaterheaterandthegassupplyline.
2. Whenthegasconnectionsarecompleted,itisnecessarytoperformagasleaktest(seebelow)
eitherbyapplyingsoapywatertoallgasfittingsandobservingforbubblesorbyusingagasleak
detectiondevice.
Thewaterheateranditsindividualshutoffvalvemustbedisconnectedfromthegassupply
pipingsystemduringanypressuretestingofthatsystemattestpressuresinexcessof1/2psi
(3.5kPa).
Thewaterheatermustbeisolatedfromthegassupplypipingsystembyclosingitsindividual
manualshutoffvalveduringanypressuretestingofthegassupplypipingsystemattest
pressuresequaltoorlessthan1/2psi(3.5kPa).
3. Alwayspurgethegaslineofanydebrisand/orwaterbeforeconnectingtothegasinlet.






WARNING
NOTICE

Installation
18│Page


‐NaturalGasSupplyPiping‐
MaximumDeliveryCapacityofCubicFeetofGasperHourofIPSPipeCarryingNaturalGasof0.60SpecificGravity
BasedonPressureDropof0.5”WC

BasedonEnergyContentof1,000BTU/CubicFt.:Thewaterheaterrequires140CubicFt./hr.
Unit:CubicFeetperHour
PipeSizeLength
Diameter10’20’30’40’50’60’70’80’90’100’125’150’ 200’
¾”363249200171152138127118111104938472
1”684470377323286259239222208197174158 135
1¼”1,404965775663588532490456428404358324 278
1½”2,1031,445 1,161993 880 798 734 683 641 605536486 416
2”4,0502,784 2,2351,913 1,696 1,536 1,413 1,315 1,2341,1651,033 936 801
‐Propane(LP)SupplyPiping‐
MaximumCapacityofPropane(LP)Basedon11”WCsupplypressureata0.5”WCpressuredrop
Unit:kBTUperHour
PipeSize Length
Diameter 10’20’30’40’50’60’70’80’90’100’125’150’ 200’
¾”567393315267237217196185173162146132112
1”1,071732590504448409378346322307275252213
1¼”2,2051,4961,2121,039913834771724677630567511440
1½”3,3072,2991,8581,5591,417 1,275 1,181 1,086 1,023 976866787675
2”6,2214,3313,4652,9922,646 2,394 2,205 2,047 1,921 1,8111,6061,496 1,260
Formoreinformation,pleaseseethebelow.
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BasedonEnergyContentof1,000BTU/CubicFt:
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Divideeachappliance’sBTUrequirementby1,000BTUtoget
theappliancesCubicFt.requirement.

Takeintoaccountthedistancetheapplianceisfromthegas
meter,lookintheabovegascharttoproperlysizetheline.

Forsectionsofthegaslinesupplyinggastomorethanone
appliance(Ex:PointAtoPointB),addupthecubicft.
requirementsoftheappliancesthatarebeingsuppliedbythat
section,andsizetothefarthestappliance.

ForExample:ThesectionfromAtoBsuppliesgastothe
furnace,range,anddryer.AddinguptheBTUrequirements
anddividingby1,000yieldsacubicft.requirementof220
cubicft.ofgas.Thefarthestapplianceistherange,whichis50
ft.awayfromthemeter.Lookingattheabovechart,and
underthecolumnof50ft.,SectionAtoBneedstobe1”in
ordertosupply220cubicft.
10’Length
1”PipeSizeC
GasSizingExample
(NaturalGas)
10’Length
3/4”PipeSize
15’Length
1/2”PipeSize
10’Length
1/2”PipeSize
Furnace
120,000BTU
Water
Heater
199,000BTU
5’Length
1‐1/4”PipeSize
Range
65,000BTU
10’Length
3/4”PipeSize
Dryer
35,000BTU
15’Length
1”PipeSize
5’Length
1‐1/4”PipeSize
GasMeter
B
A

Installation
19│Page
1. Turnoffallelectricpowertothewaterheaterifserviceistobeperformed.
2. Turnthemanualgasvalvelocatedontheoutsideoftheunitclockwiseto
theoffposition.
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‐Measuringinletgaspressure‐
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Thewaterheatercannotperformproperlywithoutsufficientinletgaspressure.Belowareinstructions
onhowtochecktheinletgaspressure.THISISONLYTOBEDONEBYALICENSEDPROFESSIONAL.

1. Shutoffthemanualgasvalveonthesupplygasline.
2. Removethescrewforthepressureportlocatedon
thegasinletofthewaterheatershowninthe
diagramtotheright.
3. Connectthemanometertothepressureport.
4. Re‐openthemanualgasvalve.Checktoseethat
therearenogasleaks.Opensomeofthefixtures
thatusethehighestflowratetoturnonthewater
heater.
5. Checktheinletgaspressure.Whenthewaterheater
isonmaximumburn,themanometershouldread
from5.0”to10.5”WCforNaturalgas,from8.0”to
14.0”WCforPropane.
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Pressureport

Installation
20│Page
Donotusethiswaterheaterifanyparthasbeensubmersedunderwater.
Immediatelycallalicensedprofessionaltoinspectthewaterheatertoreplace
anydamagedparts.
Donotreversethehotoutletandcoldinletconnectionstothewaterheater.
Thiswillnotproperlyactivatethewaterheater.
WATERCONNECTIONS
Allpipes,pipefittings,valvesandothercomponents,includingsolderingmaterials,mustbesuitablefor
potablewatersystems.
1. Amanualshutoffvalvemustbeinstalledonthecoldwaterinlettothewaterheaterbetween
themainwatersupplylineandthewaterheater.
2. Inaddition,amanualshutoffvalveisalso
recommendedonthehotwateroutletofthe
unit.Ifthewaterheaterisinstalledwithin,or
subjectedto,aclosedloopwatersystem,a
thermalexpansiontankmustbeinstalled.
3. Beforeinstallingthewaterheater,flushthe
waterlinetoremovealldebris,andafter
installationiscomplete,purgetheairfromthe
line.Failuretodosomaycausedamagetothe
heater.
4. Thereisawirewithinthecoldinlettotrap
debrisfromenteringyourheater.Thiswillneed
tobecleanedperiodicallytomaintainoptimum
flow.
‐Pressurereliefvalve‐
Thewaterheaterhasahigh‐temperatureshutoffswitchbuiltinasastandardsafetyfeature(calleda
Hi‐Limitswitch)thereforea“pressureonly”reliefvalveisrequired.
Thisunitdoesnotcomewithanapprovedpressurereliefvalve.
Anapprovedpressurereliefvalvemustbeinstalledonthehotwateroutlet.
ThepressurereliefvalvemustconformtoANSIZ21.22orCAN1‐4.4andinstallationmustfollow
localcode.
Thedischargecapacitymustbeatleast140,000BTU/h.
Thepressurereliefvalveneedstoberatedforamaximumof150psi.
Thedischargepipingforthepressurereliefvalvemustbedirectedsothatthehotwatercannot
splashonanyoneoronnearbyequipment.
Attachthedischargetubetothepressurereliefvalveandruntheendofthetubetowithin6"
fromthefloor.Thisdischargetubemustallowfreeandcompletedrainagewithoutany
restrictions.
Ifthepressurereliefvalveinstalledonthewaterheaterdischargesperiodically,thismaybedue
toadefectivethermalexpansiontankordefectivepressurereliefvalve.
Thepressurereliefvalvemustbemanuallyoperatedperiodicallytocheckforcorrectoperation.
Novalvemustbeplacedbetweenthereliefvalveandthewaterheater.
Pressure
ReliefValve
Hot
outlet
Cold
inlet
Gas
inlet
AsCloseas
Possible
CAUTION