American Water Heater 98 Gallon 80 Thermal Efficiency UltraLow NOx Heavy Duty Commercial Gas Water Heater User Manual

							11
WATER PIPING
WATER (POTABLE) HEATING AND SPACE HEATING
This	water	 heater	 shall	not	be	connected	 to	any	 heating	 systems 	
or	 component(s)	 used	with	a	non-potable	 water	heating	 appliance.
All	 piping	 components	 connected	to	this	 unit	 for	space	 heating 	
applications	shall	be	suitable	for	use	with	potable	water.
Toxic	 chemicals,	 such	as	those	 used	for	boiler	 treatment 	shall	 not	
be	introduced	into	this	system.
When	 the	system	 requires	 water	for	space	 heating	 at	temperatures 	
higher	 than	required	 for	domestic	 water	purposes,	 a	mixing	 valve	
must	 be	installed.		 Please	refer	to	Figure	 6	for	 suggested	 piping	
arrangement. 	
These	 water	heaters	 cannot	be	used	 in	space	 heating	 applications 	
only.
CLOSED WATER SYSTEMS
Water	 supply	 systems	 may,	because	 of	code	 requirements	 or	
such	 conditions	 as	high	 line	pressure,	 among	others,	 have	
installed	 devices	such	as	pressure	 reducing	valves,	check	
valves,	 and	back	 flow	preventers.	 Devices	such	as	these	 cause	
the	water	system	to	be	a	closed	system.
THERMAL EXPANSION
As	 water	 is	heated,	 it	expands	 (thermal	expansion).	 In	a	closed 	
system	 the	volume	 of	water	 will	grow	 when	 it	is	 heated.	 As	the	
volume	 of	water	 grows	 there	will	be	a	corresponding	 increase	in	
water	 pressure	 due	to	thermal	 expansion.	 Thermal	expansion 	
can	 cause	 premature	 tank	failure	 (leakage).	 This	type	 of	failure 	
is	 not	 covered	 under	the	limited	 warranty.	 Thermal	expansion 	
can	 also	 cause	 intermittent	 Temperature-Pressure	 Relief	Valve	
operation:	 water	discharged	 from	the	valve	 due	to	excessive 	
pressure	 build	up.	This	 condition	 is	not	 covered	 under	the	limited 	
warranty.	 The	Temperature-Pressure	 Relief	Valve	is	not	 intended 	
for	the	constant	relief	of	thermal	expansion.
A 	properly	 sized	thermal	 expansion	 tank	must	 be	installed	 on	
all	 closed	 systems	 to	control	 the	harmful	 effects	of	thermal 	
expansion.	 Contact	a	local	 plumbing	 service	technician	 to	have 	
a	thermal	expansion	tank	installed.
FIGURE 7.
NOTE:	 To	protect	 against	 untimely	 corrosion	of	 hot	 and	cold 	
water	 fittings,	 it	is	 strongly	 recommended	 that	di-electric	 unions	
or	 couplings	 be	installed	 on	this	 water	 heater	 when	connected	 to	
copper	pipe.
Figure	 7	shows	 the	typical	 attachment	 of	the	 water	 piping	 to	the 	
water	heater.
TEMPERATURE-PRESSURE RELIEF VALVE
Explosion Hazard
Te mperature-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	
certified	 combination	 Temperature-Pressure	 Relief	Valve	 (T&P	
valve) 	by 	the	 manufacturer. 	The	 valve	 is	certified	 by	a	 nationally 	
recognized	 testing	laboratory	 that	maintains	 periodic	inspection 	
of	 production	 of	listed	 equipment	 of	materials	 as	meeting	 the	
requirements	 for	Relief	 Valves	 for	Hot	 Water	 Supply	 Systems, 	
ANSI	 Z21.22	 •	CSA 	4.4,	 and	the	code	 requirements	 of	ASME.
If	 replaced,	 the	new	 T&P	valve	 must	meet	 the	requirements 	
of	 local	 codes,	 but	not	less	 than	 a	combination	 Temperature-
Pressure	 Relief	Valve	rated/sized	 and	certified	 as	indicated	 in	
the	 above	 paragraph.	 The	new	 valve	 must	be	marked	 with	a	
maximum	 set	pressure	 not	to	exceed	 the	marked	 hydrostatic 	
working	 pressure	 of	the	 water	 heater	 (150	psi	=	1,035	 kPa)	
and	 a	discharge	 capacity	not	less	 than	 the	water	 heater	 Btu/
hr	 or	kW	 input	 rate	as	shown	 on	the	 water	 heater’s	 model	
rating	label. 
						

							12
NOTE:	In	addition	 to	the	 factory	 installed	 Temperature-Pressure 	
Relief	 Valve	on	the	 water	 heater,	 each	remote	 storage	 tank	that	
may	 be	installed	 and	piped	 to	a	water	 heating	 appliance	 must	also	
have	 its	own	 properly	 sized,	rated	 and	approved	 Temperature-
Pressure	 Relief	Valve	installed.	 Call	the	toll	free	 technical	 support	
phone	 number	 listed	on	the	 back	 cover	 of	this	 manual	 for	technical 	
assistance	 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	
directly	 into	the	fitting	 of	the	 water	 heater	 designed	 for	the	 relief	 valve. 	
Install	 discharge	 piping	so	that	 any	discharge	 will	exit	 the	pipe	 within	
6	 inches	 (15.2	cm)	above	 an	adequate	 floor	drain,	 or	external	 to	the	
building.	 In	cold	 climates	 it	is	 recommended	 that	it	be	 terminated	 at	
an	 adequate	 drain	inside	 the	building.	 Be	certain	 that	no	contact	 is	
made	 with	any	live	electrical	 part.	The	discharge	 opening	must	not	
be	 blocked	 or	reduced	 in	size	 under	 any	circumstances.	 Excessive	
length,	 over	30	feet	 (9.14	 m),	or	use	 of	more	 than	four	elbows	 can	
cause	restriction	and	reduce	the	discharge	capacity	of	the	valve.
No	 valve	 or	other	 obstruction	 is	to	 be	 placed	 between	 the	
Temperature-Pressure	 Relief	Valve	and	the	tank.	 Do	not	 connect 	
discharge	 piping	directly	 to	the	 drain	 unless	 a	6”	 (15.2	 cm)	air	gap	 is	
provided. 	To	 prevent 	bodily	 injury,	hazard	 to	life, 	or	 property	 damage,	
the	 relief	 valve	 must	be	allowed	 to	discharge	 water	in	adequate 	
quantities	 should	circumstances	 demand.	If	the	 discharge	 pipe	is	
not	 connected	 to	a	drain	 or	other	 suitable	 means,	the	water	 flow	
may	cause	property	damage.
Wa ter Damage Hazar d
 Temperature- Pressure Relief  Valve discharge
  pipe must terminate at adequate drain.
CAUT ION
T&P Valve Discharge Pipe Requirements:
•  Shall	not	be	smaller	in	size	than	the	outlet	pipe	size	of	the	valve, 	
or	have	any	reducing	couplings	or	other	restrictions.
•  Shall	not	be	plugged	or	blocked.
•  Shall	not	be	exposed	to	freezing	temperatures.
•  Shall	be	of	material	listed	for	hot	water	distribution.
•  Shall	be	installed	so	as	to	allow	complete	drainage	of	both	the 	
Temperature-Pressure	Relief	Valve	and	the	discharge	pipe.
•  Must	terminate	a	maximum	of	six	inches	above	a	floor	drain	
or	external	to	building.	In	cold	climates,	it	is	recommended	
that 	discharge	pipe	be	terminated	at	an	adequate	drain	inside 	
building.
•  Shall	not	have	any	valve	or	other	obstruction	between	the	
relief	valve	and	the	drain.
Burn hazard.
Hot water discharge. Keep clear of  Temperature-
Pressure Relief V alve
discharge outlet.
The	 Temperature-Pressure	 Relief	Valve	must	be	manually	 operated	
at 	least 	twice	 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	 discharge	 line,	and	 (2)	the	 water 	manually 	discharged 	
will 	not	 cause 	any	 bodily	 injury	or	property	 damage	because 	
the	 water	 may	be	extremely	 hot.	If	after	 manually	 operating	 the	
valve,	 it	fails	 to	completely	 reset	and	continues	 to	release	 water,	
immediately	 close	the	cold	 water	 inlet	to	the	 water	 heater,	 follow	the	
draining	 instructions	 in	this	 manual,	 and	replace	 the	Temperature-
Pressure	 Relief	Valve	with	a	properly	 rated/sized	 new	one.
NOTE:	 The	purpose	 of	a	Temperature-Pressure	 Relief	Valve	is	to	
prevent	 excessive	 temperatures	 and	pressures	 in	the	 storage	 tank.	
The	 T&P	valve	 is	not 	intended	 for	the	 constant	 relief	of	thermal 	
expansion.	 A	properly	 sized	thermal	 expansion 	tank	 must	 be	installed 	
on	 all	closed	 systems	 to	control	 thermal	 expansion, 	see	 Closed 	
Water	 Systems	 and	Thermal	 Expansion	 on	page	 11.
If	 you	 do	not	 understand	 these	instructions	 or	have	 any	questions	
regarding	 the	Temperature-Pressure	 Relief	Valve	 call	the	toll	free	 number 	
listed	on	the	back	cover	of	this	manual	for	technical	assistance.
FILLING THE WATER HEATER
Never	 use	this	water	 heater	 unless	 it	is	 completely	 full	of	water.	 To	
prevent	 damage	 to	the	 tank,	 the	tank	 must	 be	filled	 with	water.	 Water	
must	 flow	from	 the	hot	water	 faucet	 before	 turning	 “ON”	gas	to	the	
water	heater.
To	fill	the	water	heater	with	water:
1.		Close	 the	water	 heater	 drain	valve	 by	turning	 the	handle	 to	the	
right	 (clockwise).	 The	drain	 valve	 is	on	 the	 lower	 front	of	the	 water	
heater.
2.	 Open	 the	cold	 water	 supply	 valve	to	the	 water	 heater. 		  
NOTE:	 The	cold	 water	 supply	 valve	must	be	left	 open	 when	 the	
water	heater	is	in	use.
3. 		To	 insure	 complete	 filling	of	the	 tank,	 allow	 air	to	exit	 by	opening	 the	
nearest	 hot	water	 faucet.	 Allow	water	 to	run	 until	 a	constant	 flow	is	
obtained.	 This	will	let	air	out	of	the	water	heater	and	the	piping.
4.	 Check	 all	water	 piping	 and	connections	 for	leaks.	 Repair	 as	
needed.
AIR REQUIREMENTS
Breathing Hazard - Carbon Monoxide Ga s
Install water heater in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To  avoid injur y, 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	 uncontaminated	 air	for	
combustion	and	ventilation	must	be	provided.
An	 insufficient	 supply	of	air	 can	 cause	 recirculation	 of	combustion 	
products	 resulting	in	contamination	 that	may	 be	hazardous	 to	life. 	
Such	 a	condition	 often	will	result	 in	a	yellow,	 luminous	 burner	flame,	
causing	 sooting	of	the	 combustion	 chamber,	burners	and	flue	tubes	
and	creates	a	risk	of	asphyxiation.
Do	 not	 install	 the	water	 heater	 in	a	confined	 space	unless	 an	adequate 	
supply	 of	air	 for	 combustion	 and	ventilation	 is	brought	 in	to	 that	 space	
using	 the	methods	 described	 in	the	 Confined	 Space	section	 that	follows. 	
Never	 obstruct	 the	flow	 of	ventilation	 air.	If	you	 have	 any	doubts	 or	
questions	 at	all,	 call	 your	 gas	supplier.	 Failure	to	provide 	the 	proper	 
						

							13
amount	of	combustion	 air	can	 result	 in	a	fire	 or	explosion	 and	cause	 property 	
damage,	serious	bodily	injury	or	death.
UNCONFINED SPACE
An	 Unconfined	 Space	is	one	 whose	 volume	 is	not	 less	 than	 50	
cubic	 feet	per	1,000	 Btu/hr	 (4.8	cubic	 meters	 per	kW)	 of	the 	
total	 input	 rating	 of	all	 appliances	 installed	in	the	 space.	 Rooms	
communicating	 directly	with	the	space,	 in	which	 the	appliances 	
are	 installed, 	through	 openings	 not	furnished	 with	doors, 	are 	
considered	a	part	of	the	unconfined	space.
Makeup	 air	requirements	 for	the	 operation	 of	exhaust	 fans,	kitchen 	
ventilation	 systems,	clothes	dryers	and	fireplaces	 shall	also	be	
considered	 in	determining	 the	adequacy	 of	a	space	 to	provide 	
combustion,	ventilation	and	dilution	air.
UNUSUALLY TIGHT CONSTRUCTION
In	 unconfined	 spaces	in	buildings,	 infiltration	 may	be	adequate	 to	
provide	 air	for	 combustion,	 ventilation	and	dilution	 of	flue	 gases. 	
However,	 in	buildings	 of	unusually	 tight	construction	 (for	example, 	
weather	 stripping,	 heavily	insulated,	 caulked,	vapor	barrier,	 etc.)	
additional	 air	must	 be	provided	 using	the	methods	 described	 in	
the	Confined	Space	section	that	follows.
CONFINED SPACE
A 	Confined	 Space	is	one	 whose	 volume	 is	less	 than	 50	cubic	 feet	per	
1,000	 Btu/hr	 (4.8	cubic	 meters	 per	kW)	 of	the	 total	 input	 rating	 of	all	
appliances	installed	in	the	space.
Openings	 must	be	installed	 to	provide	 fresh	air	for	 combustion,	 ventilation	
and	 dilution	 in	confined	 spaces.	The	 required	 size	for	the	 openings 	is 	
dependent	 on	the	 method	 used	to	provide	 fresh	air	to	the	 confined	 space	
and	the	total	Btu/hr	input	rating	of	all	appliances	installed	in	the	space.
DIRECT VENT APPLIANCES
Appliances	 installed	in	a	Direct 	Vent 	configuration	 that	derive	 all	
air	 for	combustion	 from	the	outdoor	 atmosphere	 through	sealed	
intake	 air	piping	 are	not	factored	 in	the	 total	 appliance	 input	Btu/hr	
calculations	 used	to	determine	 the	size	 of	openings	 providing	fresh	
air	into	confined	spaces.
EXHAUST FANS
Where 	exhaust 	fans 	are 	installed, 	additional 	air 	shall 	be 	provided 	
to 	replace 	the	exhausted 	air.	When 	an	exhaust 	fan	is	installed 	in	
the	 same	 space	 with	a	water	 heater, 	sufficient 	openings	 to	provide 	
fresh	 air	must	 be	provided	 that	accommodate	 the	requirements 	
for	 all	appliances	 in	the	 room	 and	the	exhaust	 fan.	Undersized 	
openings	 will	cause	 air	to	be	 drawn	 into	the	room	 through	 the	water 	
heater’s	 vent	system	 causing	 poor	combustion.	 Sooting,	serious	
damage 	to 	the 	water 	heater 	and 	the 	risk 	of 	fire 	or 	explosion 	may 	
result.	It	can	also	create	a	risk	of	asphyxiation.
LOUVERS AND GRILLES
The	 free	areas	 of	the	 fresh	 air	openings	 in	the	 instructions	 that	follow	 do	not 	
take	 in	to	 account 	the	 presence	 of	louvers,	 grilles	or	screens	 in	the	 openings.
The	 required	 size	of	openings	 for	combustion,	 ventilation	and	dilution 	
air	 shall	 be	based	 on	the	 “net	 free	area”	 of	each	 opening.	 Where	the	
free	 area	 through	 a	design	 of	louver	 or	grille	 or	screen	 is	known,	 it	shall 	
be	 used	 in	calculating	 the	size	 of	opening	 required	 to	provide	 the	free 	
area	 specified.	 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	fixed	in	the	open	position.
FRESH AIR OPENINGS FOR CONFINED SPACES
The	 following	 instructions	 shall	be	used	 to	calculate	 the	size, 	
number	 and	placement	 of	openings	 providing	 fresh	air	for	
combustion,	 ventilation	and	dilution	 in	confined	 spaces.	The	
illustrations 	shown	in	this 	section 	of	the 	manual 	are	a	reference 	
for 	the 	openings 	that 	provide 	fresh 	air 	into 	confined 	spaces 	
only.	 Do	not	 refer	 to	these	 illustrations	 for	the	 purpose	 of	vent 	
installation.	 See	Venting	 Installation	 on	page	 14	for	 complete 	
venting 	installation 	instructions.
OUTDOOR AIR THROUGH TWO OPENINGS
FIGURE 8.
The	 confined	 space	shall	be	provided	 with	two	permanent 	
openings,	 one	commencing	 within	12	inches	 (300	mm)	of	the	 top	
and	 one	commencing	 within	12	inches	 (300	mm)	of	the	 bottom	 of	
the	 enclosure.	 The	openings	 shall	communicate	 directly	with	the	
outdoors.	See	Figure	8.
Each	 opening	 shall	have	 a	minimum	 free	area	 of	1	square	 inch	per	
4,000	 Btu/hr	 (550	mm2	 per	kW)	 of	the	 aggregate	 input	rating	 of	all	
appliances 	installed	 in	the	 enclosure. 	Each	 opening	 shall	not	be	 less 	
than	100	square	inches	(645	cm2). 	
OUTDOOR AIR THROUGH ONE OPENING
FIGURE 9.
Alternatively	a	single	 permanent	 opening,	commencing	 within	12 	
inches	 (300	mm)	of	the	 top	of	the	 enclosure,	 shall	be	provided.	 See	
Figure	 9.	The	 water	 heater	 shall	have	 clearances	 of	at	least	 1	inch	
(25	 mm)	 from	 the	sides	 and	back	 and	6	inches	 (150	mm)	from	 the	
front	 of	the	 appliance.	 The	opening	 shall	directly	 communicate	 with	
the	 outdoors	 or	shall	 communicate	 through	a	vertical	 or	horizontal	 duct	
to	 the	 outdoors	 or	spaces	 that	freely	 communicate	 with	the	outdoors	
and	shall	have	a	minimum	free	area	of	the	following:
1.  1	square	 inch	per	3000	 Btu/hr	 (733	mm
2	per	 kW)	 of	the	 total	
input	rating	of	all	appliances	located	in	the	enclosure,	and
2.  Not	less	 than	 the	sum	 of	the	 areas	 of	all	 vent	 connectors	 in	
the	space. 
						

							14
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
FIGURE 10.
The	confined	 space	shall	be	provided	 with	two	permanent	 horizontal	
ducts,	 one	commencing	 within	12	inches	 (300	mm)	of	the	 top	and	
one	 commencing	 within	12	inches	 (300	mm)	of	the	 bottom	 of	the	
enclosure.	 The	horizontal	 ducts	shall	communicate	 directly	with	the	
outdoors.	See	Figure	10.
Each	 duct	opening	 shall	have	 a	minimum	 free	area	 of	1	square	 inch	
per	 2,000	 Btu/hr	 (1100	mm2	per	kW)	 of	the	 aggregate	 input	rating	 of	
all	appliances	installed	in	the	enclosure.
When	 ducts	are	used,	 they	shall	 be	of	the	 same	 cross	sectional	 area	
as	 the	 free	 area	 of	the	 openings	 to	which	 they	connect.	 The	minimum	
dimension	of	rectangular	air	ducts	shall	be	not	less	than	3	inches.	
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
The	 illustrations 	shown	 in	this	 section	 of	the	 manual	 are	a	
reference	 for	the	 openings	 that	provide	 fresh	air	into	 confined	
spaces	only.
DO NOT	 refer	to	these	 illustrations	 for	the	 purpose	 of	vent	
installation.	 See	Venting	 Installation	 on	page	 14	for	 complete	
venting	installation	instructions.
FIGURE 11.
The	 confined	 space	shall	be	provided	 with	two	permanent	 vertical	
ducts,	 one	commencing	 within	12	inches	 (300	mm)	of	the	 top	and	
one	 commencing	 within	12	inches	 (300	mm)	of	the	 bottom	 of	the	
enclosure.	 The	vertical	 ducts	shall	communicate	 directly	with	the	
outdoors.	See	Figure	11.
Each	 duct	opening	 shall	have	 a	minimum	 free	area	 of	1	square	 inch	
per	 4,000	 Btu/hr	 (550	mm2	 per	kW)	 of	the	 aggregate	 input	rating	 of	
all	appliances	installed	in	the	enclosure.	
When	 ducts	are	used,	 they	shall	 be	of	the	 same	 cross	sectional	 area	
as	 the	 free	 area	 of	the	 openings	 to	which	 they	connect.	 The	minimum	
dimension	of	rectangular	air	ducts	shall	be	not	less	than	3	inches.
AIR FROM OTHER INDOOR SPACES
FIGURE 12.
The	 confined	 space	shall	be	provided	 with	two	permanent	 openings,	
one	 commencing	 within	12	inches	 (300	mm)	of	the	 top	and	 one	
commencing 	within 	12 	inches	 (300	mm)	 of	the 	bottom	 of	the 	enclosure. 	
See	Figure	12.
Each	 opening	 shall	communicate	 directly	with	an	additional	 room(s)	
of	 sufficient	 volume	so	that	 the	combined	 volume	of	all	 spaces	 meets	
the	criteria	for	an	Unconfined	Space.
Each	 opening	 shall	have	 a	minimum	 free	area	 of	1	square	 inch	per	
1,000	 Btu/hr	 (2200	mm2	per	kW)	 of	the	 aggregate	 input	rating	 of	all	
appliances	 installed	in	the	 enclosure.	 Each	opening	 shall	not	be	less	
than	100	square	inches	(645	cm2).	
VENTING 
						

							15
If	the	 water 	heater 	is 	being	 installed	 as	a	 replacement 	for 	an 	
existing	 heater	in	pre-existing	 venting,	a	thorough	 inspection	 of	
existing	 venting	system	must	be	 performed	 prior	to	any	 installation 	
work.
VENT	 DAMPERS	 -	Any	 vent	 damper,	 whether	it	is	 operated 	
ther mally 	or	other wise 	must	be	removed 	if	its 	use 	inhibits 	proper	
drafting	of	the	water	heater.
Thermally	 Operated	Vent	Dampers:	 this	gas-fired	 water	heater 	
has	 a	thermal	 efficiency	 at	or	 above	 80%	which	 may	produce 	
a 	relatively 	low 	flue 	gas 	temperature. 	Such 	temperatures 	may 	
not	 be	high	 enough	 to	properly	 open	thermally	 operated	vent	
dampers. 		This	would 	cause 	spillage 	of	the 	flue 	gases 	and	may 	
cause	 carbon	 monoxide	 poisoning.	Vent 	dampers	 must	bear 	
evidence	 of	certification	 as	complying	 with	the	current	 edition	of	
t h e 	A m e r i c a n 	N a t i o n a l 	S t a n d a r d 	A N S I 	Z 2 1. 6 6 	C G A 	6 .14 	(c o v e r i n g 	
electrically 	and	 mechanically 	actuated	 vent	dampers). 	Before 	
installation	 of	any	 vent	 damper,	 consult	the	local	 gas	utility	 for	
further 	information.
To 	i n s u r e 	p r o p e r 	v e n t i n g 	o f	t h i s 	g a s - f i r e d 	w a t e r	h e a t e r, 	t h e	c o r r e c t 	
vent	 pipe	 diameter	 must	be	utilized.		 Any	additions	 or	deletions 	
of	 other	 gas	appliances	 on	a	common	 vent	with	this	water	 heater 	
may	 adversely	 affect	the	operation	 of	the	 water	 heater.	 Consult	
your	gas	supplier	if	any	such	changes	are	planned.
For	 proper	 venting	 in	certain	 installations,	 a	larger	 diameter	 vent	
pipe	 may	be	necessary.	 Consult	your	gas	supplier	 to	aid	 you	 in	
determining	 the	proper	 venting	 for	your	 water	 heater	 from	the	vent 	
tables	 in	the	 current	 edition	of	the	 National	 Fuel	Gas	Code	 ANSI	
Z223.1/NFPA	 54	or	the	 Natural	 Gas	and	Propane	 Installation 	
Code CAN\CSA B 149.1. 
Periodically	 check	the	venting	 system	for	signs	 of	obstruction	 or	
deterioration	and	replace	if	needed.
The	combustion	and	ventilation	air	flow	must	not	be	obstructed.
The	 water	 heater	 with	draft	 hood	 installed	 must	be	connected 	
to 	a 	chimney 	or	listed 	vent	pipe 	system, 	which	terminates 	to	the 	
o u t d o o r s . 		N e v e r	o p e r a t e 	t h e	w a t e r 	h e a t e r 	u n l e s s 	i t	i s 	v e n t e d 	t o	t h e 	
outdoors	 and	has	adequate	 air	supply	 to	avoid	 risks	of	improper 	
operation, 	explosion 	or 	asphyxiation.
Align 	the	legs 	of	the 	draft 	hood 	with	the	holes 	provided. 	Inser t	
the	 legs	 and	secure	 the	draft	 hood	 to	the	 water	 heater’s	 top	
with	 the	four	 screws	 provided	 as	shown	 in	Figure	 13.	Do	not	
alter 	the	draf t 	hood 	in	any 	way. 	If	you 	are	replacing 	an	existing 	
water	 heater,	 be	sure	 to	use	 the	new	 draft	 hood	 supplied	 with	
the	water	heater.
Obstructed	 or	deteriorated	 vent	systems	 may	present	 serious	
health	risk	or	asphyxiation.
DRAFT HOOD
SHEET METAL SCREWS (FOUR PROVIDED)
LEGS
HOLE INSTALL THE DRAFT HOOD WITH
THE FOUR SCREWS PROVIDED.JACKET TOP
HOLE
LEGS
FIGURE 13.
The	
vent	 pipe	 from	 the	water	 heater	 must	be	no	less	 than	 the	
diameter	 of	the	 draft	 hood	 outlet	 on	the	 water	 heater	 and	must 	
slope	 upward	 at	least	 1/4	inch	 per	linear	 foot	(21	mm	 per	meter). 	
See	Figure	14.
All	 vent	 gases	 must	be	completely	 vented	to	the	 outdoors	 of	the 	
structure	 (dwelling).	 	 Install	only	the	draft	 hood	 provided	 with	the	
new	water	heater	and	no	other	draft	hood.
Vent	pipes	must	be	secured	at	each	joint	with	sheet	metal	screws.
FIGURE 14.  
There	 must	be	a	minimum	 of	6”	 (153	 mm)	clearance	 between	single	
wall	 vent	 pipe	and	any	combustible	 material.	 	Fill	and	 seal	 any	
clearance	 between	single	wall	vent	 pipe	 and	combustible	 material	
with	 mortar	 mix,	cement,	 or	other	 noncombustible	 substance.	For	
other	 than	single	 wall,	follow	 vent	pipe	 manufacturer’s	 clearance	
specifications.		 To	insure	 a	tight	 fit	of	 the	 vent	 pipe	in	a	brick	 chimney, 	
seal	around	the	vent	pipe	with	mortar	mix	cement.
Failure	 to	have	 required	 clearances	 between	vent	piping	 and	
combustible	material	will	result	in	a	fire	hazard.
Be	 sure	 vent	pipe	 is	properly	 connected	 to	prevent	 escape	of	
dangerous	flue	gases	which	could	cause	deadly	asphyxiation.
Chemical	 vapor	corrosion	 of	the	 flue	 and	vent	 system	 may	occur 	
if 	air	 for	 combustion	 contains	certain	 chemical	 vapors.	Spray	 can	
propellants,	 cleaning	solvents,	 refrigerator	 and	air	conditioner 	
refrigerants, 	swimming 	pool 	chemicals, 	calcium 	and 	sodium 	
chloride, 	waxes, 	bleach 	and 	process 	chemicals 	are 	typical 	
compounds	which	are	potentially	corrosive. 
						

							16
GAS PIPING
Contact	your	 local	 gas	service	 company	 to	ensure	 that	adequate 	
gas	 service	 is	available	 and	to	review	 applicable	 installation	 codes	
for	your	area.
Size	 the	main	 gas	line	in	accordance	 with	Table	 3.	The	 figures	 shown	
are	 for	straight	 lengths	of	pipe	 at	0.5	 in.	W.C.	 pressure	 drop,	which	 is	
considered	 normal	for	low	 pressure	 systems.	 Note:	Fittings	 such	as	
elbows,	 tees	and	line	regulators	 will	add	 to	the	 pipe	 pressure	 drop.	
Also	 refer	 to	the	 current 	editions	 of	the	 National	 Fuel	Gas	Code	 (NFPA 	
54)	 or	Natural	 Gas	and	Propane	 Installation	 Code	(CAN/CSA 	B149.1).
Make	 sure	gas	supplied	 is	same	 type	listed	 on	model	 rating	plate.	The	
inlet	 gas	pressure	 must	not	exceed	 14	inch	 water	 column	 (2.6	kPa)	
for	 natural	 and	propane	 (L.P.)	gas.	The	minimum	 inlet	gas	pressure	
shown	on	rating	plate	is	that	which	will	permit	firing	at	rated	input.
If	 the	 gas	 control	 valve	is	subjected	 to	pressures	 exceeding	 1/2	pound 	
per	 square	 inch	(3.5	kPa),	 the	damage	 to	the	 gas	 control	 valve	could	
result	in	a	fire	or	explosion	from	leaking	gas.
If	 the	 main	 gas	line	shut-off	 serving	all	gas	 appliances	 is	used,	 also	
turn	 “off”	 the	gas	 at	each	 appliance.	 Leave	all	gas	 appliances	 shut	
“off”	until	the	water	heater	installation	is	complete.
A 	gas	 line	of	sufficient	 size	must	 be	run	 to	the	 water	 heater.	 Consult	
the	 current	 edition	of	 National	 Fuel	Gas	Code	 ANSI	Z223.1/NFPA 	54	
or	 the	 Natural	 Gas	and	Propane	 Installation	 Code	CAN/CSA 	B149.1	
and	your	gas	supplier	concerning	pipe	size.
There	must	be:
•	 A 	readily	 accessible	 manual	shut	off	valve	 in	the	 gas	 supply	 line	
serving	the	water	heater,	and
•	 A 	sediment	 trap	ahead	 of	the	 gas	 control	 valve	to	help	 prevent	 dirt	
and	foreign	materials	from	entering	the	gas	control	valve.
•	 A 	flexible	 gas	connector	 or	a	ground	 joint	union	 between	 the	shut 	
off	valve	and	control	valve	to	permit	servicing	of	the	unit.
Be	 sure	 to	check	 all	the	 gas	 piping	 for	leaks	 before	 lighting	 the	water	
heater.	 Use	a	soapy	 water	solution,	 not	a	match	 or	open	 flame.	 Rinse	
off	soapy	solution	and	wipe	dry.
The	 minimum	 inlet	gas	pressure	 shown	on	the	 rating	 plate	is	that	
which	will	permit	firing	at	the	rated	input.
TABLE 3.  GAS SUPPLY LINE SIZES (IN INCHES)* 
MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR
LENGTH IN  
FEETNOMINAL IRON PIPE SIZES (INCHES) 
INPUT IN THOUSANDS (BTU/HR)
1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"
10 175360 6801400 21003960 630011000 23000
20 120250 4659501460 2750 4360770015800
30 97200 3757701180 2200 3520625012800
40 82170 320660 9901900 3000530010900
50 73151 285580 9001680 265047509700
60 66138 260530 8101520 240043008800
70 61125 240490 7501400 225039008100
80 5711 8 220460 6901300 205037007500
90 5311 0 205430 6501220 195034507200
100 50103 195400 6201150 185032506700
125 4493175 360 5501020 165029506000
150 4084160 325 500950 1500 26505500
175 3777145 300 460850 1370 24505000
200 3572135 280 430800 1280 22804600
TABLE 4.
LENGTH IN 
METERS
NOMINAL IRON PIPE SIZES (INCHES) 
INPUT IN KW
1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"
3 51105 199410 6151160 184532216735
6 3573142 278 428805 1277 22554626
9 285911 0 225 346644 1031 18303748
12 2450 94193 290556 8781552 3192
15 2144 83170 264492 7761391 2840
18 1940 76155 237445 7031259 2577
21 1837 70143 220410 6591142 2372
24 1735 64135 202381 6001083 2196
27 1632 60126 190357 5711010 2108
31 1530 5711 7 182337 5429521962
38 1327 51105 161299 4838641757
46 1225 4795146 278 4397761610
53 1123 4288135 249 4017171464
61 1021 4082126 234 3756881347
Use	pipe	 joint	compound	 or	teflon	 tape	marked	 as	being	 resistant	 to	
the	action	of	petroleum	[Propane	(L.P.)]	gases.	
The	 water	 heater	 and	its	gas	 connection	 must	be	leak	 tested	 before	
placing	the	water	heater	in	operation.
The	 water	 heater	 and	its	individual	 shut-off	valve	shall	be	
disconnected	 from	the	 gas	supply 	piping	 system 	during	 any	pressure 	
testing	 of	that	 system	 at	test	 pressures	 in	excess	 of	1/2	 pound	 per	
square	 inch	(3.5	kPa).	 It	shall	 be	isolated	 from	the	gas	 supply	 piping	
system	 by	closing 	its	 individual	 manual	shut-off	 valve	during	 any	
pressure	 testing	of	the	 gas	 supply	 piping	system	 at	test	 pressures	
equal	 to	or	 less	 than	 1/2	pound	 per	square	 inch	(3.5	kPa).
Connecting	 the	gas	 piping	 to	the	 gas	 control	 valve	of	the	 water	 heater	
can	 be	accomplished	 by	either	 of	the	 two	 methods	 shown	in	Figures	
15 and 16.
FIGURE 15.  GAS PIPING WITH FLEXIBLE CONNECTOR.
FIGURE 16.  GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL. 
						

							17
SEDIMENT TRAPS
A	sediment	 trap	shall	 be	installed	 as	close 	to	 the 	inlet	 of	the 	water 	
heater	 as	practical	 at	the	 time	 of	water	 heater	 installation.	 The	
sediment	 trap	shall	 be	either	 a	tee	 fitting	 with	a	capped	 nipple	
in	 the	 bottom	 outlet	or	other	 device	 recognized	 as	an	 effective 	
sediment 	trap. 	If 	a	 tee	 fitting	 	 is	used, 	it 	shall	 be	installed	 in	
conformance	 with	one	of	the	 methods	 of	installation	 shown	in	
the	Figures	15	and	16.
Contaminants	 in	the	 gas	 lines	 may	cause	 improper	 operation	 of	
t h e 	g a s 	c o nt r o l 	va l ve 	t h at 	m ay 	r e s u l t 	i n 	f i r e 	o r 	ex p l o s i o n. 		B ef o r e 	
attaching	 the	gas	 line	be	sure	 that	all	gas	 pipe	 is	clean	 on	the	
i n s i d e . 		To	t r a p 	a ny	d i r t	o r	f o r e i g n 	m a t e r i a l 	i n	t h e 	g a s 	s u p p l y 	l i n e ,	
a	 sediment	 trap	must	 be	incorporated	 in	the	 piping.		 The	sediment 	
trap 	must 	be 	readily 	accessible. 	Install 	in 	accordance 	with 	the 	
“Gas	 Piping”	 section.	 Refer	to	the	 current	 edition	of	the	 National 	
Fuel	 Gas	Code,	 ANSI	Z223.1/NFPA	 54	or	the	 Natural	 Gas	and	
Propane	Installation	Code	CAN/CSA	B149.1. 
						

							18
FLAMMABLE
WARNING:If you do not follow these instructions exactly , a
fire or explosion may result causing property damage, personal
injury or loss of life.
BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH W ATER  AND  AIR PURGED FROM  ALL LINES
A.
C.
D .
WHA
T 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 neighborsphone. Follow the gas suppliers instructions. If you cannot reach your gas supplier
, call the fire
department.
LIGHTING INSTRUCTIONS
T OP   KNOB
FIGURE  A
OFF POSITION
OFF
ON
PIL OT
FIGURE  B
PILOT POSITION
OFF
ON
PIL OT
FIGURE  C
ON POSITION
OFF
ON
PIL OT
1. 2.
TO TURN OFF GAS T O APPLIANCE
Set the t hermosta t to lowest se tting. Push  gas c ontrol knob  down s lightly  and t urn clock-
wis e       t o O FF .  D o no t fo rc e .  S EE FI GURE  A .
1.
10.
1 1.
12.
13.
2.
3.
5.
6.
7.
8. 9.
ST
OP! Read t he safety  inf ormat ion
above on this label.
P ush t he gas c ontrol knob  down s lightly and t urn
c lockwise     t o OFF. SEE FIGURE A.
N OTE: Knob  cannot be turned f rom PIL OT to OFF
unless k nob is pus hed  down s lightly.  Do  not force.
W ait five (5) minutes to clear out any gas.  If you
t hen  smell  gas,          ST OP! Follow B in t he
s a fe ty  informat ion ab ove on th is  label .  If
you  do not smell  gas,go t o ne xt st ep.
T his  unit  is  equipped  with a  pus h button  pilot ignitor,
on t he gas c ontrol.  
Cont inue t o hold t he gas  control knob  down f or about   one (1) minut e a fter t he pilot  is  lit.  Releas e the  gascont rol knob  and it  will  pop  back  up. Pilot  should
remain  lit. If it goes  out , repeat  step  (3) t hrough  (9).
It  may t ake several  minutes for air t o clear t he lines
bef ore t he pilot  will light .
If knob  does not pop  up when  releas ed, stop  and
immediat ely call y our serv ice technic ian or gas
supplier .
If the pilot will not  stay  lit after s everal t ries, 
turn t he gas  control knob  clockwis e       t o OFF and
c all y our s ervice t echnic ian or gas  supplier .
SEE FIGURE A
DANGER:  Hotter w ater increases  th e r is k
o f scald injur y.  C ons ult t h e instru ction
manua l before ch anging  temperatu re.
At arms  length away , turn  gas cont rol knob
counterclockwise      to ON.  SEE FIGURE C.
Set thermostat to desired setting.
Remove t he outer door  located belowthe  gas c ontrol  unit .4.
which  is used t o light the  pilot. Locat e the  ignit or
T urn  gas  control knob count erclockwis e
to  PIL OT. SEE FIGURE B.
Replace t he outer door .
DIAL
KNOB
GAS CONTROL
THERMOSTAT
GAS CONTROL
PIEZO
IGNIT OR
GENERA TOR
The  pilot  is  locat ed on t he left front corner  of the  burner . 
It can  be locat ed by  look ing t hrough t he sight glass t o
the  left  while  pressing the piez o ignit or butto n
several t imes. Look f or a s park  at the  pilot location   
.
Once t he pilot  has been f ound, push the  gas knob
all t he way  down.  Immediat ely press the  pilot ignitor
button  rapidly  (4) to (5) t imes.  If the  pilot does  not
light,  repeat step  (3) through  (9).
This appliance has a pilot which is lit by a piezo-
electric spark gas ignition system.  When lighting
the pilot, follow these instructions exactly .
B.BEFORE LIGHTING smell all around the
appliance area for gas.  Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.Use only your hand to push down or turn the gas
control knob.  Never use tools.  If the knob will
not push down or turn by hand, dont try to repair
it, call a qualified service technician.  Force or
attempted repair may result in fire or explosion.
Do not use this appliance if any part has been
under water.  Immediately contact a qualified
installer or service agency to replace a flooded
water heater .  Do not attempt to repair the unit!
It must be replaced!
Set the thermostat to the lowest setting by turning
thermostat dial fully clockwise        until it stops.
FOR  YOUR SAFETY  READ BEFORE LIGHTING
FIGURE D
PILOT
M AIN BURNER
THERMOC OUPLE &
BURNER TUBE 
						

							19
START UP CONDITIONS
DRAFT HOOD OPERATION
Check	draft	hood	 operation	 by	performing	 a	worst	 case	
depressurization	 of	the	 building.	 With	all	doors	 and	windows 	
closed, 	and 	with 	all 	air 	handling 	equipment 	and 	exhaust 	fans 	
operating	 such	as	furnaces,	 clothes	dryers,	range	hoods	 and	
bathroom	 fans,	a	match	 flame	should	 still	be	drawn	 into	the	draft 	
hood 	of 	the 	water 	heater 	with 	its 	burner 	firing. 		If	the 	flame 	is 	not 	
drawn	 toward	 the	draft	 hood,	 shut	off	water	 heater	 and	make 	
necessary	air	supply	changes	to	correct.
CONDENSATION
Whenever	 the	water	 heater	 is	filled	 with	cold	 water,	 some	
condensate	 will	form	 while	 the	burner	 is	on.		 A	water	 heater	 may	
Short	 repeated	 heating	cycles	caused	 by	small	 hot	water	 uses	can	
cause	 temperatures	 at	the	 point	 of	use	 to	exceed	 the	thermostat 	
setting	 by	up	 to	30°F	 (16.7°C).	 If	you	 experience	 this	type	 of	use 	
you	 should 	consider	 using	lower	temperature 	settings	 to	reduce 	
scald	hazards. 	
Any 	water 	heater’s 	intended 	purpose 	is 	to 	heat 	water. 		Hot 	water 	
is 	needed 	for 	cleansing, 	cleaning, 	and 	sanitizing 	(bodies, 	dishes, 	
clothing). 	Untempered	 hot	water	 can	present 	a	 scald	 hazard. 		
Depending	 on	the	 time	 element,	 and	the	people	 involved	 (adults,	
children, 	elderly,	 infirm,	etc.)	scalding	 may	occur	 at	different 	
temperatures.
HOTTER 	WATER 	CAN 	SCALD:	 Water	heaters	 are	intended 	to	 produce 	
hot	 water.	 	 Water	heated	 to	a	temperature	 which	will	satisfy	 space	
heating,	 clothes	washing,	 dish	washing,	 and	other	 sanitizing	 needs	
can	 scald	 and	permanently	 injure	you	upon	 contact.	 	 Some	people	
are	 more	 likely	to	be	 permanently	 injured	by	hot	 water	 than	others.		
These	 include	 the	elderly,	 children,	 the	infirm,	 or	physically/mentally	
handicapped.		 If	anyone	 using	hot	water	 in	your	 home	 fits	into	 one	 of	
these	 groups	 or	if	there	 is	a	local	 code	 or	state	 law	requiring	 a	certain	
temperature	 water	at	the	 hot	water	 tap,	then	 you	must	 take	special	
precautions.	 In	addition	 to	using	 the	lowest	 possible	 temperature 	
setting	 that	satisfies	 your	hot	water	 needs,	 a	means	 such	as	a	mixing	
valve	 should	 be	used	 at	the	 hot	water	 taps	used	 by	these	 people	 or	
at	 the	 water	 heater.	 Mixing	valves	are	available	 at	plumbing	 supply	or	
hardware	 stores,	see	Figure	 6.		Follow	 manufacturer’s	 instructions	for	
installation	 of	the	 valves.	 Before	changing	 the	factory	 setting	on	the	
thermostat,	 read	the	“Temperature	 Regulation”	section	in	this	 manual, 	
see	Figures	17	and	18.
TEMPERATURE REGULATION
FOR YOUR INFORMATION
appear 	to 	be 	leak ing 	w hen 	in 	fac t 	t he 	water 	is 	c ondensati on. 	T his 	
usually 	happens 	when:
a.		A	new	water	heater	is	filled	with	cold	water	for	the	first	time.
b . 		B u r n i n g 	g a s 	p r o d u c e s 	w a t e r 	v a p o r 	i n 	w a t e r 	h e a t e r s , 	p a r t i c u l a r l y 	
high	efficiency	models	where	flue	temperatures	are	lower.
c.		Large	 amounts	of	hot	 water	 are	used	 in	a	short	 time	and	the	
refill	water	in	the	tank	is	very	cold.
Moisture	 from	the	products	 of	combustion	 condense	on	the	 cooler 	
tank	 surfaces	 and	form	 drops	 of	water	 which	 may	fall	onto	 the	
burner	 or	other	 hot	surfaces	 to	produce	 a	“sizzling”	 or	“frying”	 noise.
Excessive	 condensation	 can	cause	 pilot	outage	 due	to	water 	
running	 down	the	flue	 tube	 onto	the	main	 burner	 and	putting	 out	
the	pilot.
Never	 allow	small	 children	 to	use	 a	hot	 water	 tap,	or	to	draw	 their	own	
bath	 water.	 Never	leave	a	child	 or	handicapped	 person	unattended	
in	a	bathtub	or	shower.		
NOTE:	 	 A	water	 temperature	 range	of	120°F-140°F	 (49°C-60°C)	is	
recommended	by	most	dishwasher	manufacturers.
The	 thermostat	 of	this	 water	 heater	 has	been	 factory	 set	at	its	 lowest	
position	 (PILOT LIGHTING).	 It	is	 adjustable	 and	must	 be	reset	 to	
the 	desired 	temperature 	setting	 to	reduce	 the	risk	 of	scald 	injury. 		
The	 mark	 (
	)	 indicative	 of	approximately	 120°F	(49°C)	 is	preferred	
starting	point.		Some	States	have	a	requirement	for	a	lower	setting.	
Turn	 the	water	 temperature	 dial	clockwise	 (	
	)	 to	 decrease	 the	
temperature,	 or	counterclockwise	 (			)	 to	 increase	 the	temperature.
Should	 overheating	 occur	or	the	 gas	 supply	 fail	to	shut	 off,	turn	 off	the	
manual	gas	control	valve	to	the	water	heater.
FIGURE 17.
T e m pera tu re   Tim e to  Produce  2nd  & 3 rd
Nearl y inst antaneou s 
D  =  A PPRO X.160° F (71°C)                                             A bout  1/2  second  
C  =  APPROX.150 °F  (65°C)                                    Abou t 1-1 /2  s e cond s 
B  = APPRO X.140 °F  (60°C)                                   Le ss  than  5 second s 
A  = APPRO X.130°F (54°C)                                             Abou t 30  se cond s 
=  APPRO X.1 20°F  (49°C)  More than 5 minu tes 
LO W = APPRO X.100°F  (37.8 °C)  - - - - -  - -  - 
Setting
Degree Burns on Adult Skin
VERY  HOT = APPROX.  181°F (83°C)
FIGURE 18. 
						

							20
CHECKING GAS INPUT
With	this	heater	 in	operation,	 determine	whether	it	is	 receiving	 the	
full	 rated	 input	of	gas.	 This	 may	be	done	 by	timing	 the	gas	 meter	
and	 measuring	 gas	pressure	 with	a	gauge	 or	manometer.	 When	the	
heater	 is	operating	 at	full	 capacity	 (full	gas	 input)	 it	should	 consume	
approximately	1	cubic	foot	of	gas	in	the	time	shown	in	 Table	5.
TABLE 5. INPUT CHECK TIME REQUIRED 
TO CONSUME 1 CU. FT. OF GAS
Model Type of Gas BTU Per 
Cu. Ft. Approx. Time Required To 
Consume 1 Cu. Ft. of Gas
BCN375  
BCN3100 Natural
1050 50.3	sec.
Use	this	formula	 to	“clock”	 the	meter.	 	 Be	sure	 that	other	 gas	
consuming	appliances	are	not	operating	during	this	interval.
  3,600		X		H		=		Btu/Hr
     T
	 T 		=		Time	in	seconds	needed	to	burn	one	cubic	foot	of	gas.
	 H		=		Heating	value	of	gas	in	Btu’s	per	cubic	foot	of	gas.
	 Btu/Hr		=		 Actual	heater	input	rate.
	 Example:
	 T 		=		50.3	seconds/ft
3
	 H		=		1,050	Btu/ft3	(natural	gas)
	 Btu/Hr		=		?
  3,600		X		1,050		=		75,100	Btu/Hr	(22.0	kW)
 50.3
Compare	 the	actual	 input	rate	to	that	 given	 on	the	 heater’s	 rating	
plate.	 In	the	 example,	 the	BCN3100	 full	input	 rate	should	 be	75,100	
Btu/Hr	for	natural	gas.
Because	 of	the	 suddenness 	and	 amount 	of 	water, 	condensation 	
water	 may	be	diagnosed	 as	a	“tank	 leak”.	 After	the	water	 in	the	 tank	
warms	up	(about	1-2	hours),	the	condition	should	disappear.
Do	 not	 assume	 the	water	 heater	 is	leaking	 until	there	 has	been 	
enough	time	for	the	water	in	the	tank	to	warm	up.
An	 undersized	 water	heater	 will	cause	 more	condensation.	 The	water 	
heater	 must	be	sized	 properly	 to	meet	 the	family’s	 demands	 for	hot	
water	 including	 dishwashers,	 washing	machines	 and	shower	 heads.
Excessive	 condensation	 may	be	noticed	 during	the	winter	 and	early	
spring	 months	 when	incoming	 water	temperatures	 are	at	their	 lowest.
Good	 venting	 is	essential	 for	a	 gas 	fired	 water 	heater 	to	 operate	 properly 	
as	well	as	to	carry	away	products	of	combustion	and	water	vapor.
SMOKE/ODOR
It	 is	 not	 uncommon	 to	experience	 a	small	 amount	 of	smoke	 and	odor 	
during	 the	initial	 start-up.	 This	is	due	 to	burning	 off	of	oil	 from	 metal	
parts,	and	will	disappear	in	a	short	while.
STRANGE SOUNDS
Possible	 noises	due	to	expansion 	and	 contraction	 of	some	 metal	
parts	 during	 periods	 of	heat-up	 and	cool-down	 do	not	 necessarily	
represent	harmful	or	dangerous	conditions.
Condensation	 causes	sizzling	 and	popping	 within	the	burner	 area	
during	 heating	 and	cooling	 periods	 and	should	 be	considered	 normal.		
See	“Condensation”	in	this	section.
OPERATIONAL CONDITIONS
SMELLY WATER
In	 each	 water	 heater	 there	is	installed	 at	least	 one	anode	 rod	for	
corrosion	 protection	 of	the	 tank.	 Certain	 water	conditions	 will	cause	 a	
reaction	 between	 this	rod	and	 the	water. 	The	 most 	common	 complaint 	
associated	 with	the	anode	 rod	is	one	 of	a	“rotten	 egg	smell”	 in	the	
hot	 water.	 This	odor	 is	derived	 from	hydrogen	 sulfide	gas	dissolved	
in	 the	 water.	 The	smell	 is	the	 result	 of	four	 factors	 which	must	all	be	
present	for	the	odor	to	develop:
a.		A 	concentration	of	sulfate	in	the	supply	water.
b.		Little	or	no	dissolved	oxygen	in	the	water.
c.		 A 	sulfate	 reducing	 bacteria	which	has	accumulated	 within	the	
water	heater	(this	harmless	bacteria	is	nontoxic	to	humans).
d.		An	 excess	 of	active	 hydrogen	 in	the	 tank.		 This	is	caused	 by	the	
corrosion	protective	action	of	the	anode.
Smelly	 water	may	be	eliminated	 or	reduced	 in	some	 water	 heater 	
models	 by	replacing	 the	anode(s)	 with	one	of	less	 active 	material, 	
and	 then	 chlorinating	 the	water	 heater 	tank 	and	 all	hot 	water	 lines.	
Contact	 the	local	 water	 heater	 supplier	 or	service	 technician 	for 	
further	 information	 concerning	an	Anode	 Replacement	 Kit	and 	
this	chlorination	treatment.
If	 the	 smelly	 water	persists	 after	the	anode	 replacement	 and	chlorination 	
treatment,	 we	can	 only	 suggest	 that	chlorination	 or	aeration	 of	the	 water 	
supply	be	considered	to	eliminate	the	water	problem.
Do not remove the anode leaving the tank unprotected.  By doing 
so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
HYDROGEN	 GAS:	Hydrogen	 gas	can	 be	produced	 in	a	hot 	
water	 system	 that	has	not	been	 used	for	a	long	 period	 of	time 	
(generally	 two	weeks	 or	more).	 Hydrogen	 gas	is	extremely 	
flammable	 and	explosive.	 To	prevent	 the	possibility	 of	injury 	
under	 these	conditions,	 we	recommend	 the	hot	water	 faucet, 	
located 	farthest 	away, 	be 	opened 	for 	several 	minutes 	before 	
any 	electrical 	appliances 	which	are	connected 	to	the 	hot	water 	
system	 are	used	 (such	 as	a	dishwasher	 or	washing	 machine).	 If	
hydrogen	 gas	is	present,	 there	will	probably	 be	an	unusual	 sound	
similar 	to	air 	escaping 	through	the	pipe 	as	the 	hot	water 	faucet 	
is	 opened.	 There	must	be	no	smoking	 or	open	 flame	 near	the	
faucet	at	the	time	it	is	open.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
This	 water	 heater	 is	equipped	 with	an	automatic	 gas	Shut-off 	
system.	 This	system	 works	when	high	water	 temperatures	 are	
p r e s e n t . 	T h e	h i g h 	t e m p e r a t u r e 	S h u t - o f f	i s	b u i l t 	i n t o	t h e	g a s 	c o n t r o l 	
valve. 	It 	automatically	 resets	when	the	temperature	 at	thermostat 	
level	drops	below	120	degrees	Fahrenheit.