Bock Water heaters EZ 100-76PDV-C, Installation And Operation Instruction Manual

Page 1: ...TO PROVIDE IMPORTANT SAFETY INFORMATION Read all instructions thoroughly before attempting installation or operation of your water heater Keep these instructions for future reference Local plumbing and electrical codes must be followed in the installation of this water heater In the absence of a local code use the UNIFORM PLUMBING CODE and the NFPA Code Local codes may supersede instructions in th...

Page 2: ...el These units are only certified for a single fuel type 䊱 DANGER Failure to properly install the vent and combustion air intake system as outlined in this manual can result in unsafe operation of the water heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this water heater unless it is properly vented and has adequate air supply for combustion and dilut...

Page 3: ...Specifications 4 Section II General Information 5 Section III Pre Installation 7 Section IV Installation 10 Section V Operation 30 Section VI Maintenance 33 Section VII Troubleshooting 35 Section VIII Parts List 37 Section IX Warranty 39 ...

Page 4: ... N to LP Working Pressure 150 PSI 1034 kPa Test Pressure 300 PSI 2068 kPa For natural gas Manifold pressure 4 W C 1 00 kPa Inlet pressure range 5 14 W C 1 25 3 49 kPa For propane gas Manifold pressure 10 W C 1 00 kPa Inlet pressure range 11 14 W C 2 74 3 49 kPa T P valve installed All Bock products meet or exceed current ASHRAE standards These products are design certified by UL Underwriters Labor...

Page 5: ...CO is standard on all models In the event that the water temperature becomes excessive 195 F the ECO will shut off all gas to the water heater If the ECO switch opens it will automatically reset or close when the water temperature drops to 120 F or below The water heater thermostat will automatically reset following a three minute standby period once the ECO switch closes The thermostat is factory...

Page 6: ...there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow There should be no smoking or open flame near the faucet at the time it is open TEMPERATURE AND PRESSURE RELIEF VALVE T P CAUTION To reduce the risk of excessive pressures and temperatures in this water heater install temperature and pressure protective equipment required by local codes and no...

Page 7: ... arrangement is used the condensate drain kit must be installed See Section IV Installation Vent and Combustion Air Intake Condensate Drain Kit for installation details HIGH ALTITUDE Contact Bock Water Heaters for installations at altitudes greater than 2 000 feet above sea level SECTION III PRE INSTALLATION LOCATION CAUTION This water heater must be located in an area where leakage of the tank wa...

Page 8: ...ual and in accordance with the National Fuel Gas Code NFPA 54 ANSI Z223 1 unless otherwise directed by state and local code requirements Locate the water heater such that plastic vent pipe lengths and the number of connection fittings are minimized Minimum clearances from combustible construction are Table 3 Clearances 1 Measured from water heater jacket to wall This clearance accommodates the air...

Page 9: ...l fuel burning appliances in the space Each opening shall have an area of not less than 100 square inches or a minimum dimension of not less than 3 inches B Outside Air Supply Confined spaces shall be provided with two permanent openings one within 12 inches of the top and one within 12 inches of the bottom of the enclosure These openings shall communicate directly or by ducts with the outdoors or...

Page 10: ...nnects to the blower assembly outlet The air intake piping is preassembled to route dilution air to the blower assembly and combustion air to the burner chamber All vent length measure ments specified in this manual are in addition to the preassembled piping supplied with the water heater Equivalent pipe run lengths shall not be greater than the maximum lengths or less than minimums given in Table...

Page 11: ...e DO NOT use less than 3 in diameter plastic pipe and DO NOT use unequal sizes except as shown to increase from 3 in to 4 in diameter at the point of connection to the water heater NOTE The equivalent straight pipe length of a 90 1 4 inch standard bend elbow and a 45 1 8 inch standard bend elbow is 5 feet and 2 5 feet respectively The concentric vent termination is equivalent to 10 feet of straigh...

Page 12: ...35 10 67 35 10 67 3 5 30 9 14 30 9 14 3 6 25 7 62 25 7 62 4 0 85 25 91 85 25 91 4 1 80 24 38 80 24 38 4 2 75 22 86 75 22 86 4 3 70 21 34 70 21 34 4 4 65 19 81 65 19 81 4 5 60 18 29 60 18 29 4 6 55 16 76 55 16 76 Model s Pipe Ø in of 90 Elbows per pipe run including termination fittings Maximum Equivalent Pipe Length per pipe run Air Intake Ft m Vent Ft m EZ 75 76PDV EZ 100 76PDV 3 0 45 13 72 45 13...

Page 13: ...sting vent system Verify that the materials as specified in this manual have been used Verify the maximum and minimum vent and combustion air intake equivalent lengths and terminal clearances meet the specifications in this manual Inspect the vent and combustion air intake systems for cracking Pay close attention to joints between elbows and straight pipe Inspect the system for misalignment of com...

Page 14: ...inimum of 12 25 4 cm above expected snowfall level to prevent blockage CAUTION Never install air intake terminal above vent exhaust terminal 䊱 Page 14 SECTION IV INSTALLATION cont VENT COMBUSTION AIR INTAKE cont Table 8 Direct Vent Terminal Clearances Canadian Installations1 US Installations2 A Clearance above grade veranda porch deck or balcony 12 inches 30 cm 12 inches 30 cm B Clearance to windo...

Page 15: ...inimum of 1 8 inch per foot 10mm per meter to prevent condensate from flowing back towards the water heater CAUTION Annular spaces around vent pipe wall penetrations shall be permanently sealed using approved materials to prevent entry of combustion products into the building 䊱 Page 15 SECTION IV INSTALLATION cont VENT COMBUSTION AIR INTAKE cont Vent Terminal From Water Heater Wall Outside of Buil...

Page 16: ...gle hole through the exterior of the building is required for the vent pipe Note If air from inside the building will be used for combustion air the require ments in Section III Unconfined Space must be met All clearances must comply with local codes or the latest edition of NFPA 54 ANSI Z223 1 or CSA B149 See Figure 5 and Table 9 for vent terminal clearances SECTION IV INSTALLATION cont VENT COMB...

Page 17: ...located on public property 7 feet 2 13 m 7 feet 2 13 m M Clearance under veranda porch deck or balcony 12 inches 30 cm 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelli...

Page 18: ...ontal sections of piping slope downward away from the water heater a minimum of 1 8 inch per foot 10 mm per meter to prevent condensate from flowing back towards the water heater CAUTION Annular spaces around vent pipe wall penetrations shall be permanently sealed using approved materials to prevent entry of combustion products into the building 䊱 SECTION IV INSTALLATION cont VENT COMBUSTION AIR I...

Page 19: ...hole through an exterior wall Make sure the wye concentric fitting is cemented to the large diameter pipe and that the rain cap is cemented to the small diameter pipe Install the wye concentric fitting and large pipe assembly through the 5 in diameter hole in the wall See Figure 9 for wall attachment details CAUTION Annular spaces around vent pipe wall penetrations shall be permanently sealed usin...

Page 20: ... or the latest edition of NFPA 54 ANSI Z223 1 or CSA B149 As a basic guide the following minimum clearances shall be used Minimum 12 inches 30 cm above roof Minimum 12 inches 30 cm above anticipated snow level Maximum 24 inches 61 cm above roof level without additional support for vent 4 feet 1 2 m from any gable dormer or other roof structure with building interior access e g vent or window 10 fe...

Page 21: ...pe termination In this case the water heater will be utilizing air from inside the building for combustion air A single hole through the roof of the building is required for the vent pipe Note If air from inside the building will be used for combustion air the require ments in Section III Unconfined Space must be met All clearances must comply with local codes or the latest edition of NFPA 54 ANSI...

Page 22: ...vertical venting the condensate drain kit must be installed to the exhaust adapter SECTION IV INSTALLATION cont VENT COMBUSTION AIR INTAKE cont Vent Terminal From Water Heater Dim Y Dim Y Requirements 1 Minimum 12 in 30 cm above roof US Minimum 18 in 46 cm above roof Canada 2 Minimum 12 in 30 cm above anticipated snow level US Minimum 18 in 46 cm above anticipated snow level Canada 3 Maximum 24 in...

Page 23: ...el Maximum 24 inches 61 cm above roof level without additional support for vent 4 feet 1 2 m from any gable dormer or other roof structure with building interior access e g vent or window 10 feet 3 m from any forced air inlet to the building Any fresh or make up air inlet such as a dryer or furnace area is considered to be a forced air inlet Cut a 5 in diameter hole through the roof Make sure the ...

Page 24: ...oints WARNING Cements and primers are highly flammable Assemble joints in an adequately ventilated area away from heat sources or open flames Do not smoke Read cautions and warnings on material containers CAUTION DO NOT use cement that is lumpy or thick DO NOT thin cement Connections i e joints between plastic pipe and fittings must be properly sealed This requires that an appropriate primer clean...

Page 25: ...aluminum tape around the connection to secure Form a trap by looping a portion of the plastic tube into approximately a 6 diameter circle With respect to the water heater form the loop such that it can be mounted on the upper 1 3 of the heater Use the supplied loop clamps and screws to secure the tubing to the side of the water heater and hold the loop trap in place The condensate drain tube must ...

Page 26: ...all a union and shut off valve at both potable water connections All piping should be 3 4 diameter new copper or larger A tempering valve or anti scald valve should be installed at the potable water outlet and used according to the manufacturer s specifications to prevent scalding 2 If a backflow preventer check valve or pressure regulating valve is required in the cold water supply a properly siz...

Page 27: ...o prevent flashbacks caused by momentary pressure loss For natural gas 5 W C pressure must be maintained upstream of the gas valve during operation For LP gas a minimum of 11 W C must be maintained upstream of the gas valve A 1 8 inch NPT pipe connection should be installed upstream of the manual shut off valve to check incoming gas pressure During pressure testing of the gas supply piping close t...

Page 28: ...Page 28 SECTION IV INSTALLATION cont GAS CONNECTIONS cont Figure 16 Gas Piping to Valve Control Figure 17 Recommended Water Gas Vent Connections ...

Page 29: ...ermit the used of the supplied cord remove the power cord from the blower assembly and replace with suitable power supply 120V 60 Hz wiring and connections The water heater draws less than 5 amps maximum Check for proper polarity at the main power connection prior to operating the water heater CAUTION Turn off or disconnect the electrical power supply to the water heater before servicing Label all...

Page 30: ...Page 30 SECTION V OPERATION Figure 19 Instructions To Put The Water Heater In Operation ...

Page 31: ...YES NO IS FLAME SENSE LOST IS REQUEST FOR HEAT SATISFIED MAIN VALVE OFF COMBUSTION BLOWER OFF AFTER POST PURGE DELAY MAIN VALVE CLOSES LESS THAN 3 TRIES FOR IGNITION MAIN VALVE CLOSES LOST LESS THAN 3 TIMES YES YES TURN OFF INDUCER AFTER POST PURGE DISPLAY ERROR 6 ONE HOUR AUTO LOCKOUT RESET DELAY NO NO NO YES YES NO IS PRESSURE SWITCH PROVEN OPEN WITHIN 5 SECONDS WAIT FOR PRESSURE SWITCH TO OPEN ...

Page 32: ... needed for combined appliance applications or commercial use an automatic tempering valve must be installed on all domestic hot water lines MEASURING THE OUTCOMING WATER TEMPERATURE The thermostat is factory set at 120 F for domestic use It is the responsibility of the building owner to verify that the installer follows the recommended quantitative testing for measuring the outlet water temperatu...

Page 33: ...e inspected twice in the first year and at least yearly once a time interval for inspection has been developed It is recommended to check the rod s six months after the heater is installed If the anode rod had reduced in size by two thirds of its original diameter of 3 4 or shows signs of pitting it is time for replacement Take the following steps when changing the anode rod s 1 Shut off water sup...

Page 34: ...ue with a flexible wire brush Slide the brush down the flue at the free end of each row of fins This should knock any rust flakes into the combustion chamber for removal WARNING If the flue is blocked with soot this indicates serious combustion problems related to the building and or installation These must be addressed before placing the water heater back in operation Vacuum any rust flakes or se...

Page 35: ...d away from water heater 2 Contact qualified agency to inspect vent system 3 Condensate kit not installed vertical or horizontal vent systems 3 Contact qualified agency to install condensate kt Refer to this manual 4 Vent air intake system exceeds maximum equivalent length 4 Contact qualified agency to inspect vent air intake system Poor combustion sooting yellow flame 1 Accumulation of scale on b...

Page 36: ... and or increase inlet gas pressure within specified range 2 Hot surface ignitor and flame rod assembly not positioned correctly 3 Electric polarity to unit is incorrect test and correct 4 Low voltage to the water heater Supply voltage must equal rated voltage 5 Check the vent and combustion air intake systems for blockage The maximum number of ignition retries or recyles has been reached and the ...

Page 37: ...Inner Door Right Side 2 Flue Baffle 11 Inner Door Left Side 3 Hot Outlet Nipple 12 Air Intake Boot 4 Dip Tube 13 Trim Plate 5 Anode Rods 14 PVC Pipe Ø3 x 62 5 6 T P Relief Valve 15 PVC Tee 3 x 3 x 2 7 Control Gas Valve 16 PVC Pipe Ø2 x 3 8 Drain Valve 17 Flex Coupling Ø2 x 3 5 9 Outer Door 18 1 x 3 Plastic Lined Nipple ...

Page 38: ...SECTION VIII PARTS LIST cont 1 2 3 4 Figure 23 EZ PDV C Burner Parts Table 13 EZ PDV C Burner Parts Part Description 1 Burner 2 Main Burner Tube NAT or LP 3 Ignitor and Flame Sensor Assembly 4 Orifice NAT or LP ...

Page 39: ...If a replacement tank is provided it will remain warranted under this section as if it were the original tank For example if we send you a replacement tank under this limited warranty two years after the original installation date then the replacement tank will remain warranted for the remaining three years after the original installation date HOW DO YOU GET SERVICE UNDER THE LIMITED WARRANTY In o...

Page 40: ...riginal location and install it somewhere else Fail to follow the care and maintenance instructions provided with the water heater Remove the anode rods Fail to inspect and replace the anode rods you must retain and present your paid receipts as proof of anode rod replacement HOW DOES STATE LAW RELATE TO THIS LIMITED WARRANTY This is a limited warranty WE MAKE NO OTHER EXPRESS WARRANTIES WITH RESP...