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B/W EF100T199E3N nat gas commercial gas water heater condensing in first heat exchanger.
Contractor installed a commercial B/W EF100T199E3N nat gas water heater into a laundromat. Unit worked good for 5 days and shutoff. Found PVC exhaust 90 ell installed wrong fixed that and got the condensate water out of that part of the water heater. Unit still would not fire. Checked main heat exchanger and that was full of condensate water that could not get out of the water heater. He pumped that water out. Fired the water heater it ran good for another 5 days shut off. Contractor found water in primary heat exchanger. Pumped it out unit is running fine. Owner of laundromat ran his business on two A O Smith Cyclone BTH 199 commercial water heater for six years then one failed and he then ran the business on just one A O Smith Cyclone BTH 199 commercial water heater for a year and one half. He thought he could get away with just one B/W EF100T199E3N water heater.
B/W tech told us that he should have two 399,000 BTU gas water heaters for the amount of washers he has. B/W told him only using one water heater that is way under sized with all the cold water running through the water heater is causing the flue gas to condense in the first heat exchanger and it is not supposed to condense at that point in the water heater. Has anyone installed this type of B/W water heater and had this problem of flue gas condensing in the first heat exchanger. All I can suggest is that the contractor needs to sell and install the two EF100T399E3N water heaters or install storage tanks with pumps if that would work.
Any other suggestions to keep the water heater that the contractor installed from condensing in the wrong heat exchanger.