RWH Om 1

RESIDENTIAL WATER HEATERS
CERTIFICATION PROGRAM
AHRI RWH OM – MARCH 2023
Sponsored and administered by:

2311 Wilson Blvd, Suite 400
Arlington, Virginia 22201
(703) 524-8800
PREFACE
The following manual outlines the procedures and policies of the Performance Certification Program for
Residential Water Heaters (RWH) operated by the Air-Conditioning, Heating, and Refrigeration Institute
(AHRI). This manual is to be used in conjunction with the AHRI General Operations Manual for AHRI
Certification Programs. Where the AHRI General Operations Manual and this product-specific manual
differ, this product-specific operations manual shall prevail.
The revision of this manual supersedes all previous revisions. The current edition of this manual, as well
as the AHRI General Operations Manual, can be accessed through the AHRI website, www.ahrinet.org.
The RWH Certification Program by AHRI provides for independent verification of the Commercial Water
Heater manufacturers’ stated equipment performance. Safety criteria are not within the scope of this
program.
Participation in the program is voluntary. Any manufacturer, regardless of AHRI membership, may obtain
approval of Program Ratings and use of the AHRI RWH Certification Mark hereinafter referred to as the
“Mark”. The Mark is the Participant’s public representation that the ratings of randomly selected units have
been verified by an independent laboratory in accordance with test procedures prescribed by this operations
manual. A Certification Agreement is executed between the manufacturer and AHRI specifying the
conditions under which such Ratings and the Mark may be used. No manufacturer has the right to use
Program Ratings or to state that their products have been tested in conformance with the procedures
outlined in this Rating Procedure unless and until they have received written authority from AHRI to use the
Mark as applied to the specific approved Program Ratings.
This Operations Manual has been prepared to assure that administration of the program is carried out in a
uniform manner. It is an amplification of the Certification Agreement signed by licensees and AHRI. General
information, procedural details, and copies of forms are included in this Operations Manual. Provisions of
the Operations Manual may be amended as provided in the Certification Agreements
This certification program complies with requirements of the ISO/IEC Standard 17065:2012, General
Requirements for Bodies Operating Product Certification Systems.
Note:
This manual supersedes the Residential Water Heater Operations Manual, January 2022 and is effective
March 27, 2023.
Printed in U.S.A. ©Copyright 2022, by Air-Conditioning, Heating,

and Refrigeration Institute
Registered United States Patent and Trademark Office
CERTIFICATION OPERATIONS MANUAL FOR
TABLE OF CONTENTS
SECTION PAGE
1 Program Overview
1.1 Applicable Rating Standards ........................................................................................ 1
1.1.1 Applicable U.S. Rating Standard ........................................................ 1
1.1.2 Applicable Canadian Rating Standard ............................................... 1
1.2 Product Definitions ....................................................................................................... 1
1.2.1 Residential Water Heater. .................................................................. 1
1.2.1.1 Electric Storage Water Heater.................................. 1
1.2.1.1.1 Grid Enabled Water Heater ............. 1
1.2.1.1.1.1 Activation Lock .......... 1
1.2.1.2 Heat Pump Water Heater ......................................... 1
1.2.1.3 Gas Storage Water Heater ....................................... 1
1.2.1.4 Gas Instantaneous Water Heater ............................. 2
1.2.1.5 Oil Storage Water Heater ......................................... 2
1.2.1.6 Electric Instantaneous Water Heater........................ 2
1.2.2 Residential-Duty Commercial Water Heater. ..................................... 2
1.3 Program Scope. ............................................................................................................ 2
1.3.1 Program Scope Exclusions. ............................................................... 2
1.3.2 Voluntary Program Scope Inclusion. .................................................. 2
1.3.2.1 Models Sold Exclusively in Canada ......................... 2
1.3.2.2 Other Voluntary Scope Inclusions ............................ 2
1.3.2.2.1 Electric Storage Water Heater ....... 3
1.3.2.2.2 Gas Storage Water Heater ............. 3
1.3.2.2.3 Gas Instantaneous Water Heater ... 3
1.3.2.2.4 Oil Storage Water Heater ............... 3
1.3.2.2.5 Oil Instantaneous Water Heater ..... 3
1.4 Intended Market ............................................................................................................ 3

1.5 Basic Model. ................................................................................................................. 3
1.5.1 Grandfathered Basic Model ................................................................ 3
1.6 Draw Pattern ................................................................................................................. 4
2 Qualification Process
2.1 Original Equipment Manufacturer (OEM) Applicants ................................................... 4
STEP 2.1.1 Certification Application Package ....................................................... 4
STEP 2.1.1.1 Qualify Models Using Test Reports .......................... 4
STEP 2.1.1.2 Qualify Models Using An AEDM ............................... 4
STEP 2.1.2 Processing Application Package ........................................................ 4
STEP 2.1.2.1 Performance Certification Agreement for Original
Equipment Manufacturer (OEM Agreement) ............ 4
STEP 2.1.2.2 Participation and Licensing Fee Invoice ................... 5
STEP 2.1.3 Selection and Acquisition of Test Samples ........................................ 5
STEP 2.1.3.1 Number of Qualification Tests .................................. 5
STEP 2.1.3.2 Acquisition of Qualification Test
Samples/Selection Criteria ....................................... 5
STEP 2.1.4 Qualification Testing ........................................................................... 5
STEP 2.1.4.1 Successful Completion of All Qualification Tests ..... 5
STEP 2.1.4.1.1
Maximum GPM ........................... 5
STEP 2.1.4.1.2
First Hour Rating (FHR) ............. 5
STEP 2.1.4.1.3
Uniform Energy Factor (UEF) .... 5
STEP 2.1.4.1.3.2 UEF Pass/Fail
Criteria ......... 6
STEP 2.1.4.2 Qualification Test Failure .......................................... 6
STEP 2.1.5 Welcome to the Program .................................................................... 6
2.2 Private Brand Marketer (PBM) Applicants .................................................................... 6
STEP 2.2.1 Certification Application Package ....................................................... 6
STEP 2.2.2 Processing Application Package ........................................................ 6
STEP 2.2.2.1 Performance Certification Agreement for Private
Brand Manufacturer (PBM Agreement) .................... 6
STEP 2.2.2.2 OEM Agreement on behalf of the PBM Applicant .... 6
STEP 2.2.2.3 Licensing Fee Invoice ............................................... 6
STEP 2.2.3 Welcome to the Program .................................................................... 6
3 Equipment Selection and Testing

3.1 Annual Testing Requirement ........................................................................................ 6
3.2 Location of Tests .......................................................................................................... 6
3.2.1 Presence of Participant Personnel at the Laboratory ......................... 6
3.3 Selection of Test Samples ............................................................................................ 7
3.4 Methods for Acquiring Test Samples ........................................................................... 7
3.4.1 Method for Acquiring Three (3) Additional Test Samples .................. 7
3.5 Sample Acquisition Timeframe ..................................................................................... 7
3.6 Testing Punch List ........................................................................................................ 7
3.7 Inoperable Samples ...................................................................................................... 7
3.7.1 Disposition of Inoperable Samples ..................................................... 7
3.8 Certified Data ................................................................................................................ 7
3.8.1 Maximum GPM ................................................................................... 7
3.8.2 First Hour Rating (FHR)...................................................................... 7
3.8.2.1 Models Qualified Using Test Reports ....................... 7
3.8.2.2 Electric Storage Models Qualified Using an AEDM . 7
3.8.3 Uniform Energy Factor (UEF) ............................................................. 8
3.8.3.1 UEF Test Procedure ................................................. 8
3.8.3.1.1 UEF Test following Confirmed Draw
Pattern ........................................... 8
3.8.3.1.2 UEF Test following Failed Draw
Pattern ........................................... 8
3.8.3.2 UEF Pass/Fail Criteria .............................................. 8
3.8.4 Additional Requirements for Grid Enabled Water Heaters................. 8
3.8.5 Rounding to Determine Compliance .................................................. 8
3.9 Test Failures ................................................................................................................. 8
3.9.1 Options Following First Sample Failure.............................................. 8
3.9.1.1 First Sample Failure with the Same Draw Pattern ...... 8
3.9.1.2 First Sample Failure with a Different Draw Pattern ..... 9
3.9.2 Test Additional Sample Options ......................................................... 9
3.9.3 Options Following Additional Sample Failure ..................................... 9
3.10 Discontinuing or Changing Ratings for a Basic Model ............................................... 11
3.10.1 Voluntarily Changed ......................................................................... 11
3.11 Requirement for Adding New Basic Model to the Directory ....................................... 11
3.12 Relisting a Discontinued Product ............................................................................... 11
3.13 Consequences for Improper Ratings .......................................................................... 11
4 Challenge Tests ..................................................................................................................... 11
5 AHRI Directory of Certified Product Performance

5.1 Publication of Ratings in Certified Directory ............................................................... 11
5.2 Data Forms ................................................................................................................. 12
6 Assessment and Payment of Certification Fees

6.1 Equipment Delivery/Disposal Fees............................................................................. 12
7 Issuance of Violations and/or Termination ......................................................................... 12
8 Program Hierarchy, Complaints, and the Appeals Process ............................................. 12
9 Proper Use of the AHRI Certification Mark and Claims to Certification

9.1 Advertising with Metrics Not Certified by AHRI .................................................... 12
9.1.1 Advertising with Commercial Water Heater Metrics ......................... 12
9.1.2 Advertising with Energy Factor (EF) ................................................. 14
Examples
Example 1a Residential Water Heater Performance Data Shown with Optional Thermal
Efficiency and Standby Loss in The Same Table ................................................ 13
Example 1b Residential Water Heater Performance Data Shown with Optional Thermal
Efficiency and Without Standby Loss in The Same Table ................................... 13
Example 2a Residential Water Heater Performance Data Shown with Optional Thermal
Efficiency and Standby Loss in Two Tables ........................................................ 13
Example 2b Residential Water Heater Performance Data Shown with Optional Thermal
Efficiency and Without Standby Loss in Two Tables ........................................... 14
Appendices
Appendix A Guideline for Testing Uniform Energy Factor for Electric, Gas, and Oil-Fired Residential
and Residential-Duty Commercial Water Heaters ............................................... 15
Appendix B Energy Factor Testing Guidelines for Electric, Gas and Oil-Fired Residential
Water Heaters ...................................................................................................... 55
Tables
Table A1 Minimum and Preferred Instrument Accuracies ................................................... 17
Table A2 Instruments Calibration Timetable ....................................................................... 17
Table B1 Minimum and Preferred Instrument Accuracies .................................................. 58
Table B2 Instruments Calibration Timetable ....................................................................... 58
Figures
Figure 1 RWH Electric Storage AEDM Certification Test .................................................. 10
Figure A1 Residential, Top Inlet ........................................................................................... 38
Figure A2A Residential, Bottom Inlet, Top Outlet ................................................................... 39
Figure A2B Residential, Bottom Inlet, Side Outlet .................................................................. 40
Figure A3A Tankless, Bottom Inlet, Bottom Outlet ................................................................. 41
Figure A3B Tankless, Top Inlet, Top Outlet ............................................................................ 42
Figure A4 Compact, Top Inlet ............................................................................................... 43
Figure A5 Compact, Bottom Inlet, Side Outlet ...................................................................... 44
Figure A6 Compact, Bottom Inlet, Top Outlet....................................................................... 45
Figure A7A Tabletop Water Heater Inlet Piping Diagram ....................................................... 46
Figure A7B Tabletop Water Heater Outlet Piping Diagram ...................................................... 4
Figure A8A Inlet and Outlet Piping ........................................................................................ 468
Figure A8B Inlet and Outlet Piping Set-up 1 ........................................................................... 49
Figure A8C Inlet and Outlet Piping Set-up 2 ........................................................................... 50
Figure A9 Tank Height Rod Fitting ....................................................................................... 51
Figure A10 Tank Height Determination .................................................................................. 52
Figure A11 Marking Tank Height on Water Heater Jacket ..................................................... 53
Figure B1 Tank Height Rod Fitting ....................................................................................... 74
Figure B2 Tank Height Determination .................................................................................. 75
Figure B3 Height Determination ........................................................................................... 76
Figure B4 Marking Tank Height on Water Heater Jacket ..................................................... 77
Figure B5 Inlet and Outlet Thermocouple Placement ......................................................... 78
Figure B6 Thermocouple Tree Fitting Examples .................................................................. 79
Figure B7 Thermocouple Tree Fitting and Adapter .............................................................. 80
Figure B8 Curve Fit: Water Specific Heat vs. Temperature ................................................. 81
Figure B9 Curve Fit: Water Density vs. Temperature........................................................... 81
RWH OM – MARCH 2023
1. Program Overview
1.1 Applicable Rating Standards. It is mandatory for program Participants to comply with the procedures
outlined in this Operations Manual and the provisions of the latest edition of the following Standards:
1.1.1 Applicable U.S. Rating Standard. 10 CFR Part 430 Subpart B Appendix E (Uniform Test
Method for Measuring the Energy Consumption of Water Heaters).
1.1.2 Applicable Canadian Rating Standard. CAN/CSA P.3-15 (Testing method for measuring
energy consumption and determining efficiencies of gas-fired and fuel oil-fired water heaters).
A copy of the CFR is available for download from the U.S. Government Printing Office website, GPO
Access, at http://www.gpo.gov/fdsys/.
1.2 Product Definitions. All terms in this document shall follow the AHRI General Operations Manual and the
Standard definitions unless otherwise defined in this section.
1.2.1 Residential Water Heater. A product which utilizes oil, gas, or electricity to heat potable water
for use outside the heater upon demand, including the following:
1.2.1.1 Electric Storage Water Heater. A water heater that uses electricity as the
energy source, has a nameplate input rating of 12 kW (40,956 Btu/h) or less, has a DOE Rated
Storage Volume of not less than 20 gallons nor more than 120 gallons, and contains more than
one gallon of water per 4,000 Btu per hour of input.
1.2.1.1.1 Grid-Enabled Water Heater. Grid-Enabled Water Heater means

an electric resistance water heater that:
• Has a DOE Rated Storage Volume of more than 75 gallons;

• Is manufactured on or after April 16, 2015;
• Is equipped at the point of manufacture with an activation lock; and
• Bears a permanent label applied by the manufacturer that identifies the
product as such.
1.2.1.1.1.1 Activation Lock. Activation lock means a control

mechanism (either by a physical device directly on the water
heater or a control system integrated into the water heater) that is
locked by default and contains a physical, software, or digital
communication that must be activated with an activation key to
enable the product to operate at its designed specifications and
capabilities and without which the activation of the product will
provide not greater than 50 percent of the rated first hour delivery
of hot water certified by the manufacturer.
1.2.1.2 Heat Pump Water Heater. A water heater with a maximum current rating of
24 amperes (including the compressor and all auxiliary equipment such as fans, pumps,
controls, and, if on the same circuit, any resistive elements) at an input voltage of no greater
than 250 volts, has a DOE Rated Storage Volume of not less than 20 gallons nor more than
120 gallons, and is designed to transfer thermal energy from one temperature level to a higher
temperature level for the purpose of heating water, including all ancillary equipment such as
fans, storage tanks, pumps, or controls necessary for the device to perform its function.
1.2.1.3 Gas Storage Water Heater. A water heater that uses gas as the main energy
source, has a nameplate input rating less than or equal to 75,000 Btu/h, has a DOE Rated
1
Storage Volume greater than or equal to 20 gallons and less than or equal to 100 gallons, and
contains more than one gallon of water per 4,000 Btu per hour of input
1.2.1.4 Gas Instantaneous Water Heater. A water heater that uses gas as the main
energy source, has a nameplate input rating greater than 50,000 Btu/h but less than or equal
to 200,000 Btu/h, has a DOE Rated Storage Volume of less than 2 gallons, and contains no
more than one gallon of water per 4,000 Btu per hour of input.
1.2.1.5 Oil Storage Water Heaters. A water heater that uses oil as the main energy
source, has a nameplate input rating less than or equal to 105,000 Btu/h, has a DOE Rated
Storage Volume capacity of 50 gallons or less, and contains more than one gallon of water per
4,000 Btu per hour of input.
1.2.1.6 Electric Instantaneous Water Heaters. A water heater that has a nameplate
input rating with energy input ratings less than or equal to 12 kilowatts, has a DOE Rated
Storage Volume of less than 2 gallons, and contains no more than one gallon of water per
4,000 Btu per hour of input.
1.2.2 Residential-duty Commercial Water Heater. Any gas-fired storage, oil-fired storage, or electric
instantaneous commercial water heater that meets the following conditions:
• For models requiring electricity, uses single-phase external power supply;
• Is not designed to provide outlet hot water at temperatures greater than 180°F; and
• Is not one of the following:
• Gas-fired Storage: Gas-fired Storage Water Heaters with a rated input greater than
105 kBtu/h or a DOE Rated Storage Volume greater than 120 gallons.
• Oil-fired Storage: Oil-fired Storage Water Heaters with a rated input greater than
140 kBtu/h or a DOE Rated Storage Volume greater than 120 gallons.
• Electric Instantaneous: Electric Instantaneous Water Heaters with a rated input

greater than 58.6 kW or a DOE Rated Storage Volume greater than 2 gallons.
1.3 Program Scope. This program applies to Production Models of Residential Water Heaters, as defined in
Section 1.2, with nameplate input ratings and capacities within the Standard.
1.3.1 Program Scope Exclusions. The following are excluded from the RWH Certification Program:
• Residential Water Heaters, as defined in Section 1.2 that are sold exclusively in Canada.
1.3.2 Voluntary Program Scope Inclusions.
1.3.2.1 Models Sold Exclusively in Canada. Residential Water Heaters, as defined in

Section 1.2, that are sold exclusively in Canada and meeting the scope of the Standard may
be included in the Program at the Participant’s option. However, for all products meeting the
Program Scope and not subject to Section 1.3.1, the requirement pertaining to the AHRI
General OM Section 7, Certify-All Policy shall be met.
1.3.2.2 Other Voluntary Scope Inclusions. Residential Water Heaters as defined in this
section that meet the scope of the Standard may be included in the Program at the Participant’s
option. However, for all products meeting the Program Scope, the requirement pertaining to
the AHRI General OM Section 7, Certify-All Policy shall be met.
2
1.3.2.2.1 Electric Storage Water Heater. A water heater that uses electricity
as the energy source, has a nameplate input rating of 12 kW (40,956 Btu/h) or
less, has a DOE Rated Storage Volume of less than 20 gallons or greater than
120, and contains more than one gallon of water per 4,000 Btu per hour of input.
1.3.2.2.2 Gas Storage Water Heater. A water heater that uses gas as the
main energy source, has a nameplate input rating less than or equal to 75,000
Btu/h, has a DOE Rated Storage Volume of less than 20 gallons or greater than
100 gallons, and contains more than one gallon of water per 4,000 Btu per hour of
input.
1.3.2.2.3 Gas Instantaneous Water Heaters. A water heater that uses gas
as the main energy source, has a nameplate input rating of 50,000 Btu/h or less,
contains no more than one gallon of water per 4,000 Btu per hour of input, and
does not fall under Section 1.2.1.4 of this OM.
1.3.2.2.4 Oil Storage Water Heaters. A water heater that uses oil as the
main energy source, has a nameplate input rating less than or equal to 105,000
Btu/h, has a DOE Rated Storage Volume greater than 50 gallons, and contains
more than one gallon of water per 4,000 Btu per hour of input.
1.3.2.2.5 Oil Instantaneous Water Heaters. A water heater that uses oil as
the main energy source, has a nameplate input rating of 210,000 Btu/h (220 MJ/h)
or less, and contains no more than one gallon of water per 4,000 Btu per hour of
input.
Participants must ensure that certified Residential Water Heaters and non-certified Residential Water
Heaters have a separate name and or designation to avoid marketplace confusion. It is a violation of the
program if a buyer can look on the AHRI Directory of Certified Product Performance (Directory) and find
the name of the “non-certified” unit listed. AHRI certified units must be a different model number and that
model number must always be sold as certified. It is permissible for a participant to have another set of
model numbers for uncertified units as long as certification is not implied or claimed.
1.4 Intended Market. The Intended Market for this Certification Program includes all products defined in Section
1.3 that are sold for use in the U.S. (including U.S. Territories) and Canada.
1.5 Basic Model Definitions
1.5.1 Basic Model. A Participant’s listings of models shall be grouped by product families such that they
do not have differing electrical, physical, or functional characteristics that affect energy consumption.
1.5.1.1 Grandfathered Basic Models. Residential Water Heaters and Residential-Duty

Commercial Water Heaters as defined in Section 1.2 that:
o Have been introduced in commerce prior to July 13, 2015;
o Have ratings that met or exceeded the applicable federal standards at the time; and
o Have UEF ratings that fall below the federal minimums.
1.5.1.2 Basic Model Provision for Gas and Electric Storage Models with Ratings Established
Using an Alternative Efficiency Determination Method (AEDM). Gas and electric storage
models with alternate input ratings whose efficiency ratings are established in accordance with
10 CFR 429.70(g), shall be in the same Basic Model within the certification program.
3
1.6 Draw Pattern. Residential Water Heaters and Residential-duty Commercial Water Heaters, as defined in
Section 1.2, shall be tested under a draw profile that depends upon the First Hour Rating (FHR) or the Maximum
GPM whichever is applicable. See 10 CFR Part 430 Subpart B Appendix E for more details.
2. Qualification Process
2.1 Original Equipment Manufacturer (OEM) Applicants. With the additions noted below, the OEM qualification
process shall proceed according to the AHRI General Operations Manual, Section 4.
STEP 2.1.1 Certification Application Package. In addition to the Application for AHRI Certification and New
Applicant License Fee Form – Sales Volume noted in the AHRI General Operations Manual, Section 4,
STEP 1.
Applicants shall also submit data for models specified in Section 1.5 seeking qualification. Product data
submitted for acceptance shall be supported by ratings based on test reports produced by either a
manufacturer’s facility or by a Nationally Recognized Testing Laboratory (NRTL) showing the applicable
certified test results as follows:
• All types of Residential Storage Water Heaters – Uniform Energy Factor (UEF) and First
Hour Rating (FHR)
• All types of Residential Instantaneous Water Heaters – Uniform Energy Factor (UEF)
and Maximum GPM Rating
• All Grid-Enabled Water Heaters – Uniform Energy Factor (UEF) and First Hour Rating
(FHR) in the unlocked condition
STEP. 2.1.1.1 Methods to Establish Ratings
STEP 2.1.1.1.1 Qualify Models Using Test Reports. Applicants shall establish
ratings for models specified in Section 1.5.1 based on a minimum of two (2) test
reports on different samples in accordance with the sampling provisions in 10 CFR
429.17; or
STEP 2.1.1.1.2 Qualify Models Using An AEDM. Applicants shall establish ratings
for models specified in Section 1.5.2 based on a model qualified using STEP
2.1.1.1.1 provided that the following conditions are met:
o Gas Storage, Gas Instantaneous, or Residential-duty Commercial

Gas Storage. A model qualified without test reports must have an input
rating within 10% of the model qualified using STEP 2.1.1.1.1.
o Electric Storage. A model qualified without test reports must meet

the following conditions:
• Has an input rating above that of the model qualified using STEP
2.1.1.1.1; or
• Has its First Hour Rating result in the same draw pattern as that
of model qualified using STEP 2.1.1.1.1 when its input rating is
below that of the model qualified using STEP 2.1.1.1.1.
STEP 2.1.2 Processing Application Package.
STEP 2.1.2.1 Performance Certification Agreement for Original Equipment Manufacturer

(OEM Agreement). No further action required beyond that listed in Section 4, STEP 4.2 of the
AHRI General Operations Manual.
4
STEP 2.1.2.2 Participation and Licensing Fee Invoice. Payment of the Participation and
Licensing Fee is due within 30 calendar days of the invoice issue date. Testing shall not be
conducted until the invoice is paid in full. No further action required beyond that listed in Section
4, STEP 4.2 of the AHRI General Operations Manual.
STEP 2.1.3 Selection and Acquisition of Test Samples.
STEP 2.1.3.1 Number of Qualification Tests. Thirty percent (30%) of an Applicant’s Basic
Models shall be tested. Fractional models should be rounded to the nearest whole number
using traditional rounding methods. Each Applicant shall test a minimum of one (1) Residential
Water Heater Basic Model.
STEP 2.1.3.2 Acquisitions of Qualification Test Samples/Selection Criteria. Within 30

calendar days of a request from AHRI, the Applicant shall have samples available for selection.
Samples shall be acquired in accordance with Section 3 of this manual.
STEP 2.1.4 Qualification Testing. AHRI shall supply the Laboratory with the Applicant’s published ratings.
The Laboratory shall conduct the testing of the samples in accordance with the Standard, against the
published ratings.
STEP 2.1.4.1 Successful Completion of All Qualification Tests. If all qualification tests pass,
proceed to STEP 2.1.5.
STEP 2.1.4.1.1 Maximum GPM. Required on all Instantaneous Water Heaters.
For qualification testing, the Maximum GPM test results shall be greater than or equal to
95.0% of the rated value.
STEP 2.1.4.1.2 First Hour Rating (FHR). Required on all Storage Water Heaters.
STEP 2.1.4.1.2.1 Models Qualified Using Test Reports. For qualification

testing the FHR test results shall be greater than or equal to 95.0% of
the rated value.
STEP 2.1.4.1.2.2 Electric Storage Models Qualified Using an AEDM. For

alternate input rates, the FHR test results shall confirm the rated Draw
Pattern. If the FHR test results give the sample a lower Draw Pattern,
the FHR test results shall be greater than or equal to 95.0% of the
certified FHR rating. Tests will be run per Figure 1.
STEP 2.1.4.1.3 Uniform Energy Factor (UEF). Required on all Water Heaters.
STEP 2.1.4.1.3.1 UEF Test Procedure
STEP 2.1.4.1.3.1.1 UEF Test Following Confirmed Draw Pattern.

If the FHR or Maximum GPM test confirms or exceeds the rated
Draw Pattern, the Laboratory shall conduct the UEF test to the
rated draw pattern.
STEP 2.1.4.1.3.1.2 UEF Test following Failed Draw Pattern.

If the FHR or Maximum GPM test has a failing result that gives the
sample a lower Draw Pattern, the Laboratory shall conduct the
UEF test to the draw pattern based on the measured result.
5
STEP 2.1.4.1.3.2 UEF Pass/Fail Criteria. For qualification testing,

the UEF test results shall be greater than or equal to 98.0%
of the rated value.
STEP 2.1.4.2 Qualification Test Failure. In the event that the qualification tests fail according
to Section 3.8, the Applicant shall have the options described in Section 3.9.
STEP 2.1.5 Welcome to the Program. No further action required beyond that listed in Section 4, STEP 6
of the AHRI General Operations Manual.
2.2 Private Brand Marketer (PBM) Applicants. With the additions noted below, the PBM qualification process
shall proceed according to the AHRI General Operations Manual, Section 5.
PBM Applicants are not required to undergo qualification testing. PBM product certification is contingent upon the
certification of the associated OEM product.
STEP 2.2.1 Certification Application Package. In addition to the Application for AHRI Certification Form
noted in the AHRI General Operations Manual, Section 4, STEP 1, the Applicant shall also complete
product data submittal spreadsheets. These spreadsheets, which show the correlation between PBM
Participant and OEM Participant samples, are available from AHRI. These spreadsheets shall be correctly
completed in their entirety, and returned to AHRI, for the qualification process to continue.
STEP 2.2.2 Processing Application Package.
STEP 2.2.2.1 Performance Certification Agreement for Private Brand Marketer (PBM
Agreement). In addition to the Application for AHRI Certification Form noted in the AHRI
General Operations Manual, Section 5, STEP 5.1, Applicants shall submit the following
documentation to AHRI:
• An Applicant requesting AHRI to submit data to CEC, DOE, FTC, and NRCan shall
submit third-party authorization, compliance forms and other necessary information.
• Additional information may be needed to meet EPA ENERGY STAR® program
requirements.
STEP 2.2.2.2 OEM Agreement on Behalf of the PBM Applicant. No further action required
beyond that listed in Section 5, STEP 5.2.2 of the AHRI General Operations Manual.
STEP 2.2.2.3 Licensing Fee Invoice. Payment of the Licensing Fee is due within 30 calendar
days of the invoice issue date.
STEP 2.2.3 Welcome to the Program. No further action required beyond that listed in Section 5, STEP 3
of the AHRI General Operations Manual.
3. Equipment Selection and Testing
3.1 Annual Testing Requirement. Thirty percent (30%) of a Participant’s Basic Models shall be tested per year.
Fractional models shall be rounded to the nearest whole number using traditional rounding methods. Each program
Participant shall test a minimum of one (1) Residential Water Heater Basic Model per year.
3.2 Location of Tests. Testing shall be performed at the Laboratory and the sample shall be installed in the test
facility in accordance with the Participant’s published installation instructions in printed or electronic format.
3.2.1 Presence of Participant Personnel at the Laboratory. Refer to Section 9 of the General
Operations Manual.
6
3.3 Selection of Test Samples. Selections shall be made based on data contained in the Directory. AHRI shall
inform the Participant, in writing, of the sample(s) selected for test.
3.4 Methods for Acquiring Test Samples. AHRI, or its representative, shall make a Random Sample Selection
from the Participant’s stock inventory; a minimum of three (3) samples of each selected model shall be available.
Selected samples shall be shipped to the Laboratory accompanied by written installation and operating instructions.
Whenever possible and practical, shipped sample(s) should be placed on pallets (multiple samples per pallet is
preferred) to ensure efficient handling and storage. Grid-Enabled Water Heaters shall be shipped with the Activation
Lock that has not been disabled and instructions for unlocking it.
3.4.1 Method for Acquiring Three (3) Additional Test Samples. If a participant has chosen to test
three (3) additional samples after a first sample failure (described in Section 3.8), a minimum of four (4)
samples of the failed model shall be made available for the Random Sample Selection.
3.5 Sample Acquisition Timeframe. Within 30 calendar days of a request from AHRI, the Participant shall have
each selected Basic Model available for Random Sample Selection as described in Section 3.4.
3.6 Testing Punch List. The Participant shall complete and provide a Punch List (refer to the AHRI website) in
electronic format to the Laboratory prior to sample arrival at the Laboratory. The Participant may choose to furnish
a single Punch List for multiple tests.
The Punch List shall not contradict the installation and operations manual provided by the Participant, nor shall it
contradict the guidelines provided in Appendix A of this operations manual. If there is a discrepancy between notes
written on the Punch List, Installation and Operations Manual, products specific operations manual, applicable test
procedure and/or the Directory, AHRI shall determine which document takes precedence.
3.7 Inoperable Samples. In addition to the requirements for Inoperable Samples in the General Operations
Manual, samples received at the Laboratory which produce more than 400 ppm air-free CO (sample taken at steady
state following the procedure described in ANSI Z21.10.1) at normal input shall be deemed Inoperable Samples.
3.7.1 Disposition of Inoperable Samples. All Inoperable Samples shall be returned, with all costs
associated with the Inoperable Sample borne by the Participant. Time limitation on the acquisition of a new
sample shall be the same as Section 3.5.
3.8 Certified Data. Within the program, tests shall be conducted to verify the following certified data:
3.8.1 Maximum GPM. Required on all Instantaneous Water Heaters.
For annual testing, if the Maximum GPM test results confirm the rated Draw Pattern, the Maximum GPM
test results shall be greater than or equal to 90.0% of the certified rating. If the Maximum GPM test results
give the sample a different Draw Pattern, the Maximum GPM Rating test results shall be greater than or
equal to 95.0% of the certified rating.
3.8.2 First Hour Rating (FHR). Required on all Storage Water Heaters.
3.8.2.1 Models Qualified Using Test Reports. For annual testing, if the FHR test results confirm
the rated Draw Pattern, the FHR test results shall be greater than or equal to 90.0% of
the certified rating. If the FHR test results give the sample a lower Draw Pattern, the
FHR test results shall be greater than or equal to 95.0% of the certified rating.
3.8.2.2 Electric Storage Models Qualified Using an AEDM. For alternate input rates, the FHR
test results shall confirm the rated Draw Pattern. If the FHR test results give the sample
a lower Draw Pattern, the FHR test results shall be greater than or equal to 95.0% of
the certified FHR rating. Tests will be run per Figure 1.
7
3.8.3 Uniform Energy Factor (UEF). Required on all Water Heaters.
3.8.3.1 UEF Test Procedure
3.8.3.1.1 UEF Test following Confirmed Draw Pattern. If the FHR or Maximum GPM
test confirms or exceeds the rated Draw Pattern, the Laboratory shall conduct the UEF test
to the rated draw pattern.
3.8.3.1.2 UEF Test following Failed Draw Pattern. If the FHR or Maximum GPM
test has a failing result that gives the sample a lower Draw Pattern, the Laboratory shall
conduct the UEF test to the draw pattern based on the measured result.
3.8.3.2 UEF Pass/Fail Criteria. For annual testing, the UEF test results shall be greater than
or equal to 95.0% of the certified rating.
3.8.4 Additional Requirements for Grid-Enabled Water Heaters. For annual testing of Grid-Enabled
Water Heaters, the UEF test results in unlocked condition shall be greater than or equal to 95.0% of the
certified rating. If the FHR test results in unlocked condition confirm the rated Draw Pattern, the FHR test
results in unlocked condition shall be greater than or equal to 90.0% of the certified rating. If the FHR test
results in unlocked condition give the sample a different Draw Pattern, the FHR test results in unlocked
condition shall be greater than or equal to 95.0% of the certified rating. The FHR test results in locked
condition shall be less than or equal to 50.0% of the certified rating.
For qualification testing of Grid-Enabled Water Heaters, the UEF test results in unlocked condition shall be
greater than or equal to 98.0% of the certified rating. The FHR test results in unlocked condition shall be
greater than or equal to 95.0% of the certified rating. The FHR test results in locked condition shall be less
than or equal to 50.0% of the certified rating.
3.8.5 Rounding to Determine Compliance. The required number of significant digits, per the
Applicable Rating Standard, shall be used for calculations. The result of the FHR shall be rounded to the
nearest whole number using traditional rounding to determine compliance and the measured draw pattern.
The results of the Maximum GPM test shall be rounded to one decimal place using traditional rounding to
determine compliance and the measured draw pattern. The result of the UEF test shall be rounded to two
decimal places using traditional rounding to determine compliance.
When determining compliance using the results of more than two samples, the mean of the applicable test
results shall be determined before rounding.
3.9 Test Failures.
3.9.1 Options Following First Sample Failure.
3.9.1.1 First Sample Failure with the Same Draw Pattern. For test failures that confirm the Draw
Pattern, the Participant will be notified of a first sample certified rating failure. The Participant has
seven (7) calendar days to select one of the following options:
• Re-rate the Basic Model and its derivatives proportionate to the failed test results (Not
available for Grid-Enabled Water Heater failing FHR in locked condition). If the Basic
Model is a Grandfathered Model and the Participant chooses to rerate the UEF, an EF
test shall be conducted on the sample to determine compliance with the federal
minimum. The EF test result shall be greater than or equal to 95.0% of the federal
minimum;
• Test additional samples (up to 3). The Participant shall establish the number of additional
samples to be tested at the time of choosing this option (samples shall be available within
8
the time frame and procedure allotted in Section 3 following notification of decision to
AHRI via Manufacturer’s Decision Form [MDF]). Please refer to section 3.9.3 for
information on how compliance will be determined when testing additional samples;
• Obsolete the basic model and its derivatives; or
• Remove the tested input rate from the alternative input rate list in the Directory (only
applicable for failures of electric storage models qualified using STEP 2.1.1.1.2).
3.9.1.2 First Sample Failure with a Different Draw Pattern. For test failures that do not
confirm the Draw Pattern, the Participant will be notified of a first sample certified rating failure.
The Participant has seven (7) calendar days to select one of the following options:
• Test additional samples (up to 3). The Participant shall establish the number of additional
samples to be tested at the time of choosing this option (samples shall be available within
the time frame and procedure allotted in Section 3 following notification of decision to
AHRI via Manufacturer’s Decision Form [MDF]). Please refer to section 3.9.2 for
information on how compliance will be determined when testing additional samples;
• Obsolete the basic model and its derivatives. The Participant shall indicate whether the
UEF test shall be conducted to the rated Draw Pattern or the measured Draw Pattern; or
3.9.2 Test Additional Samples Option. The Laboratory shall conduct the FHR or Maximum GPM test
on the second sample. If the second sample FHR or Maximum GPM test is a passing result, the Laboratory
shall conduct the UEF test on the second sample using the rated Draw Pattern. If the second sample UEF
test is a passing result, testing shall cease and the unit shall be determined compliant.
If the second sample FHR, Maximum GPM, or UEF test is a failing result, the Laboratory shall conduct the
FHR or Maximum GPM test on all additional samples and use the mean of the results, including the first
sample result, to determine compliance. If the mean FHR or Maximum GPM is a passing result, the
Laboratory shall conduct the UEF test on all samples using the rated Draw Pattern. If the mean FHR or
Maximum GPM is a failing result, the Laboratory shall conduct the UEF test on all samples using the Draw
Pattern determined by the mean of the FHR or Maximum GPM tests. Compliance shall be determined by
the mean of all test results.
3.9.3 Options Following Additional Sample Failure. When the Participant is notified of a second-
sample or additional sample certified rating failure, the Participant has seven (7) calendar days to select
one of the following options
• Re-rate the Basic Model. The re-rating of the affected Basic Model shall be no better
than the mean results of the tested samples (Not available for Grid-Enabled Water
Heater failing FHR in locked condition). If the Basic Model is a Grandfathered Model and
the Participant chooses to rerate the UEF, an EF test shall be conducted on all samples,
and the mean result will be used to determine compliance with the federal minimum. The
EF test result shall be greater than or equal to 95.0% of the federal minimum;
• Obsolete the basic model and its derivatives; or
9
Figure 1. RWH Electric Storage AEDM Certification Test
10
3.10 Discontinuing or Changing Ratings for a Basic Model.
3.10.1 Voluntarily Changed Rating.
• The Participant may voluntarily discontinue or lower the certified rating for any existing
model at any time prior to the Program’s selection for compliance testing of that model
or any of its associated models.
• The Participant may increase the certified rating if supporting data is submitted following
the requirements of Section 2.1 STEP 2.1.1.1.1. The increased rating shall not be
included in the program until any questions concerning the re-rating are answered to the
satisfaction of AHRI. Models with increased ratings may be subject to increased review
and selection for verification testing.
3.11 Requirement for Adding New Basic Model to the Directory. Product data submitted for acceptance shall
meet the requirements of Section 2.1 STEP 2.1.1.1.1.
3.12 Relisting a Discontinued Product. Models previously discontinued for which the Participant is seeking
relisting, shall meet the requirements of Section 2.1 STEP 2.1.1.1.1. Those models meeting the requirements of
Section 2.1 STEP 2.1.1.1.1 shall not require qualification testing. Test reports originally submitted are acceptable.
3.13 Consequences for Improper Ratings. Assign one (1) Penalty Test immediately for any Electric Storage input
rate removed from the alternative input rate list in the Directory following a testing failure.
4. Challenge Tests
The Challenge Test process shall proceed according to the AHRI General Operations Manual, Section 10.
5. AHRI Directory of Certified Product Performance
All certified products shall be listed in the Directory, www.ahridirectory.org. Certification shall not be implied nor
claimed for any product not listed in the Directory. Except as noted below, the Participant shall follow the steps
outlined in Section 11 of the AHRI General Operations Manual.
5.1 Publication of Ratings in Certified Directory. The following information pertaining to each model certified
shall be published in the Directory:
• AHRI Certified Reference Number

• Model Status
• Brand Name
• Model Number(s) or Designation(s)
• Energy Source
• Heater Type
• Usage Bin
• UEF
• FHR (GPH)1
• Maximum GPM (GPM)2
• Nominal Capacity (gallons)
• DOE Rated Storage Volume (gallons)
• Input (MBtu/h or kW)
• UED Recovery Efficiency (%)
11
1 Required on all Storage Water Heaters

2 Required on all Instantaneous Water Heaters
Additional data may be shown for products sold in areas requiring further product information/ratings or EPA
ENERGY STAR® listings.
5.2 Data Forms. Each Participant shall list its products, by Basic Model. OEM and PBM Participants shall
submit/edit product data via the Directory.
6. Assessment and Payment of Certification Fees
Refer to Section 12 of the AHRI General Operations Manual.
7. Issuance of Violations and/or Termination
8. Program Hierarchy, Complaints, and the Appeals Process
9. Proper Use of the AHRI Certification Mark and Claims to Certification
9.1 Advertising with Metrics Not Certified by AHRI
9.1.1 Advertising with Commercial Water Heater Metrics: Pursuant to the February 8, 2019
Department of Energy (DOE) Enforcement Policy Statement for Water Heater Efficiency Representations,
manufacturers will not receive a program violation for a model advertised in the AHRI Directory as a
Residential Water Heater that is also advertised in the market with metrics in accordance with 10 CFR Part
431 Subpart G provided that the following criteria are met:
• Should be able to provide test reports in accordance with 10 CFR Part 431 Subpart G.
• The model does not fall within the scope of the DOE Enforcement Policy for Circulating Water Heaters
effective September 5, 2019 and ending December 31, 2021.
• The model does not fall within the scope of the DOE Enforcement Policy for Certain Consumer Water
Heaters effective October 1, 2019 and ending December 31, 2021.
• AHRI Certification and AHRI Certification Mark only apply to the model as a Residential Water Heater.
All product literature clearly differentiates between AHRI Certified and non-certified metrics, and
program Ratings and other data shall be placed into a table meeting the specified format found in the
examples below or equivalent.
12
Example 1a: Residential Water Heater Performance Data Shown With Optional Thermal
Efficiency and Standby Loss In The Same Table
Ratings Not Certified by AHRI
Rated
Model Input Rate,
Volume,
Number Btu/h
Gal F.H.R., Thermal Efficiency Standby Loss
UEF
Gal % Btu/hr
WH04050 40 50,000 80 0.80 90 600
Example 1b: Residential Water Heater Performance Data Shown With Optional Thermal
Efficiency and Without Standby Loss In The Same Table
Model Input Rate,

Number Btu/h
Thermal Efficiency
Max GPM UEF
%
WH199 199,000 5.7 0.93 95
Example 2a: Residential Water Heater Performance Data Shown With Optional Thermal
Efficiency and Standby Loss In Two Tables
Rated
Model Input Rate,
Volume,
Number Btu/h
Gal F.H.R.,
UEF
Gal
WH04050 40 50,000 80 0.80

Rated
Model Input Rate,
Volume,
Number Btu/h
Gal Thermal Efficiency, Standby Loss
% Btu/hr
WH04050 40 50,000 90 600
13
Example 2b: Residential Water Heater Performance Data Shown With Optional Thermal
Efficiency and Without Standby Loss In Two Tables
Model Input Rate,

Number Btu/h
Max GPM UEF
WH199 199,000 5.7 0.93
Model Input Rate,

Number Btu/h Thermal Efficiency,
%
WH199 199,000 95
9.1.2 Advertising with Energy Factor (EF): For sales in the U.S., manufacturers of covered products
are restricted from making energy efficiency representations that are not in accordance with the Department
of Energy (DOE) test procedures. (42 U.S. Code § 6293 (c)(1)) Manufacturers must use the prescribed
DOE test procedure as the basis for certifying to DOE that their products comply with the applicable energy
conservation standards adopted under EPCA. (42 U.S.C. 6295(s)) Members are strongly discouraged from
making energy efficiency representations that are not DOE accepted metrics.
14
APPENDIX A. GUIDELINE FOR TESTING UNIFORM ENERGY FACTOR FOR ELECTRIC, GAS, AND OIL-
FIRED RESIDENTIAL AND RESIDENTIAL-DUTY COMMERCIAL WATER HEATERS
Note: The purpose of this guideline is to provide details on the specific instrumentation, test setup, and testing
procedures used to measure water heater efficiency. This document is an adjunct to the Department of Energy
(DOE) test method for determining the energy efficiency of residential water heaters as published in the July 11,
2014 Federal Register notice 10 CFR Part 430 Subpart B Appendix E. It is used by the AHRI Residential Water
Heater Certification Program as a guideline providing clarification on how testing is conducted by the contracted
third-party laboratory. None of the details contained in this document are counter to or inconsistent with the DOE
test method.
Section A1. Test Guidelines
A1.1 Test Preparation.
A1.1.1 Documentation.
A1.1.1.1 Reference Standard. The following standard shall be referenced:

10 CFR Part 430 Subpart B Appendix E and ANSI Z21.10.1.
A1.1.1.2 Operator shall initiate a new test file and assign a new test number for each
test unit.
A1.1.2 Instrumentation. At a minimum, all instruments shall meet the accuracies listed in Table A1.
A1.1.2.1 The flow shall be measured on the inlet side of the water heater, which is where
the mass should be used from when conducting calculations. The volume measured on the
inlet shall be converted to obtain the volume withdrawn using the ratio of the inlet to outlet
densities, as detailed in Section A1.4.3.
A1.1.3 Calibration. Instruments shall be calibrated at a minimum of every 12 months (refer to Table
A2). Instrument calibration records shall be maintained and instruments shall be labeled with an
identification number matching its calibration record. Operator shall ensure that calibrations are current and,
if applicable, instruments are zeroed out prior to test. Instruments shall be calibrated by an ISO 17025
certified laboratory unless:
A1.1.3.1 When using external calibration services:
A1.1.3.1.1 Traceability of measurements is assured by the use of

calibration services for laboratories that can demonstrate competence,
measurement capability and traceability and;
A1.1.3.1.2 Calibration certificates issued by these laboratories contain

the measurement results for the ranges being used.
A1.1.3.2 When equipment is internally calibrated:
A1.1.3.2.1 Laboratory established traceability of its own measurement

standards and measuring instruments by means of an unbroken chain of
calibrations or comparisons linking them to the relevant primary standards of
the units of measurement and;
A1.1.3.2.2 The link to units achieved by reference to national

measurement standards (i.e. measurement standards and instruments directly
15
traceable to the National Institute of Standards and Technology (NIST) or other

nationally recognized organization such as A2LA, UKAS, SCC, IAS, etc.).
A1.1.4 Thermocouples Submerged in Water. Thermocouples submerged in water shall be of the

sheathed, ungrounded type. For the thermocouple tree, beaded-type thermocouple wires may be used
instead of probes when:
• Using the outlet fitting, its diameter is insufficient to pass the six probe assembly without
restricting the water flow; or
• There is a top center outlet with no anode, requiring an offset in the TC’s in order to clear
the elements; or
• There are side relief openings where the TC’s require a 90-degree bend, which would
destroy probes; or
• Encountering other circumstances after the testing agency and the manufacturer have
consulted and agreed it is necessary.
A1.1.5 Use of Quick Connect Fittings.
A1.1.5.1 Quick connect fittings shall only be used to: connect water supply, bypass, and
return hoses to the piping; and on the thermocouple tree.
A1.1.5.2 Quick connect fittings shall not be used to connect the inlet and outlet piping to the
water heater’s fittings.
A1.1.5.3 The acceptable quick connect fittings are described in A1.2.2.5. Any other
alternatives to these fittings shall be approved by the WHTC and Lab Evaluation WG prior to
their use.
16
Table A1. Minimum and Preferred Instrument Accuracies

DOE Test Method
Measurement Units Source Minimum Requirement
(For information only)
Electric Power watt-hour transducer ± 0.25% ± 0.5% of RDG
Water Flow Rate gpm or lbm/min flow meter ± 0.25% ± 1% of RDG
Wf lbm scale ± 0.5% ± 0.5% of RDG
± 0.05%
Barometric Pressure in. Hg barometer ± 0.1 in Hg
(0.017 in Hg)
cu-ft or cu-
Volume of Gas gas meter ± 1% ± 1% of RDG
ft/min
Gas
Chromatograph,
HHV Btu/cu-ft ± 0.5% ± 1% of RDG
Calorimeter or
spectrometer
pressure gauge or
P2 psig ± 1 psi ± 1 psi
transducer
Pgas in. H2O manometer ±0.1 inch of water column ±0.1 inch of water column
Water I/O
°F TC or RTD ± 0.2°F ± 0.2°F
Temperature
Tank Temperature °F TC or RTD ± 0.5°F ± 0.5°F
Ambient Temperature °F TC or RTD ± 0.2°F ± 0.2°F
Gas Temperature °F TC or RTD ± 0.5°F N/A
Time hr 0.000139 hr 0.000139 hr
Volt volts transducer 1.0 volt None
Amps amp amp transducer 0.1 amp None
Relative Humidity % transducer ± 1.5% ± 1.5%
Table A2. Instruments Calibration Timetable

Equipment Calibration Cycle
Natural Gas Calorimeter Every year
Gas Chromatograph Quarterly
Water Flow Meter Every year
Manometer Every year
Temperature Readout Every year
Stopwatch Every year
Pressure Transducer Every year
Scale Every year
Water Heater Test Stand Every year
U-Tube Manometer Every year
T/C Assembly Every year
Pressure gauge Every year
Digital Multimeter Every year
17
CO / CO2 Analyzer verify daily if used, calibrate annually
A1.2 Test Setup.
A1.2.1 Test Unit Preparation and Storage Vessel Capacity.
A1.2.1.1 The unit shall be placed in a conditioned space for at least 24 hours. The
conditioned space must be maintained at a minimum of 65°F.
A1.2.1.2 If applicable, operator shall install relief valves and water connections.
A1.2.1.3 The water heater shall be connected to a compressed air supply and a drain
hose shall be connected to the water heater’s drain valve.
A1.2.1.4 The water heater’s drain valve shall be opened and the compressed air supply
shall be turned on.
A1.2.1.4.1 Tip the water heater towards its drain valve while the air supply is turned
on to allow all water that may be inside the tank to be drained off. After all water is
removed, remove the drain hose and compressed air supply line.
A1.2.1.5 Test unit shall be weighed and dry weight recorded.
A1.2.1.6 Water heater shall be filled with water at a minimum pressure of 40 psi and
checked for leaks.
A1.2.1.7 Air shall be purged from the water heater during this process, including any other
time the water heater is filled, transferred to a different test station, or disconnected from the
water supply. A top spud location shall be used to purge any air from the water heater.
A1.2.1.8 Temperature of water shall be noted, and density of water at that temperature
shall be used to calculate the volume.
A1.2.1.9 Water heater shall be weighed. The weight of the water minus the weight of the
water in the pipe connections (W) shall be recorded in the test report.
A1.2.2 Thermocouple Placement.
A1.2.2.1 Standard Tank Height Measurement Procedure (Top water connections on a

storage water heater).
A1.2.2.1.1 Measure the height of the hot water outlet spud or anode spud using a
tape measure by hooking the tape under the tank, directly under the spud. This is
dimension "S" in Figure A10.
A1.2.2.1.2 Insert the rod fitting into the hot water outlet spud so that the top of the
fitting is “Y” inches above the top of the spud.
A1.2.2 1.3 Insert the rod through the fitting until it bottoms out against the
bottom of the tank. The tight clearance between the rod and fitting ensures the rod is
straight.
A1.2.2.1.4 Place a mark or piece of masking tape on the rod at the top of the rod
fitting.
18
A1.2.2.1.5 Remove the rod and measure dimension "L" from the bottom of the rod
to the mark.
A1.2.2.1.6 Calculate Tank Height H = L – S – Y in inches.
A1.2.2.1.7 Place the water heater on a level floor.
A1.2.2.1.8 Insert two fittings (or nipples) into the hot and cold spuds.
A1.2.2.1.9 Place a level across the two fittings.
A1.2.2.1.10 Lower or raise the fittings as appropriate to zero the level.
A1.2.2.1.11 Remove level and measure the length "X" from the bottom of the spud to
the top of the fittings (using tape measure and method from A1.2.2.1.1).
A1.2.2.1.12 Mark the top of the tank “T” on the water heater jacket by replacing level
and measuring down "X" inches as determined in A1.2.1.11 from bottom of level.
A1.2.2.1.13 Place mark for water heater tank bottom “B” by measuring down from the
tank top mark from A1.2.1.12 a distance equal to the tank height determined in A1.2.1.6.
A1.2.2.1.14 An acceptable alternate method for determining thermocouple placement

for side outlet water heaters is also described in A1.2.3.1 through A1.2.3.4.
A1.2.2.2 Thermocouple Placement Procedure.
A1.2.2.2.1 For water heaters with rated storage volumes greater than or equal to
20-gallons, use a six thermocouple tree with a vertical distance of at least 4 inches
between successive sensors.
A1.2.2.2.2 For water heaters with rated storage volumes between 2 and 20 gallons,
use a three thermocouple tree inside the water heater tank.
A1.2.2.2.3 Position a thermocouple at the vertical midpoint of each of the six equal
volume nodes within a tank larger than 20 gallons or the three equal volume nodes within
a tank between 2 and 20 gallons. Nodes designate the equal volumes used to evenly
partition the total volume of the tank. As much as is possible, the thermocouple should be
positioned away from any heating elements, anodic protective devices, tank walls, and
flue pipe walls.
A1.2.2.2.4 If the tank cannot accommodate six thermocouples and meet the
installation requirements above, install the maximum number of sensors that comply with
the installation requirements. Thermocouple wires may be used instead of probes when:
• Using the outlet fitting, its diameter is insufficient to pass the six probe
assembly, without restricting the water flow; or
• There is a top center outlet with no anode, requiring an offset in the TC’s
in order to clear the elements; or
• There are side relief openings where the TC’s require a 90 degree bend,
which would destroy probes; or
• Encountering other circumstances after the testing agency and the
manufacturer have consulted and agreed it is necessary.
A1.2.2.2.5 Install clear 0.25 in. i.d. tube on drain cock. Draw tube up the side of the
water heater jacket and affix to top of jacket.
19
A1.2.2.2.6 Using the weight of water in tank (W) as determined in A1.1.1.6,

determine placement of thermocouples.
A1.2.2.2.7 Open the water heater drain valve.
A1.2.2.2.8 For tree with six thermocouples, fill tank with W/12 ± 0.5 lb. of water. For
tree with three thermocouples, fill tank with W/6 ± 0.5 lb. of water.
A1.2.2.2.9 Allow the water level in the tube to stabilize. Mark water level in tube on
water heater jacket.
A1.2.2.2.10 For tree with six thermocouples, P1 is the measured distance from mark
indicating tank bottom to mark indicating 1/12 capacity. For tree with three
thermocouples, P1 is the measured distance from mark indicating tank bottom of mark
indicating 1/6 capacity.
A1.2.2.3 For tree with six thermocouples, calculate the remaining thermocouple positions
as follows:
P2 = (H – 2P1)/10 + 2P1
P6
P3 = (H – 2P1)/5 + P2
P4 = (H – 2P1)/5 + P3 P5
P5 = (H – 2P1)/5 + P4
P4
P6 = (H – 2P1)/5 + P5
P3
Where:
P2
H = Height of the water heater inside the tank. P1
Pi = Position of the thermocouples.
For tree with three thermocouples, calculate the remaining thermocouple positions as
follows:
P2 = (H-2P1)/4+2P1
P3=(H-2P1)/2+P1
A1.2.2.4 Using thermocouple placements determined in A1.2.2.3 and taking into account
thread engagement of the thermocouple tree fitting, set thermocouples in tree within ± 0.25” of
the calculated thermocouple positions. See Figures A10 and A11 for suggestions.
A1.2.2.5 Install thermocouple tree in the anode spud on the test unit. Ensure tree is
straight and is not in contact with any component inside the water heater, such as an element. If
the tree cannot be installed in the anode spud, install the tree in the outlet spud. Ensure that any
fittings are insulated with a minimum R-value of 8 ft²·°F·h/Btu.
To address the problem of nipple engagement depth on the TC probe, use the rod fitting with a
camlock fitting, McMaster-Carr Part Nos. 52155K51 and 52155K21, at the end. Use an O-ring on
the bottom thread to make a perfect seal between the spud and the rod fitting and allow the fitting
to bottom out on spud.
A1.2.2.6 Install piping on the unit per the diagrams shown in Figures A1 through A8.
A1.2.2.7 If applicable, operator shall install fittings, heat traps, and insulation (if provided)
on pipes, relief valves, and water connections. Any other supplied components with the water
20
heater must be installed per the manufacturer’s installation instructions. This includes, but is not
limited to the following: blowers, burners, controls, etc.
A1.2.2.7 If the heat trap is removed on the outlet side of the water heater to install the
temperature probe, the heat trap must be incorporated into the remainder of the outlet piping.
A1.2.2.8 Fill the water heater and examine it for leaks at a minimum pressure of 40 psi.
A1.2.2.9 Operator shall install insulation with a minimum R-Value of 8 h∙ft2∙°F/Btu on top of
thermocouple tree and any additional fittings that were added by the operator. All insulation must
be tightly secured to minimize heat loss potential.
A1.2.3 Side-Inlet Tank Height Measurement and Thermocouple Placement Procedure (use only if tank
does not have a top outlet, anode, or T&P fitting available on Storage Water Heaters).
A1.2.3.1 Install a clear 0.25 in. i.d. tube on tank drain cock. Draw tube up the side of the
A1.2.3.2 Fill tank with water.
A1.2.3.3 Open drain cock and allow water level to stabilize in tube. Ensure the water level
comes up to outlet spud. CAUTION: Do not to overfill! Should overfill occur and insulation
become wet, heater will be considered defective and must be replaced with a new unit.
A1.2.3.4 Place tank top mark “T” on the water heater jacket at level of full water heater.
A1.2.3.5 For tree with six thermocouples, Using the weight of the water in the tank (W),
remove W/12 ± 0.5 lb. of water. For tree with six thermocouples, Using the weight of the water in
the tank (W), remove W/6 ± 0.5 lb. of water.
A1.2.3.6 Allow the water level in the tube to stabilize. Mark water level in tube on water
heater jacket. For tree with six thermocouples, P6 is the measured distance from mark indicating
tank top (T) to mark indicating 1/12 capacity. For tree with three thermocouples, P3 is measured
distance from mark indicating tank top (T) to mark indicating 1/6 capacity.
A1.2.3.7 For tree with six thermocouples, remove W/6 ± 0.5 lb. of water for each
successive thermocouple. For tree with three thermocouples, remove W/3 ± 0.5 lb of water for
each successive thermocouple. After each draw, allow the water level in the tube to stabilize.
A1.2.3.8 Mark water level in tube on water heater jacket.
A1.2.3.9 Measure distance from previous thermocouple mark to successive thermocouple

mark until all thermocouple locations have been identified.
A1.2.3.10 Using thermocouple placements determined in A1.2.3.6 through A1.2.3.9, and

taking into account placement of the thermocouple tree fitting, set thermocouples in tree within ±
0.25” of the measured thermocouple positions. See Figures A10 and A11.
A1.2.4 Thermocouple Placement Procedure (Tankless Water Heaters Only).
A1.2.4.1 Install piping on the unit per the DOE test procedure document (see Figures A1
through A8).
A1.2.4.2 If applicable, operator shall install fittings, heat traps, and insulation (if provided)
on pipes, relief valves, and water connections. Any other supplied components with the water
21
heater must be installed per the manufacturer’s installation instructions. This includes, but is not
limited to the following: blowers, burners, controls, etc.
A1.2.4.3 Operator shall install insulation with a minimum R-Value of 8 ft²·°F·h/Btu on inlet
and outlet thermocouples and any additional fittings that were added by the operator. All
insulation must be tightly secured to minimize heat loss potential.
A1.2.5 Test Unit Setup.
A1.2.5.1 For power vent, power direct vent, and direct vent gas-fired water heaters only,
install the minimum length venting, per the manufacturer’s instructions. For atmospheric vent
water heaters, connect a 5-foot vertical vent pipe extension to the outlet of the water heater’s
draft hood.
A1.2.5.2 For oil-fired water heaters only, install the minimum length venting, per the
manufacturer’s instructions.
A1.2.5.2.1 Then, adjust the vent length according to 10 CFR Part 430 Subpart B
Appendix E to achieve the proper chimney/stack draft.
A1.2.5.3 For heat pump water heaters, a minimum of one (1) humidity sensor shall be
located 18” away from the water heater air inlet. If there is more than one, the sensors shall be
spaced evenly around the circumference of the water heater. Vertically, the sensor(s) must be
located halfway between the top and bottom of the heat pump portion of the water heater and
shielded from direct airflow out of the heat pump. The sensor(s) must monitor the surrounding
area’s humidity for all testing conducted.
A1.2.5.4 At least one picture must be taken of the water heater, including its venting,
piping, etc. This picture must be saved with the test file and be provided, upon request.
A1.2.5.5 All air movement across and/or on the water heater shall be eliminated prior to
starting any test. No air movement is determined by airflow around the unit to be less than 50
fpm.
A1.3 Test Procedure.
A1.3.1 Electric Storage Water Heaters (including Heat Pump Water Heaters):
A1.3.1.1 Test Setup.
Note: Section A1.2, Test Setup shall be followed prior to proceeding to this section.
A1.3.1.1.1 Install Electrical connections
A1.3.1.1.2 Install current clamp to upper most element.
A1.3.1.1.3 Inlet and outlet thermocouples shall be located as indicated in Figure A5.
A1.3.1.1.4 Fill the water heater and test it for leaks at a minimum pressure of 40 psi.
Isolate the water heater from the expansion tank by closing a ball valve between the two.
The pressure inside the tank must be monitored to see if it changes over a period of 10
minutes. The starting and ending pressures shall be recorded.
A1.3.1.1.5 Adjust the water heater setpoint to allow the main power source to cut-in
22
A1.3.1.1.6 Turn on the water heater and set the water heater thermostat(s) for
approximately 120°F.
A1.3.1.1.7 Set the voltage to nameplate voltage ± 1%
A1.3.1.1.8 Setting the outlet discharge temperature procedure: Drain and refill with
supply water at 58°F ± 2°F. Initiate operation of water heater. After cut-out, initiate a
draw based on part 1, 2, or 3 below. Document thermostat setting by photographing the
position of the thermostat and record the maximum outlet temperature on the test report.
(1) For storage volumes less than 20 gallons. After cutout initiate a draw of
1.0 gpm ±.25 gpm for 2 minutes. Starting 15 seconds after start of draw and
every 15 second interval record the outlet temperature. Determine if the
maximum outlet temperature is within the range of 125°F ± 5°F. If not turn
heater off adjust thermostat drain and refill the tank with supply water then
repeat the 2 minute outlet temperature test.
(2) For storage volumes greater than and equal to 20 gallons. After cutout
initiate a draw of 1.7 gpm ±.25 gpm for 5 minutes. Starting 15 seconds after
start of draw and every 15 second interval record the outlet temperature.
Determine if the maximum outlet temperature is within the range of 125°F ±
5°F. If not turn heater off adjust thermostat drain and refill the tank with
supply water then repeat the 5 minute outlet temperature test.
(3) For flow activated water heaters. At full input rating or maximum fire set
the outlet discharge temperature to 125°F ±5°F. If the heater cannot provide
this condition at 1.7 gpm ±.25gpm then adjust flow rate to achieve 125°F ±
5°F outlet temperature:
• If the outlet discharge temperature can be achieved above 1 gpm, then
the unit must be operated at the adjusted flow rate and maximum input
rate during the maximum gpm test. However, during the simulated use
test, the firing rate must be reduced to maintain the outlet discharge
temperature at 1 gpm.
• If the outlet discharge temperature cannot be achieved above 1 gpm,
then the adjusted flow rate is the flow rate to be used during maximum
gpm test and simulated use test.
(4) Tanks with Two or More Temperature Controllers. Verify the temperature
controller set-point while removing water in accordance with the procedure
set forth for the First Hour rating test.
(a) At least 50 percent of the water drawn during the first draw of the
First Hour rating test procedure shall be delivered at a temperature of
125°F ± 5°F (51.7°C ± 2.8°C).
(b) No water is delivered above 130°F (54.4°C) during First Hour

rating test.
(c) The delivery temperature measured 15 seconds after

commencement of each draw begun prior to an elapsed time of 60
minutes from the start of the test shall be at 125°F ± 5°F (51.7°C ±
2.8°C).
A1.3.1.1.9 If these conditions are not met, turn off the water heater, adjust the
temperature controllers and then drain and refill the tank with supply water. Repeat
A1.3.1.1.8 until the criteria for setting the temperature controllers is met. Once the setting
23
is met, the temperature controllers shall remain at the setting for the First Hour Rating
test and Simulated Use Test.
A1.3.1.1.10 Allow the test unit to soak-in for a minimum period of 12 hours. At no
time shall the unit be disconnected from its energy supply for more than 1 hour.
A1.3.1.2 Electric Storage Water Heaters (including Heat Pump Water Heaters): First Hour
Rating (FHR) Test.
Note: Section A1.2 and A1.3.1, Test Setup shall be followed prior to proceeding to this section.
A1.3.1.2.1 After the setting the outlet discharge, turn the power off, and disconnect
the electrical connections if transferring between a warm-up station and test station. At
the test station, connect the ambient, tank, inlet and outlet thermocouples, current
sensors, and power cord. Seal any gaps in water heater jacket due to sensor leads to
minimize heat loss. At no time shall the unit be disconnected from its energy supply for
more than 1 hour when transferring stations.
A1.3.1.2.2 Ensure the water heater’s temperature controllers are set to the same
setting when setting the outlet discharge temperature was determined.
A1.3.1.2.3 If the water heater is not presently operating, initiate a draw. Terminate
the draw when the outlet temperature drops 15 °F below the maximum recorded outlet
temperature or when cut-in occurs, whichever is longer. If the water heater is operating,
wait for max. mean tank temperature after cut-out or for thirty-minutes, whichever is
shorter, then initiate a draw. Terminate the draw when the outlet temperature drops 15°F
below the maximum recorded outlet temperature or when cut-in occurs, whichever is
longer.
A1.3.1.2.4 Initiate the FHR test and data acquisition system. Conduct the test as
detailed in Section 5.3.3 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.1.2.5 T-mean max is defined as the temperature at which the rolling 60 second
average (of readings taken every (5) seconds) T-mean temperature drops 0.05°F from
the previous rolling average reading.
A1.3.1.2.6 Starting fifteen seconds into the draw, record temperatures every five
seconds, until the outlet water temperature drops 15°F below the maximum recorded
outlet temperature.
A1.3.1.2.7 Allow the test unit to recover and draw, at cut-out, as many times as
possible in one hour. On water heaters with two or more thermostats, recovery is
determined by the cut-out of the upper thermostat or thermocouple.
A1.3.1.2.8 Confirm section A1.3.1.1.9 (4) has been met for water heater with two or
more temperature controllers. If not, repeat section A1.3.1.1.9.
A1.3.1.2.9 Compile data and save report.
A1.3.1.2.10 Validate the test results.
A1.3.1.3 Electric Storage Water Heaters (including Heat Pump Water Heaters): Simulated
Use Test (SUT).
24
A1.3.1.3.1 Refer to section 3.7 to determine the draw pattern to be used for the
SUT.
A1.3.1.3.2 After the FHR test turn on the water heater and allow it to fully recover.
A1.3.1.3.3 Water heater shall sit idle for (1) hour after cut-out prior to the start of the
24-hour SUT. No water can be withdrawn from the unit during this period.
A1.3.1.3.4 Initiate the 24-hour simulated use test and data acquisition system after
the 1 hour idle period. Using the draw pattern determined in section A1.3.1.2, conduct
the test as detailed in Section 5.4 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.2 Gas-Fired Storage Water Heaters:
A1.3.2.1 Test Setup
Note: Section A1.2 must be followed prior to proceeding to this section
A1.3.2.1.1 Install the gas line and the manifold pressure line.
A1.3.2.1.2 Connect the gas meter.
A1.3.2.1.3 Inlet and outlet thermocouples shall be located as indicated in Figures

A1 through A9.
A1.3.2.1.5 Light the pilot, if applicable. Otherwise, turn on the water heater.
A1.3.2.1.6 Adjust the water heater setpoint to allow the burner to fire.
A1.3.2.1.7 Check the entire gas train for leaks using a liquid leak detector or
combustible gas detector.
A1.3.2.1.8 Check the input rate. It must be within ± 2% of its rated value using the
method detailed in ANSI Z21.10.1. The manifold pressure shall be within ± 10% of that
printed on the rating plate.
A1.3.2.1.9 If input rate is not within ± 2% of the rated value, the operator shall
adjust manifold pressure, assuming he stays within the allowed ± 10% to attempt to
achieve ±2% of the rated input.
A1.3.2.1.10 If adjusting the manifold pressure does not achieve the rated input, the
operator shall re-orifice the unit using an alternate orifice supplied by the manufacturer.
[Note: Manufacturers are to supply test facility with a selection of orifices for use at the
test facility. When a test unit is re-orificed, the test facility will notify the manufacturer of
the alternate orifice used, and the manufacturer shall re-supply the test facility with a
replacement orifice.
25
A1.3.2.1.11 The operator shall check the entire gas train for leaks after re-orificing
the water heater. Any leaks discovered shall be fixed.
A1.3.2.1.12 Combustion must only be checked when the water heater is very clearly
operating abnormally (e.g. CO alarms are going off, producing smoke (when it is not
supposed to), flames are shooting out of the vent, etc.).
A1.3.2.1.13 Install unit on test station, connect the fuel supply, ambient, tank, inlet
and outlet thermocouples, current sensors, and power cord. Seal any gaps in water
heater jacket due to sensor leads to minimize heat loss. At no time shall the unit be
disconnected from its energy supply for more than (1) hour when transferring stations.
draw based on part 1, 2, 3 or 4 below. Document thermostat setting by photographing the
1.0 gpm ±.25 gpm for 2 minutes. Starting 15 seconds after start of draw
and every 15 second interval record the outlet temperature. Determine if
the maximum outlet temperature is within the range of 125°F ± 5°F. If not
turn heater off adjust thermostat drain and refill the tank with supply water
then repeat the 2 minute outlet temperature test.
initiate a draw of 1.7 gpm ±.25 gpm for 5 minutes. Starting 15
seconds after start of draw and every 15 second interval record the outlet
temperature. Determine if the maximum outlet temperature is within the
range of 125°F ±± 5°F. If not turn heater off adjust thermostat drain and
refill the tank with supply water then repeat the 5 minute outlet temperature
test.
the outlet discharge temperature to 125°F ± 5°F. If the heater cannot
provide this condition at 1.7 gpm ±.25gpm then adjust flow rate to achieve
125°F ± 5°F outlet temperature. The adjusted flow rate is the flow rate to be
used during the maximum gpm test and simulated use test.
controller set-point while removing water in accordance with the procedure
set forth for the First Hour rating test.
First Hour rating test procedure shall be delivered at a temperature
of 125°F ± 5°F (51.7°C ± 2.8°C).

rating test.

2.8°C).
26
A1.3.2.14 until the criteria for setting the temperature controllers is met. Once the setting
is met the temperature controllers shall remain at the setting for the FHR test and SUT.
A1.3.2.2 Gas-Fired Storage Water Heaters: First Hour Rating Test.
Note: Section A1.2 shall be completed before proceeding with this section
the draw when the outlet temperature drops 15°F below the maximum recorded outlet
wait for max. mean tank or for thirty-minutes, whichever is shorter, temperature after cut-
out then initiate a draw. Terminate the draw when the outlet temperature drops 15°F
longer.
A1.3.2.2.3 T-mean max is defined as the temperature at which the rolling 60 second
average (of readings taken every (5) seconds) T-mean temperature drops 0.05°F from
the previous rolling average reading.
A1.3.2.2.5 Starting (15) seconds into the draw, record temperatures every (5)
outlet temperature.
possible in one hour.
A1.3.2.3 Gas-Fired Storage Water Heaters: Simulated Use Test.
A1.3.2.3.1 Manifold pressure shall be monitored throughout the test to detect

improper gas valve operation or leaks.
SUT.
A1.3.2.3.3 After the FHR test, turn on the water heater and allow it to fully recover.
A1.3.2.3.4 The water heater shall sit idle for 1 hour prior to the start of the 24-hour
SUT. No water can be withdrawn from the unit during this period.
27
the 1 hour idle period. Using the draw pattern determined in step A1.3.2.2, conduct the
test as detailed in Section 5.4 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.2.3.6 Compile data and print report.
A1.3.3 Oil-Fired Storage Water Heaters:
A1.3.3.1 Test Setup

Note: Section A1.2 shall be followed prior to proceeding to this section.
A1.3.3.1.1 Install the fuel line quick connect fitting.
A1.3.3.1.2 Install a pressure gauge.
A1.3.3.1.3 Install the electrical sensing leads.
A1.3.3.1.4 Connect the fuel supply line.
A1.3.3.1.6 Turn the water heater on and check the entire fuel train for leaks by
confirming that the fuel stream contains no bubbles while priming the oil pump.
A1.3.3.1.7 Using the pressure gage, verify the pump is operating within the
manufacturer’s specifications and adjust only if necessary.
A1.3.3.1.8 After the burner has been on for 10 minutes, check the input rate. It
must be within ± 2% of the rated value.
A1.3.3.1.9 Adjust the burner for minimum stack, or over fire draft, as outlined in the
A1.3.3.1.10 Without exceeding a #1 smoke, the CO2 level shall be adjusted, as

outlined in the manufacturer’s instructions.
A1.3.3.1.11 Install unit on test station, connect the fuel supply, ambient, tank, inlet
and outlet thermocouples, current sensors, and power cord. Seal any gaps in water
heater jacket due to sensor leads to minimize heat loss. At no time shall the unit be
disconnected from its energy supply for more than (1) hour when transferring stations.
draw based on part 1, 2, or 3 below. Document thermostat setting by photographing the
1.0 gpm ±.25 gpm for 2 minutes. Starting 15 seconds after start of draw and
every 15 second interval record the outlet temperature. Determine if the
maximum outlet temperature is within the range of 125°F ± 5°F. If not turn heater
28
off adjust thermostat drain and refill the tank with supply water then repeat the 2
minute outlet temperature test.
initiate a draw of 1.7 gpm ±.25 gpm for 5 minutes. Starting 15 seconds after start
of draw and every 15 second interval record the outlet temperature. Determine if
the maximum outlet temperature is within the range of 125°F ± 5°F. If not turn
heater off adjust thermostat drain and refill the tank with supply water then repeat
the 5 minute outlet temperature test.
the outlet discharge temperature to 125°F ± 5°F. If the heater cannot provide this
condition at 1.7 gpm ±.25gpm then adjust flow rate to achieve 125°F ± 5°F outlet
temperature. The adjusted flow rate is the flow rate to be used during the
maximum gpm test and simulated use test.
controller set-point while removing water in accordance with the procedure set
forth for the First Hour rating test.
First Hour rating test procedure shall be delivered at a temperature of
125°F ± 5°F (51.7°C ± 2.8°C).

rating test.

2.8°C).
A1.3.3.1.12 until the criteria for setting the temperature controllers is met. Once the
setting is met the temperature controllers shall remain at the setting for the FHR test and
SUT.
A1.3.3.2 Oil-Fired Storage Water Heaters: First Hour Rating Test.

Note: Section A1.2 shall be completed before proceeding with this section
the draw when the outlet temperature drops 15°F below the maximum recorded outlet
wait for max. mean tank or for thirty-minutes, whichever is shorter, temperature after cut-
out then initiate a draw. Terminate the draw when the outlet temperature drops 15°F
longer.
29
A1.3.3.2.4 Starting (15) seconds into the draw, record temperatures every (5)
outlet temperature.
possible in one hour.
A1.3.3.3 Oil-Fired Storage Water Heaters: Simulated Use Test.

SUT.
A1.3.3.3.3 After the FHR test turn on the water heater and allow it to fully recover.
A1.3.3.3.4 The water heater shall sit idle for 1 hour prior to the start of the 24-hour
SUT. No water can be withdrawn from the unit during this period.
the 1 hour idle period. Using the draw pattern determined in step A1.3.3.2, conduct the
test as detailed in Section 5.4 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.4 Gas-Fired Tankless Water Heaters:

A1.3.4.1 Test Setup
A1.3.4.1.1 Install the gas line and the manifold pressure line.
A1.3.4.1.2 Connect the gas meter.
A1.3.4.1.3 Inlet and outlet thermocouples shall be located as indicated in Figure A3.
A1.3.4.1.4 Fill the water heater and test for leaks at a minimum pressure of 40 psi.
A1.3.4.1.5 Turn on the water heater.
A1.3.4.1.6 Allow water to flow through the unit to allow the burner to fire at its
maximum input rate.
30
A1.3.4.1.7 Check the entire gas train for leaks using a liquid leak detector or
combustible gas detector.
A1.3.4.1.8 Check the input rate. It must be within ± 2% of its maximum rated value
using the method detailed in ANSI Z21.10.3. The manifold pressure shall be within ±
10% of that printed on the rating plate.
A1.3.4.1.9 If input rate is not within ± 2% of the maximum rated value, the operator
shall adjust manifold pressure, assuming he stays within the allowed ± 10% to attempt to
achieve ± 2% of the rated input.
A1.3.4.1.10 If adjusting the manifold pressure does not achieve the rated input or it
cannot be adjusted, the operator shall re-orifice the unit using (an) alternate orifice(s)
supplied by the manufacturer.
Note: Manufacturers are to supply test facility with a selection of orifices for use at the
test facility. When a test unit is re-orificed, the test facility will notify the manufacturer of
the alternate orifice(s) used, and manufacturer shall re-supply the test facility with a
replacement orifice(s).
A1.3.4.1.11 The operator shall check the entire gas train for leaks after re-orificing
the water heater. Any leaks discovered shall be fixed.
A1.3.4.1.12 Combustion shall only be checked when the water heater is very clearly
operating abnormally (e.g. CO alarms are going off, producing smoke (when it is not
supposed to), flames are shooting out of the vent, etc.).
A1.3.4.1.13 Set the water heater to 125°F. If the water heater cannot be set exactly
at 125°F, the unit shall be set within 125°F ± 5°F.
A1.3.4.1.14 Draw water from the unit for approximately 30 minutes. Allow the test
unit to soak-in for a minimum period of (4) hours. At no time shall the unit be
disconnected from its energy supply for more than 1 hour.
A1.3.4.1.15 After soak-in period, turn off gas. Disconnect gas supply connections if
transferring between a warm-up station and a test station. At no time shall the unit be
disconnected from its energy supply for more than (1) hour.
A1.3.4.1.16 Ensure the water supply temperature is 58°F ± 2°F.
A1.3.4.1.17 Set the outlet discharge temperature based on below.
For flow activated water heaters. At full input rating or maximum fire set
the outlet discharge temperature to 125°F ± 5°F. If the heater cannot
provide this condition at 1.7 gpm ±.25gpm then adjust flow rate to
achieve 125°F ± 5°F outlet temperature. The adjusted flow rate is the
flow rate to be used during the maximum gpm test and simulated use
test.
31
A1.3.4.2 Gas-Fired Tankless Water Heaters: Maximum GPM Rating Test.
Note: Section 4.2, Test Setup shall be followed prior to proceeding to this section.
A1.3.4.2.1 Establish a target flow for the “Maximum GPM Rating” test for a period of
5 minutes or until the conditions stabilize, whichever is greater.
A1.3.4.2.2 Initiate the “Maximum GPM Rating” test. Conduct the test as detailed in
section 5.3.2 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.4.2.3 Draw water from the test unit for 10 minutes. Using a water meter, or an
alternative means, measure the amount of water drawn over the course of the test.
Throughout the test, record the inlet and outlet water temperatures.
A1.3.4.3 Gas-Fired Tankless Water Heaters: Simulated Use Test.
Note: Section 4.2, Test Setup shall be followed prior to proceeding to this section.
SUT.
A1.3.4.3.2 The water heater must sit in an idle state for (1) hour prior to the start of
the SUT. The water heater controls are active during this period but no water is
withdrawn.

A1.3.4.3.4 Initiate 24-hour SUT and the data acquisition system. Conduct the test
as detailed in Section 5.4.3 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.5 Electric Tankless Water Heaters:
A1.3.5.1 Test Setup
A1.3.5.1.1 Connect a power cord if one is not provided.
A1.3.5.1.2 Inlet and outlet thermocouples shall be located as indicated in Figures

A1 through A8.
A1.3.5.1.3 Fill the water heater and test for leaks at a minimum pressure of 40 psi.
A1.3.5.1.4 Turn on the water heater.
32
A1.3.5.1.5 Allow water to flow through the unit to allow the heater to operate at its
maximum input rate.
A1.3.5.1.6 Set the water heater thermostat to 125°F. If the water heater cannot be
set exactly at 125°F, the unit shall be set within 125°F ± 5°F.
A1.3.5.1.7 Install the unit in a test station. Connect the ambient, inlet and outlet
thermocouples, any current sensors, and power cords.
A1.3.5.1.8 Ensure the water supply temperature is 58°F ± 2°F.
A1.3.5.1.9 Set the outlet discharge temperature based below.
(1) For flow activated water heaters. At full input rating or maximum
fire set the outlet discharge temperature to 125°F ± 5°F. If the heater
cannot provide this condition at 1.7 gpm ±.25gpm then adjust flow rate to
achieve 125°F ± 5°F outlet temperature. The adjusted flow rate is the
flow rate to be used during the maximum gpm test and simulated use
test. Document thermostat setting by photographing the position of the
thermostat and record the maximum outlet temperature on the test
report.
A1.3.5.1.10 Draw water from the unit for approximately 30 minutes. Allow the test
unit to soak-in for a minimum period of 4 hours. At no time shall the unit be disconnected
from its energy supply for more than 1 hour.
A1.3.5.2 Electric Tankless Water Heaters: Maximum GPM Rating Test.
A1.3.5.2.1 Establish a target flow for the “Maximum GPM Rating” test for a period of
5 minutes or until the conditions stabilize, whichever is greater.
A1.3.5.2.2 Initiate the “Maximum GPM Rating” test. Conduct the test as detailed in
Section 5.3.2 of 10 CFR Part 430 Subpart B Appendix E.
A1.3.5.2.3 Draw water from the test unit for 10 minutes. Using a water meter, or an
alternative means, measure the amount of water drawn over the course of the test.
Throughout the test, record the inlet and outlet water temperatures.
A1.3.5.3 Electric Tankless Water Heaters: Simulated Use Test:
A1.3.5.3.1 Initiate the 24-hour simulated use test and the data acquisition system.
Conduct the test as detailed in Section 5.2.4 of 10 CFR Part 430 Subpart B Appendix E.
33
SUT.
A1.3.5.3.3 The water heater must sit in an idle state for (1) hour prior to the start of
the SUT. The water heater controls are active during this period but no water is
withdrawn.
A1.3.5.3.4 Initiate 24-hour SUT and the data acquisition system. Conduct the test
as detailed in Section 5.4.3 of 10 CFR Part 430 Subpart B Appendix E.
34
A1.4 Calculation Methods.
A1.4.1 Heating Value Calculation Method for Gas-Fired Water Heaters.
Fossil fuel Btu on gas-fired water heaters are calculated using Equation 1 or 1A.
Q = HHV ∙ [(V ∙ Corr) ∙ (520/(460 + T) ∙ (B + P ∙ 0.0735559) / 30)] 1
Where:
B = Barometric pressure, in Hg
Corr = Meter correction (meter correction gets applied here
because it changes depending on rate)
HHV = Higher heating value, Btu per cubic-foot
P = Gas pressure, in H20 WC
T = Gas temperature, °F
V = Volume of gas, cubic feet
Fossil fuel BTU on gasfired appliances, Qt
𝑉𝑖=𝑡
520 𝐵𝑡+𝑃𝑡∗.073559
Qt = ∑ 𝐻𝐻𝑉𝑡 ∗ [(𝑉𝑖 ∗ 𝐶𝑜𝑟𝑟𝑡) ∗ ((460+𝑇𝑡)) ∗ ( )] 1A
𝑉𝑖=0 30
Where:
Bt = Barometric pressure update at a minimum of 180 seconds, in Hg
Corrt = Meter correction, constant.
HHVt = HHV updated at a minimum of 30 minutes, Btu/ft3
Pt = Gas pressure updated at a minimum of 60 seconds, in. H2O
Tt = Gas temperature updated at a minimum of 60 seconds, °F
Vi = Uncorrected Gas consumption, ft3
t = time of test.
Fossil fuel Btu on gas-fired water heaters for the 24-hr simulated use test (SUT) are determined
using Equation 2 or 2A.
1. Qt = Total fossil fuel Btu consumed during the entire 24-hr SUT
Qt = HHVt ∙ [(Vt ∙ Corr) ∙ (520/(460 + Tt) ∙ (Bt + Pt ∙ 0.0735559) / 30)] 2
Where:
Bt = Average barometric pressure in Hg during entire 24-hr SUT
Corr = Meter correction
HHVt = Average higher heating value during entire 24-hr SUT, Btu per cubic-foot
Pt = Average Gas pressure in WC during entire 24-hr SUT
Tt = Average Gas temperature °F during entire 24-hr SUT
Vt = Volume of gas consumed during entire 24-hr SUT, cubic-feet
Fossil fuel Btu on a gas-fired appliance, Qt
𝑉𝑖=𝑡
520 𝐵𝑡+𝑃𝑡∗.073559
𝑉𝑖=0 30
35
Bt = Barometric pressure update at a minimum of 180 seconds, in. Hg

t = time of test.
2. Qr = Storage tank and instantaneous water heater fossil fuel Btu consumed from the start
of the SUT (t=0) to the cut-out following the first recovery period, recovery efficiency using
Equation 3 or 3A.
Qr = HHVr ∙ [(Vr ∙ Corr) ∙ (520/(460 + Tr) ∙ (Br + Pr ∙ 0.0735559) / 30)] 3
Where:
Br = Average barometric pressure in Hg during recovery efficiency
HHVr = Average higher heating value during recovery efficiency, Btu per cubic
foot
Pr = Average Gas pressure in WC during recovery efficiency
Tr = Average Gas temperature, °F during recovery efficiency
Vr = Volume of gas consumed during recovery efficiency, cubic-feet
Fossil fuel Btu on a gas-fired appliance, Qt
𝑉𝑖=𝑡
520 𝐵𝑡+𝑃𝑡∗.073559
𝑉𝑖=0 30
Bt = Barometric pressure update at a minimum of 180 seconds, in. Hg

t = time of test.
A1.4.2 Converting Volume (gal) to mass (lbm) using Equation 4 or 4A.
Mi = Vi x ρi 4
Where:
Mi = Mass withdrawn for the ith draw (i = 1 to ith), lbm
Vi = Total volume water measured at the point where flow volume is measured, gal
ρi = Density of the water based on water temperature measured at the point where
the flow volume is measured, lb/gal
36
A1.4.3 Converting Volume (gal) at the inlet to volume at the outlet. This is required because in the DOE
procedure all draws are based on gallons removed from the water heater not put into the water heater.
Vo shall be used for tank determination, 1st hr. test, max gpm test and 24 hr. test.
For flow meters located on the inlet of the water heater. The total volume of water at the outlet, Vo
Vo = Vi x ρi / ρo 4A
Where:
Vi = Total volume water measured at the inlet, gal
ρi = Density of the water based on water temperature measured at inlet, lb/gal (using ASME
steam table equation)
ρ0 = Density of the water based on water temperature measured at Tout, lb/gal (using ASME
A1.4.4 Converting Volume (gal) to mass (lbm) using Equation 5, Mo
Mo = Vo x ρo 5
V0 = Total volume water measured at the outlet, gal

ρ0 = Density of the water based on water temperature measured at Tout, lb/gal (using ASME
37
Section A2. Figures – Normative
Figure A1. Residential, Top Inlet
38
Figure A2A. Residential, Bottom Inlet, Top Outlet
39
Figure A2B. Residential, Bottom Inlet, Side Outlet
40
Figure A3A. Tankless, Bottom Inlet, Bottom Outlet
41
Figure A3B. Tankless, Top Inlet, Top Outlet
42
Figure A4. Compact, Top Inlet
43
Figure A5. Compact, Bottom Inlet, Side Outlet
44
Figure A6. Compact, Bottom Inlet, Top Outlet
45
Figure A7A. Tabletop Water Heater Inlet Piping Diagram
46
Figure A7B. Tabletop Water Heater Outlet Piping Diagram
47
Figure A8A. Inlet and Outlet Piping
48
Figure A8B. Inlet and Outlet Piping Set-up 1
49
Figure A8C. Inlet and Outlet Piping Set-up 2
50
Section A3. Figures - Informative
O.D.
Y
I.D.
NPT THREADS OVER-CUT SO

FITTING BOTTOMS OUT ON SPUD
O.D.= OUTSIDE DIAMETER OF SPUD

I.D.= OUTSIDE DIAMETER OF INSERTION ROD.
Figure A9. Tank Height Rod Fitting
51
1/2" ROD
ROD FITTING
(SEE FIGURE 1)
SPUD
Y
S
S= HEIGHT OF SPUD
L = LENGTH OF ROD TO TOP OF FITTING
Figure 10. Tank Height Determination
52
Figure 11. Marking Tank Height on Water Heater Jacket
53
Section A4. Standard Conversion - Informative
For conversion purposes, one may use either the ASME Int. Steam Tables Published in 2000 ASME Steam
Tables are formulated under IAPWS-IF97 or the curve fit present below:
Section A5. References - Informative
A5.1 ANSI Z21.10.1-2013/CSA 4.1-2013 - Gas water heaters - Volume I, storage water heaters with
input ratings of 75,000 Btu per hour or less. CSA Group, 8501 East Pleasant Valley Road, Cleveland, Ohio
44131-5575.
A5.2 ASHRAEwiki, Terminology. American Society of Heating, Refrigerating, and Air-Conditioning

Engineers, Inc, Web. 07 June 2013 http://wiki.ashrae.org/.
A5.3 International Steam Tables - Properties of Water and Steam based on the Industrial Formulation
IAPWS-IF97, Second Edition, Wagner and Kretzschmar, Springer, February 6, 2008.
A5.4 ISO/IEC 17025:2005 - General requirements for the competence of testing and calibration
laboratories. International Electrotechnical Commission, 3, rue de Varembe, P.O. Box 131, 1211 Geneva
20, Switzerland.
A5.5 U.S. Department of Energy (DOE) Appendix E to Subpart B of 10 CFR Part 430 - Uniform Test
Method for Measuring the Energy Consumption of Water Heaters, Federal Register, 63 FR 25996 (May 11,
1998).
54
APPENDIX B. ENERGY FACTOR TESTING GUIDELINE FOR ELECTRIC, GAS, AND OIL-FIRED
Note: This document is an adjunct to the Department of Energy (DOE) test method for determining the energy
efficiency of residential water heaters as published in the May 11, 1998 Federal Register notice10 CFR Part 430
Subpart B Appendix E. It is used by the AHRI Residential Water Heater Certification Program as a guideline
providing clarification on how testing is conducted by the contracted third-party laboratory. None of the details
contained in this document are counter to or inconsistent with the DOE test method.
Section B1. Purpose
B1.1 Purpose. The purpose of this guideline is to provide details on the specific instrumentation, test setup, and
testing procedures used to measure water heater efficiency. This document has been drafted as an adjunct to the
Department of Energy (DOE) test method for determining the energy efficiency of residential water heaters as
published in the May 11, 1998 Federal Register notice10 CFR Part 430 Subpart B Appendix E.
B1.1.1 Intent. This guideline is intended for the guidance of the industry, including manufacturers and
third-party laboratories.
B1.1.2 Review and Amendment. This guideline is subject to review and amendment as technology
advances.
Section B2. Scope
B2.1 Scope. These guidelines apply to Residential Water Heaters, as defined in Section B3.
B2.2 Exclusions. These guidelines do not apply to the rating and testing of any other type of systems providing
potable hot water.
Section B3. Definitions
All terms in this document will follow the standard industry definitions on the ASHRAE Terminology page
(https://www.ashrae.org/resources--publications/free-resources/ashrae-terminology), unless otherwise defined in
this section.
B3.1 Published Rating. A statement of the assigned values of those performance characteristics, under stated
Rating Conditions, by which a unit may be chosen to fit its application. These values apply to all units of like nominal
size and type (identification) produced by the same manufacturer. The term Published Rating includes the rating
of all performance characteristics shown on the unit or published in specifications, advertising or other literature
controlled by the manufacturer, at stated Rating Conditions.
B3.1.1 Application Rating. A rating based on tests performed at application Rating Conditions (other
than Standard Rating Conditions).
B3.1.2 Standard Rating. A rating based on tests performed at Standard Rating Conditions.
B3.2 Rating Conditions. Any set of operating conditions under which a single level of performance results and
which causes only that level of performance to occur.
B3.2.1 Standard Rating Conditions. Rating Conditions used as the basis of comparison for
performance characteristics.
B3.3 Shall. “Shall” is used to indicate provisions which are mandatory.
55
B3.4 Residential Water Heater. A closed vessel, in which water is heated by the combustion of fuels, electricity
and is withdrawn for use external to the vessel, including the apparatus by which heat is generated and all controls
and devices necessary to prevent water temperatures from exceeding 210°F.
B3.4.1 Electric Storage Water Heaters. Electric Storage Water Heaters with energy input ratings less
than or equal to 12 kilowatts and has a storage capacity of not less than 20 gallons nor more than 120
gallons, and is designed to heat and store water at a thermostatically controlled temperature less than
180°F.
B3.4.2 Heat Pump Water Heaters. Heat Pump Water Heaters that use electricity as the energy
source, are designed to heat and store water at a thermostatically controlled temperature of less than
180°F, have a maximum current rating of 24 amperes for an input voltage of 250 volts or less, and a storage
capacity of not less than 20 gallons nor more than 120 gallons. Auxiliary water heating electric heat pumps
with maximum current ratings of 24 amperes for an input voltage of 250 volts or less, intended for
connection to an existing water heater or storage tank installation.
B3.4.3 Gas Storage Water Heaters. Gas Storage Water Heaters with energy input ratings less than
or equal to 75,000 Btu/h, has a storage capacity of not less than 20 gallons nor greater than 100 gallons,
and designed to heat and store water at a thermostatically controlled temperature less than 180ºF .
B3.4.4 Gas Instantaneous Water Heaters. Gas Instantaneous Water Heaters with energy input
greater than 50,000 Btu/h but less than 200,000 Btu/h, designed to deliver water at a controlled temperature
less than 180ºF, and with a storage capacity of less than 2 gallons.
B3.4.5 Oil Storage Water Heaters. Oil Storage Water Heaters with energy input less than or equal to
105,000 Btu/h and has a storage capacity of 50 gallons or less.
B3.4.6 Electric Instantaneous Water Heaters. Electric Instantaneous Water Heaters with energy input
ratings less than or equal to 12 kilowatts.
B3.5 Energy Factor (EF). A measure of water heater overall efficiency, Energy Factor is the ratio of useful energy
output from the water heater to the total amount of energy delivered to the water heater.
B3.6 First Hour Rating (FHR). A measure of the maximum volume of hot water (in gallons) that a storage water
heater can supply within an hour that begins with the water heater fully heated.
B3.7 Maximum Gallons per Minute (GPM) Test. The maximum amount of hot water that can be supplied by an
instantaneous water heater per minute while maintaining a nominal temperature rise of 77°F during steady state
operation.
B3.8 Simulated Use Test (SUT). A 24-hour test with six water draws, conducted every hour, for the first six hours
of the test. Between and during a water draw, the water heater is allowed to recover. After the last water draw, the
test goes into a standby period.
B3.9 Storage Vessel Capacity (SVC). A test to measure the actual volume (in gallons) of stored water inside the
water heater.
Section B4. Test Guidelines
B4.1 Test Preparation.
B4.1.1 Documentation.
B4.1.1.1 Reference Standard. The following standard shall be referenced:
56
10 CFR Part 430 Subpart B Appendix E and ANSI Z21.10.1.
B4.1.1.2 Operator shall initiate a new test file and assign a new test number for each
test unit.
B4.1.2 Instrumentation. At a minimum, all instruments shall meet the accuracies listed in Table B1.
B4.1.3 Calibration. Instruments shall be calibrated at a minimum of every 12 months (refer to Table
B2). Instrument calibration records shall be maintained and instruments shall be labeled with an
identification number matching its calibration record. Operator shall ensure that calibrations are current and,
if applicable, instruments are zeroed out prior to test. Instruments shall be calibrated by an ISO 17025
certified laboratory unless:
B4.1.3.1 When using external calibration services:
B4.1.3.1 Traceability of measurements is assured by the use of

calibration services for laboratories that can demonstrate competence,
measurement capability and traceability and;
B4.1.3.1.2 Calibration certificates issued by these laboratories contain

the measurement results for the ranges being used.
B4.1.3.2 When equipment is internally calibrated:
B4.1.3.2.1 Laboratory established traceability of its own measurement

standards and measuring instruments to the International System of Units (SI)
by means of an unbroken chain of calibrations or comparisons linking them to
the relevant primary standards of the SI units of measurement and;
B4.1.3.2.2 The link to SI units achieved by reference to national

measurement standards (i.e. measurement standards and instruments directly
traceable to the National Institute of Standards and Technology (NIST) or other
nationally recognized organization such as A2LA, UKAS, SCC, IAS, etc.).
B4.1.4 Thermocouples. Thermocouples submerged in water shall be of the sheathed, ungrounded type.
57
Table B1. Minimum and Preferred Instrument Accuracies

DOE Test Method
Measurement Units Source Minimum Requirement
(For information only)
Electric Power watt-hour transducer ± 0.25% ± 1%
Water Flow Rate gpm or lbm/min flow meter ± 0.5 % ± 1% RDG
Wf lbm scale 0.5% None
0.05%
Barometric Pressure in Hg barometer ± 0.1 in Hg
(0.017 in Hg)
Volume of Gas cu-ft or cu-ft/min gas meter 1% ± 1%
HHV Btu/cu-ft Calorimeter or spectrometer ± 1% ± 1%
P2 psig pressure gauge or transducer ± 1 psi ± 1 psi
Pgas in H2O manometer 1% ±0.1 inch of water column
Water I/O Temperature °F TC or RTD ± 0.2°F ± 0.2°F
Tank Temperature °F TC or RTD ± 0.5°F ± 0.5°F
Ambient Temperature °F TC or RTD ± 0.2°F ± 0.2°F
Gas Temperature °F TC or RTD ± 0.5°F N/A
Time hr 0.000139 hr no greater than 5 seconds
Volt volts transducer 1.0 volt None
Amps amp amp transducer 0.1 amp None
Table B2. Instruments Calibration Timetable

Equipment Calibration Cycle
Natural Gas Calorimeter Every year
Water Flow Meter Every year
Manometer Every year
Temperature Readout Every year
Stopwatch Every year
Scale Every year
Scale Every year
Water Heater Test Stand Every year
U-Tube Manometer Every year
T/C Assembly Every year
Pressure gauge Every year
Digital Multimeter Every year
CO / CO2 Analyzer Every year
58
4.2 Test Set-up.
B4.2.1 Test Unit Preparation and Storage Vessel Capacity.
B4.2.1.1 Operator shall place the unit on a test platform in a conditioned space for at
least 24 hours. The conditioned space must be maintained at a minimum of 65°F. The test
stand must match the construction that is detailed in the applicable efficiency testing standard.
B4.2.1.2 If applicable, operator shall install relief valves and water connections.
B4.2.1.3 Test unit shall be weighed and dry weight recorded.
B4.2.1.4 Water heater shall be filled with water at a minimum pressure of 40 psi and
checked for leaks.
B4.2.1.4.1 Air shall be purged from the water heater during this process,
including any other time the water heater is filled, transferred to a different test
station, or disconnected from the water supply. A top spud location shall be
used to purge any air from the water heater.
B4.2.1.5 Temperature of water shall be noted, and density of water at that temperature
shall be used to calculate the volume.
B4.2.1.6 Water heater shall be weighed. The weight of the water minus the weight of
the water in the pipe connections (W) shall be recorded in the test report.
B4.2.2 Thermocouple Placement.
B4.2.2.1 Standard Tank Height Measurement Procedure (Top water connections on a

storage water heater)
B4.2.2.1.1 Measure the height of the hot water outlet spud or anode spud
using a tape measure by hooking the tape under the tank, directly under the
spud. This is dimension "S" in Figure 2.
B4.2.2.1.2 Insert the rod fitting into the hot water outlet spud so that the
top of the fitting is “Y” inches above the top of the spud.
B4.2.2 1.3 Insert the rod through the fitting until it bottoms out against the
bottom of the tank. The tight clearance between the rod and fitting ensures the
rod is straight.
B4.2.2.1.4 Place a mark or piece of masking tape on the rod at the top of
the rod fitting.
B4.2.2.1.5 Remove the rod and measure dimension "L" from the bottom
of the rod to the mark.
B4.2.2.1.6 Calculate Tank Height H = L – S – Y in inches.
B4.2.2.1.7 Place the water heater on a level floor.
B4.2.2.1.8 Insert two fittings (or nipples) into the hot and cold spuds
(Figure 3).
B4.2.2.1.9 Place a level across the two fittings.
59
B4.2.2.1.10 Lower or raise the fittings as appropriate to zero the level.
B4.2.2.1.11 Remove level and measure the length "X" from the bottom of
the spud to the top of the fittings (using tape measure and method from
B4.2.2.1.1).
B4.2.2.1.12 Mark the top of the tank “T” on the water heater jacket by
replacing level and measuring down "X" inches as determined in B4.2.1.11
from bottom of level.
B4.2.2.1.13 Place mark for water heater tank bottom “B” by measuring
down from the tank top mark from B4.2.1.12 a distance equal to the tank height
determined in B4.2.1.6.
B4.2.2.1.14 An acceptable alternate method is also described in B4.2.3.1

through B4.2.3.4.
B4.2.2.2 Thermocouple Placement Procedure.
B4.2.2.2.1 Use a 6-thermocouple tree required by the DOE test

procedure. Thermocouple wires may be used instead of probes when:
• Using the outlet fitting, its diameter is insufficient to pass

the six probe assembly, without restricting the water
flow; or
• There is a top center outlet with no anode, requiring an
offset in the TC’s in order to clear the elements; or
• There are side relief openings where the TC’s require a
90 degree bend, which would destroy probes; or
• Encountering other circumstances after the testing
agency and the manufacturer have consulted and
agreed it is necessary.
B4.2.2.2.2 Install clear 0.25 in. i.d. tube on drain cock. Draw tube up the
side of the water heater jacket and affix to top of jacket.
B4.2.2.2.3 Using the weight of water in tank (W) as determined in

B4.1.1.6, determine placement of thermocouples.
B4.2.2.2.4 Open the water heater drain valve.
B4.2.2.2.5 For tree with 6 thermocouples, fill tank with W/12 ± 0.5 lbm of
water.
B4.2.2.2.6 Allow the water level in the tube to stabilize. Mark water level
in tube on water heater jacket.
B4.2.2.2.7 Measure distance from mark indicating tank bottom to mark

indicating 1/12 capacity. This value is P1.
60
B4.2.2.3 Calculate the remaining thermocouple positions as follows:
P2 = (H – 2P1)/10 + 2P1 P6
P5
P3 = (H – 2P1)/5 + P2 P4
P4 = (H – 2P1)/5 + P3 P3
P5 = (H – 2P1)/5 + P4 P2
P6 = (H – 2P1)/5 + P5 P1
Where:
H = Height of the water heater inside the tank.

Pi = Position of the thermocouples.
B4.2.2.4 Using thermocouple placements determined in B4.2.2.3, and taking into

account thread engagement of the thermocouple tree fitting, set thermocouples in tree within ±
0.063” of the calculated thermocouple positions. See Figures 6 and 7 for suggestions.
B4.2.2.5 Install thermocouple tree in the anode spud on the test unit. Ensure tree is
straight and is not in contact with any component inside the water heater, such as an element.
If the tree cannot be installed in the anode spud, install the tree in the outlet spud.
B4.2.2.6 Install piping on the unit per the DOE test procedure document (see Figure 5
in Section B7 and Figures B1 through B7 in 10 CFR Part 430 Subpart B Appendix E for detailed
schematics). Note that the 24 in. dimension in Section B7, Figure B5 is referenced from the top
of the plumbing connection fitting supplied with the heater (spud or nipple).
B4.2.2.7 If applicable, operator shall install fittings, heat traps, and insulation (if
provided) on pipes, relief valves, and water connections. Any other supplied components with
the water heater must be installed per the manufacturer’s installation instructions. This
includes, but is not limited to the following: blowers, burners, controls, etc.
B4.2.2.7.1 If the heat trap is removed on the outlet side of the water heater to install the
temperature probe, the heat trap must be incorporated into the remainder of the outlet
piping.
B4.2.2.8 Fill the water heater and examine it for leaks at a minimum pressure of 40 psi.
B4.2.2.9 Operator shall install insulation with a minimum R-Value of 8 ft²·°F·h/Btu on

top of thermocouple tree and any additional fittings that were added by the operator. All
B4.2.3 Side-Inlet Tank Height Measurement and Thermocouple Placement Procedure (use only if tank
does not have a top fitting available on Storage Water Heaters).
B4.2.3.1 Install a clear 0.25 in. i.d. tube on tank drain cock. Draw tube up the side of the
B4.2.3.2 Fill tank with water.
B4.2.3.3 Open drain cock and allow water level to stabilize in tube. Ensure the water
level comes up to outlet spud. CAUTION: Do not to overfill! Should overfill occur and insulation
become wet, heater will be considered defective and must be replaced with a new unit.
B4.2.3.4 Place tank top mark “T” on the water heater jacket at level of full water
heater.
61
B4.2.3.5 Using the weight of the water in the tank (W), remove W/12 ± 0.5 lbm of
water.
B4.2.3.6 Allow the water level in the tube to stabilize. Mark water level in tube on water
heater jacket. Measure distance from mark indicating tank top (T) to indicate 1/12 capacity.
This value is P6.
B4.2.3.7 Remove W/6 ± 0.5 lbm of water for each successive thermocouple. After each
draw, allow the water level in the tube to stabilize.
B4.2.3.8 Mark water level in tube on water heater jacket.
B4.2.3.9 Measure distance from previous thermocouple mark to successive

thermocouple mark until all 6 thermocouple locations have been identified.
B4.2.3.10 Using thermocouple placements determined in B4.2.3.6 through B4.2.3.9, and

taking into account placement of the thermocouple tree fitting, set thermocouples in tree within
± 0.063” of the measured thermocouple positions. See Figures 6 and 7.
B4.2.4 Thermocouple Placement Procedure (Tankless Water Heaters Only).
B4.2.4.1 Install piping on the unit per the DOE test procedure document (see Figure 4
in Section B7 and Figures 1 through 7 in 10 CFR Part 430 Subpart B Appendix E for detailed
schematics).
B4.2.4.2 If applicable, operator shall install fittings, heat traps, and insulation (if
provided) on pipes, relief valves, and water connections. Any other supplied components with
the water heater must be installed per the manufacturer’s installation instructions. This
includes, but is not limited to the following: blowers, burners, controls, etc.
B4.2.4.3 Operator shall install insulation with a minimum R-Value of 8 ft²·°F·h/Btu on

inlet and outlet thermocouples and any additional fittings that were added by the operator. All
B4.2.4.3.1 Confirm that all thermocouples are calibrated and clearly

marked with an appropriate tag.
B4.2.5 Test Unit Set-up.
B4.2.5.1 For gas-fired water heaters only, install the minimum length venting, per the
B4.2.5.2 For oil-fired water heaters only, install the minimum length venting, per the
B4.2.5.2.1 Then, adjust the vent length according to 10 CFR Part 430
Subpart B Appendix E to achieve the proper chimney/stack draft.
B4.2.5.3 For heat pump water heaters, a minimum of one (1) humidity sensor shall be
located 18” away from the water heater air inlet. If there is more than one, the sensors shall
be spaced evenly around the circumference of the water heater. Vertically, the sensor(s) must
be located half way between the top and bottom of the heat pump portion of the water heater
and shielded from direct airflow out of the heat pump. The sensor(s) must monitor the
surrounding area’s humidity for all testing conducted.
62
B4.2.5.4 At least one picture must be taken of the water heater, including its venting,
piping, etc. This picture must be saved with the test file and be provided, upon request.
B4.2.5.5 All air movement across and/or on the water heater shall be eliminated prior
to starting any test.
B4.3 Test Procedure.
B4.3.1 Electric Storage Water Heaters (including Heat Pump Water Heaters): Simulated Use Test.
Notice: Section B4.2, Test Set-up shall be followed prior to proceeding to this section.
B4.3.1.1 Fill the water heater and test it for leaks at a minimum pressure of 40 psi.
B4.3.1.2 Turn the power on and set the water heater thermostat(s) for approximately
135°F. Allow the test unit to soak-in for a minimum period of 24 hours and the average tank
temperature has reached a temperature of 135°F ± 5°F. At no time shall the unit be
B4.3.1.3 After the soak-in period, turn the power off, and disconnect the electrical
connections if transferring between a warm-up station and test station. At the test station,
connect the ambient, tank, inlet and outlet thermocouples, current sensors, and power cord.
Seal any gaps in water heater jacket due to sensor leads to minimize heat loss. At no time shall
the unit be disconnected from its energy supply for more than 1 hour.
B4.3.1.4 Ensure the water supply temperature is 58°F ± 2°F and at a flow rate of 3 gpm
± 0.25 gpm.
B4.3.1.5 Set thermostat(s) to 135°F. Initiate a water draw and continue draw until
bottom element or heat pump cut-in.
B4.3.1.5.1 For electric water heaters only, monitor tank temperatures

located above upper element and force the upper element to cut-out when the
temperatures are 135°F ± 5°F.
B4.3.1.5.2 For electric water heaters only, monitor tank temperatures

and force the lower element to cut-out when average tank temperature is
135ºF ± 5°F.
B4.3.1.5.3 Ensure the average tank temperature is 135°F ± 5°F. If the

average tank temperature is not 135°F ± 5°F, initiate a water draw until lower
element cut-in or heat pump cut-in and repeat the thermostat setting procedure
above.
B4.3.1.6 Unless specified by the manufacturer in advance of the test, perform one pre-
draw until cut-in. The number of pre-draws is limited to three.
B4.3.1.7 Initiate the 24-hour simulated use test and data acquisition system after lower
element cut-out. Conduct the test as detailed in Section 5.1.5 of 10 CFR Part 430 Subpart B
Appendix E.
B4.3.1.8 Compile data and print report.
B4.3.2 Electric Storage Water Heaters (including Heat Pump Water Heaters): First Hour Rating Test.
63
B4.3.2.1 If the heater has just completed the 24 hr simulated use test:
B4.1.3.1.1 Initiate a water draw until lower element or heat pump cut-
in.
B4.1.3.1.2 After element or heat pump cut-out, confirm that the average
tank temperature is within the limit specified in B4.3.1.5.
B4.1.3.1.3 Initiate the "First Hour Rating" test.
If the heater has not just completed a 24 hr. simulated use test, set thermostats
per B4.3.1.5 above. Initiate a water draw until lower element or heat pump cut-
in, then initiate first hour rating test after lower element or heat pump cut-out.
B4.3.2.2 Water shall be supplied for first hour rating test at 58°F ± 2°F and at a rate of
3 gpm ± 0.25 gpm.
B4.3.2.2.1 Wait 60 seconds before beginning to monitor T-mean.
B4.3.2.3 Record T-mean at 60 second intervals.
B4.3.2.4 Initiate the First Hour Rating Test and data acquisition system at T-mean
max after cut-out (135°F ± 5°F). Conduct the test as detailed in Section 5.1.4.3 of 10 CFR
Part 430 Subpart B Appendix E.
B4.3.2.4.1 T-mean max is defined as the temperature at which the rolling

60 second average (of readings taken every 5 seconds) T-mean temperature
drops 0.05°F from the previous rolling average reading.
B4.3.2.4.2 Record temperatures every five seconds, until the outlet water
temperature drops 25°F below the maximum recorded outlet temperature.
B4.3.2.4.3 Allow the test unit to recover and draw, at cut-out, as many
times as possible in one hour. On electric water heaters, recovery is
determined by the cut-out of the upper thermostat or thermocouple.
B4.3.3 Gas-Fired Storage Water Heaters: Simulated Use Test.
Note: Section B4.2, Test Set-up shall be followed prior to proceeding to this section.
B4.3.3.1 Install the gas line and the manifold pressure line.
B4.3.3.2 Connect the gas meter.
B4.3.3.3 Inlet and outlet thermocouples shall be located as indicated in Figure 5.
B4.3.3.5 Light the pilot, if applicable. Otherwise, turn on the water heater.
B4.3.3.6 Adjust the water heater set point to allow the burner to fire.
B4.3.3.7 Check the entire gas train for leaks.
64
B4.3.3.8 Check the input rate. It must be within ± 2% of its rated value using the method
detailed in ANSI Z21.10.1. The manifold pressure shall be within ± 10% of that printed on the
rating plate.
B4.3.3.8.1 If input rate is not within ± 2% of the rated value, the operator
shall adjust manifold pressure, assuming he stays within the allowed ± 10% to
attempt to achieve ± 2% of the rated input.
B4.3.3.8.2 If adjusting the manifold pressure does not achieve the rated
input, the operator shall re-orifice the unit using an alternate orifice supplied
by the manufacturer. [Note: Manufacturers are to supply test facility with a
selection of orifices for use at the test facility. When a test unit is re-orificed,
the test facility will notify the manufacturer of the alternate orifice used, and the
manufacturer shall re-supply the test facility with a replacement orifice.]
B4.3.3.8.3 The operator shall check the entire gas train for leaks after
re-orificing the water heater. Any leaks discovered shall be fixed.
B4.3.3.8.4 Combustion must only be checked when the water heater is

very clearly operating abnormally (e.g. CO alarms are going off, producing
smoke (when it is not supposed to), flames are shooting out of the vent, etc.).
B4.3.3.9 Set the water heater thermostat for approximately 135°F. Allow the test unit to
soak-in for a minimum period of 24 hours and the average tank temperature has reached a
temperature of 135°F ± 5°F. At no time shall the unit be disconnected from its energy supply
for more than 1 hour.
B4.3.3.10 After soak-in period, turn off gas. Disconnect gas supply connections if
transferring between a warm-up station and test station. At no time shall the unit be
B4.3.3.11 Install the unit in a test station, connect the gas meter, manifold pressure line,
and manifold pressure transducer. Connect the ambient, tank, inlet and outlet thermocouples,
any current sensors, and power cords.
± 0.25 gpm.
B4.3.3.13 Manifold pressure shall be monitored throughout the test to detect improper
gas valve operation or leaks.
B4.3.3.14 Set thermostat to 135°F. Initiate a water draw and continue the draw until cut-
in.
B4.3.3.14.1 Monitor tank temperature and cut-out when the average tank
temperature is 135°F ± 5°F.
B4.3.3.14.1 Ensure average tank temperature is 135°F ± 5°F. If the

average tank temperature is not 135°F ± 5°F, initiate a water draw until cut-in
and repeat thermostat setting procedure above.
65
B4.3.3.16 Initiate 24-hour simulated use test and data acquisition system after burner
cut-out. Conduct the test as detailed in Section 5.1.5 of 10 CFR Part 430 Subpart B Appendix
E.
B4.3.4 Gas-Fired Storage Water Heaters: First Hour Rating Test.
Note: Section B4.2, Test Set-up must be followed prior to proceeding to this section.
B4.3.4.1.1 Initiate a water draw until cut-in.
B4.3.4.1.2 After cut-out, confirm that the average tank temperature is

within the limit specified in B4.3.3.14.
If heater has not just completed a 24 hr. simulated use test, set thermostats
per Section B4.3.3.14 above. Initiate water draw until burner cut-in, then
initiate first hour rating test after burner cut-out.
B4.3.4.2 Ensure the water supply temperature is 58°F ± 2°F and at a rate of 3 gpm ±
0.25 gpm.
B4.3.4.3 Wait 60 seconds before beginning to monitor T-mean.
B4.3.4.5 Initiate the first hour rating test and data acquisition system at T-mean max
after cut-out (135 ± 5°F). Conduct the test as detailed in Section 5.1.4.3 of 10 CFR Part 430
Subpart B Appendix E.

B4.3.4.5.2 Record temperatures every five seconds, until the outlet

water temperature drops 25°F below the maximum recorded outlet
temperature.
times as possible in one hour.
B4.3.5 Oil-Fired Storage Water Heaters: Simulated Use Test.
B4.3.5.1 Install the fuel line quick connect fitting.
B4.3.5.2 Install a pressure gauge.
B4.3.5.3 Install the electrical sensing leads.
66
B4.3.5.4 Connect the fuel supply line.
B4.3.5.6 Turn the water heater on and check the entire fuel train for leaks.
B4.3.5.7 Using the pressure gage, verify the pump is operating within the
manufacturer’s specifications and adjust as necessary.
B4.3.5.8 After the burner has been on for 10 minutes, check the input rate. It must be
within ± 2% of the rated value.
B4.3.5.9 Adjust the burner for minimum stack, or over fire draft, as outlined in the
B4.3.5.10 Without exceeding a #1 smoke, the CO2 level shall be adjusted, as outlined in
the manufacturer’s instructions.
B4.3.5.11 Set the water heater thermostat for approximately 135°F. Allow the test unit to
soak-in for a minimum period of 24 hours and the average tank temperature has reached a
temperature of 135°F ± 5°F. At no time shall the unit be disconnected from its energy supply
for more than 1 hour.
B4.3.5.12 After soak-in period, turn off fuel supply, disconnect fuel supply and electric
connections if transferring between a warm-up and test station. At no time shall the unit be
B4.3.5.13 Install the unit in a test station, connect the fuel supply, the ambient, tank, inlet
and outlet thermocouples, any current sensors, and power cords.
± 0.25 gpm.
B4.3.5.15 Set thermostat to 135°F. Initiate a water draw and continue draw until cut-in.
B4.3.5.15.1 Monitor tank temperature and cut-out when the average tank
temperature is 135°F ± 5°F.
B4.3.5.15.2 Ensure the average tank temperature is 135°F ± 5°F. If the

average tank temperature is not 135°F ± 5°F, initiate a water draw until cut-in
and repeat thermostat setting procedure above.
B4.3.5.17 Initiate 24-hour simulated use test and data acquisition system after burner
cut-out. Conduct the test as detailed in Section 5.1.5 of 10 CFR Part 430 Subpart B Appendix
E.
B4.3.6 Oil-Fired Storage Water Heaters: First Hour Rating Test.
Note: Section B4.2, Test Set-up must be followed prior to proceeding to this section.
67
B4.3.6.1.1 Initiate a water draw until cut-in.
B4.3.6.1.2 After cut-out, confirm that the average tank temperature is

within the limit specified in B4.3.5.15.

If heater has not just completed a 24 Hr. simulated use test, set thermostats
per B4.3.5.15 above. Initiate one water draw until cut-in, then initiate first hour
rating test after cut-out.
B4.3.6.2 Water shall be supplied for first hour rating test at 58°F ± 2°F and at a rate of
3 gpm ± 0.25 gpm.
B4.3.6.3 Wait 60 seconds before beginning to monitor T-mean.
B4.3.6.5 Initiate the first hour rating test and data acquisition system at T-mean max
after cut-out (135°F ± 5°F). Conduct the test as detailed in Section 5.1.4.3 of 10 CFR Part 430
Subpart B Appendix E.

B4.3.6.5.2 Record temperatures every five seconds, until the outlet water
temperature drops 25°F below the maximum recorded outlet temperature.
times as possible in one hour.
B4.3.7 Gas-Fired Tankless Water Heaters: Simulated Use Test.
B4.3.7.1 Install the gas line and the manifold pressure line.
B4.3.7.2 Connect the gas meter.
B4.3.7.4 Fill the water heater and test for leaks at a minimum pressure of 40 psi.
B4.3.7.5 Turn on the water heater.
B4.3.7.6 Allow water to flow through the unit to allow the burner to fire at its maximum
input rate.
B4.3.7.7 Check the entire gas train for leaks.
68
B4.3.7.8 Check the input rate. It must be within ± 2% of its maximum rated value using
the method detailed in ANSI Z21.10.3. The manifold pressure shall be within ± 10% of that
printed on the rating plate.
B4.3.7.9 If input rate is not within ± 2% of the maximum rated value, the operator shall
adjust manifold pressure, assuming he stays within the allowed ± 10% to attempt to achieve ±
2% of the rated input.
B4.3.7.9.1 If adjusting the manifold pressure does not achieve the rated
input or it cannot be adjusted, the operator shall re-orifice the unit using (an)
alternate orifice(s) supplied by the manufacturer.
Note: Manufacturers are to supply test facility with a selection of orifices for
use at the test facility. When a test unit is re-orificed, the test facility will notify
the manufacturer of the alternate orifice(s) used, and manufacturer shall re-
supply the test facility with a replacement orifice(s).
B4.3.7.9.2 The operator shall check the entire gas train for leaks after
re-orificing the water heater. Any leaks discovered shall be fixed.
B4.3.7.9.3 Combustion shall only be checked when the water heater is

very clearly operating abnormally (e.g. CO alarms are going off, producing
smoke (when it is not supposed to), flames are shooting out of the vent, etc.).
B4.3.7.10 Set the water heater thermostat to 135°F. If the water heater cannot be set
exactly at 135°F, the unit shall be set within ± 5°F.
B4.3.7.11 Draw water from the unit for approximately 30 minutes. Allow the test unit to
soak-in for a minimum period of 4 hours. At no time shall the unit be disconnected from its
energy supply for more than 1 hour.
B4.3.7.12 After soak-in period, turn off gas. Disconnect gas supply connections if
transferring between a warm-up station and a test station. At no time shall the unit be
B4.3.7.13 Install the unit in a test station, connect the gas meter, manifold pressure line,
and manifold pressure transducer. Connect the ambient, tank, inlet and outlet thermocouples,
any current sensors, and power cords.
B4.3.7.14 Ensure the water supply temperature is 58°F ± 2°F.
B4.3.7.15 If the test unit has a variable input, determine the maximum flow rate that the
unit can produce an outlet temperature of 135°F ± 5°F. This is V max, which shall be used for
the first three draws of the SUT.
B4.3.7.15.1 If the unit has a fixed input, all six draws shall be conducted
at Vmax.
B4.3.7.16 Determine the minimum flow rate that the unit can produce an outlet
temperature of 135°F ± 5°F. This is Vmin, which shall be used for the last three draws of the
SUT.
B4.3.7.17 Manifold pressure shall be monitored throughout the test to detect improper
gas valve operation or leaks.
69
B4.3.7.18 Initiate 24-hour simulated use test and the data acquisition system. Conduct
the test as detailed in Section 5.2.4 of 10 CFR Part 430 Subpart B Appendix E.

B4.3.8 Gas-Fired Tankless Water Heaters: Maximum GPM Rating Test.
B4.3.8.1 Draw water from the test unit at a flow rate that will allow the unit to operate at
its maximum firing rate. The outlet temperature must be 135°F ± 5°F.
B4.3.8.2 Initiate the “Maximum GPM Rating” test. Conduct the test as detailed in
section 5.2.3 of 10 CFR Part 430 Subpart B Appendix E.
B4.3.8.3 Draw water from the test unit for 10 minutes. Using a water meter, or an
alternative means, measure the amount of water drawn over the course of the test. Throughout
the test, record the inlet and outlet water temperatures.
B4.3.9 Electric Tankless Water Heaters: Simulated Use Test.
B4.3.9.1 Connect a power cord if one is not provided.
B4.3.9.3 Fill the water heater and test for leaks at a minimum pressure of 40 psi.
B4.3.9.4 Turn on the water heater.
B4.3.9.5 Allow water to flow through the unit to allow the heater to operate at its
maximum input rate.
B4.3.9.6 Set the water heater thermostat to 135°F. If the water heater cannot be set
exactly at 135°F, the unit shall be set within ± 5°F.
B4.3.9.7 Install the unit in a test station. Connect the ambient, tank, inlet and outlet
thermocouples, any current sensors, and power cords.
B4.3.9.8 Draw water from the unit for approximately 30 minutes. Allow the test unit to
soak-in for a minimum period of 24 hours. At no time shall the unit be disconnected from its
energy supply for more than 1 hour.
B4.3.9.9 Ensure the water supply temperature is 58°F ± 2°F.
B4.3.9.10 If the test unit has a variable input, determine the maximum flow rate that the
unit can produce an outlet temperature of 135°F ± 5°F. This is V max, which shall be used for
the first 3 draws of the SUT.
B4.3.9.11 If the unit has a fixed input, all six draws shall be conducted at Vmax.
B4.3.9.12 Determine the minimum flow rate that the unit can produce an outlet
temperature of 135°F ± 5°F. This is Vmin, which shall be used for the last three draws of the
SUT.
70
B4.3.9.13 Initiate the 24-hour simulated use test and the data acquisition system.
Conduct the test as detailed in Section 5.2.4 of 10 CFR Part 430 Subpart B Appendix E.
B4.3.10 Electric Tankless Water Heaters: Maximum GPM Rating Test.
B4.3.10.1 Draw water from the test unit at a flow rate that will allow the unit to operate at
its maximum kW rate. The outlet temperature must be 135°F ± 5°F.
B4.3.10.2 Initiate the “Maximum GPM Rating” test. Conduct the test as detailed in
Section 5.2.3 of 10 CFR Part 430 Subpart B Appendix E.
B4.3.10.3 Draw water from the test unit for 10 minutes. Using a water meter, or an
alternative means, measure the amount of water drawn over the course of the test. Throughout
the test, record the inlet and outlet water temperatures.
B4.4 Calculation Methods.
B4.4.1 Heating Value Calculation Method for Gas-Fired Water Heaters.
Fossil fuel Btu on gas-fired water heaters are calculated using Equation 1.
Q = HHV ∙ [(V ∙ Corr) ∙ (520/(460 + T) ∙ (B + P ∙ 0.0735559) / 30)] 1
Where:
B = Barometric pressure, in Hg
Corr = Meter correction (meter correction gets applied here
because it changes depending on rate)
HHV = Higher heating value, Btu per cubic-foot
P = Gas pressure, in H2O
T = Gas temperature, °F
V = Volume of gas, ft3
Fossil fuel Btu on gas-fired water heaters for the 24-hr simulated use test (SUT) are determined
using Equation 2.
3. Qt = Total fossil fuel Btu consumed during the entire 24-hr SUT
Qt = HHVt ∙ [(Vt ∙ Corr) ∙ (520/(460 + Tt) ∙ (Bt + Pt ∙ 0.0735559) / 30)] 2
Where:
Bt = Average barometric pressure in Hg during entire 24-hr SUT
HHVt = Average higher heating value during entire 24-hr SUT, Btu per cubic-foot
Pt = Average Gas pressure in WC during entire 24-hr SUT
Tt = Average Gas temperature °F during entire 24-hr SUT
Vt = Volume of gas consumed during entire 24-hr SUT, cubic-feet
71
4. Qr = Storage tank and fixed input instantaneous water heater fossil fuel Btu consumed
between cut-out prior to the first draw and cut-out following the first draw, recovery efficiency
using Equation 3.
Qr = HHVr ∙ [(Vr ∙ Corr) ∙ (520/(460 + Tr) ∙ (Br + Pr ∙ 0.0735559) / 30)] 3
Where:
Br = Average barometric pressure in Hg during recovery efficiency
HHVr = Average higher heating value during recovery efficiency, Btu per cubic
foot
Pr = Average Gas pressure in WC during recovery efficiency
Tr = Average Gas temperature, °F during recovery efficiency
Vr = Volume of gas consumed during recovery efficiency, cubic-feet
5. Qr,max = Variable input rate instantaneous water heater fossil fuel Btu consumed between
cut-out prior to the first draw and cut-out following the first draw, max recovery efficiency using
Equation 4.
Qr,max = HHVr,max ∙ [(Vr,max ∙ Corr) ∙ (520/(460 + Tr,max) ∙ (Br,max + Pr,max ∙ 0.0735559) / 30)]
4
Where:
Br,max = Average barometric pressure in Hg during max recovery efficiency
HHVr,max = Average higher heating value during max recovery efficiency, Btu per
cubic-foot
Pr,max = Average Gas pressure in WC during max recovery efficiency
Tr,max = Average Gas temp °F during max recovery efficiency
Vr,max = Volume of gas consumed during max recovery efficiency, cubic-feet
6. Qr,min = Variable input rate instantaneous water heater fossil fuel Btu consumed between
cut-out prior to the fourth draw and cut-out following the fourth draw, min recovery efficiency
using Equation 5.
Qr,min = HHVr,min ∙ [(Vr,min∙Corr) ∙ (520/(460+Tr,min) ∙ (Br,min+Pr,min∙0.0735559)/30)] 5
Where:
Br, min = Average barometric pressure, in Hg during min recovery efficiency
HHVr,min = Average higher heating value during min recovery efficiency, Btu per cubic-
foot
Pr, min = Average Gas pressure, in H20 WC during min recovery efficiency
Tr, min = Average Gas temperature, °F during min recovery efficiency
Vr,min = Volume of gas consumed during min recovery efficiency, cubic-feet
B4.4.2 Converting Volume (gal) to mass (lbm) using Equation 6.
Mi = Vi x ρi 6
Where:
Mi = Mass withdrawn for the ith draw (i = 1 to 6), lbm
Vi = Total volume water measured at the point where flow volume is measured, gal
ρi = Density of the water based on water temperature measured at the point where
the flow volume is measured, lbm/gal
72
Section B5. References - Normative
None.
Section B6. References - Informative
B6.1 ANSI Z21.10.1-2013/CSA 4.1-2013 - Gas water heaters - Volume I, storage water heaters with
input ratings of 75,000 Btu per hour or less. CSA Group, 8501 East Pleasant Valley Road, Cleveland, Ohio
44131-5575.
B6.2 ASHRAE, Terminology. American Society of Heating, Refrigerating, and Air-Conditioning

Engineers, Inc, 2015 https://www.ashrae.org/resources--publications/free-resources/ashrae-terminology
B6.3 International Steam Tables - Properties of Water and Steam based on the Industrial Formulation
IAPWS-IF97, Second Edition, Wagner and Kretzschmar, Springer, February 6, 2008.
B6.4 ISO/IEC 17025:2005 - General requirements for the competence of testing and calibration
laboratories. International Electrotechnical Commission, 3, rue de Varembe, P.O. Box 131, 1211 Geneva
20, Switzerland.
B6.5 U.S. Department of Energy (DOE) Appendix E to Subpart B of 10 CFR Part 430 - Uniform Test
Method for Measuring the Energy Consumption of Water Heaters, Federal Register, 63 FR 25996 (May 11,
1998).
73
Section B7. Figures - Informative
O.D.
Y
I.D.
NPT THREADS OVER-CUT SO

FITTING BOTTOMS OUT ON SPUD
O.D.= OUTSIDE DIAMETER OF SPUD

I.D.= OUTSIDE DIAMETER OF INSERTION ROD.
Figure B1. Tank Height Rod Fitting
74
1/2" ROD
ROD FITTING
(SEE FIGURE 1)
SPUD
Y
S
S= HEIGHT OF SPUD
L = LENGTH OF ROD TO TOP OF FITTING
Figure B2. Tank Height Determination
75
Figure B3. Height Determination
76
Figure B4. Marking Tank Height on Water Heater Jacket
77
Figure B5. Inlet and Outlet Thermocouple Placement
78
Section B8. Suggested Fittings - Informative
Here are suggestions for fittings that address the problem of nipple engagement depth on the TC probe. They
may not all be viable for every manufacturer but provide ideas on ways to solve the problem:
1- Use the rod fitting with a camlock fitting or a quick connect fitting at the end. Use an O-ring on the bottom
thread to make a perfect seal between the spud and the rod fitting and allow the fitting to bottom out on
spud. The distance “X” is known and we know that the TC probe will always be at the same position
because of the camlock fitting or the quick connect fitting.
2- Same as No 1 but use a flange fitting with a gasket in between. Again, we know dimension “X”.
This fitting would allow the TC probe to move up or down to adjust it to the right position. Position “X” would have
to be measured each time and then the TC probe would have to be adjusted consequently.
Figure B6. Thermocouple Tree Fitting Examples
79
Figure B7. Thermocouple Tree Fitting and Adapter
80
Section B9. Standard Weights, Measures and Conversions - Informative
For conversion purposes, one may use either the ASME Int. Steam Tables Published in 2000 ASME Steam
Tables formulated under IAPWS-IF97 or the curve fits present below:
Curve Fit: Water Specific Heat vs. Temperature

2000 ASME Steam Tables (IAPWS-IF97)
Cp = -4.903944E-09T^3 + 2.584046E-06T^2 - 0.000375475T + 1.015074
R Squared = 0.9973
1.00200
1.00150
1.00100
Specific Heat (btu/lbm-F)
1.00050
1.00000
0.99950
0.99900
0.99850
0.99800
0 20 40 60 80 100 120 140 160 180
Temperature (deg F)
Series1
Figure B8. Curve Fit: Water Specific Heat vs. Temperature
Curve Fit: Water Density vs. Temperature

2000 ASME Steam Tables (IAPWS-IF97)
Cp = -7.36376E-5T^2 + 0.002427088T + 62.48442
R Squared = 0.9999
62.400
62.200
62.000
Density (lbm/cuft)
61.800
61.600
61.400
61.200
61.000
0 20 40 60 80 100 120 140 160 180
Temperature (deg F)
Series1
Figure B9. Curve Fit: Water Density vs. Temperature
81

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RESIDENTIAL WATER HEATERS

AHRI RWH OM – MARCH 2023

Sponsored and administered by:

Printed in U.S.A. ©Copyright 2022, by Air-Conditioning, Heating,

RESIDENTIAL WATER HEATERS

1.4 Intended Market ............................................................................................................ 3

3 Equipment Selection and Testing

5 AHRI Directory of Certified Product Performance

6 Assessment and Payment of Certification Fees

7 Issuance of Violations and/or Termination ......................................................................... 12

8 Program Hierarchy, Complaints, and the Appeals Process ............................................. 12

9 Proper Use of the AHRI Certification Mark and Claims to Certification

1.2.1.1.1 Grid-Enabled Water Heater. Grid-Enabled Water Heater means

• Has a DOE Rated Storage Volume of more than 75 gallons;

1.2.1.1.1.1 Activation Lock. Activation lock means a control

• For models requiring electricity, uses single-phase external power supply;

• Is not one of the following:

• Electric Instantaneous: Electric Instantaneous Water Heaters with a rated input

1.3.2 Voluntary Program Scope Inclusions.

1.3.2.1 Models Sold Exclusively in Canada. Residential Water Heaters, as defined in

1.5 Basic Model Definitions

1.5.1.1 Grandfathered Basic Models. Residential Water Heaters and Residential-Duty

STEP. 2.1.1.1 Methods to Establish Ratings

o Gas Storage, Gas Instantaneous, or Residential-duty Commercial

o Electric Storage. A model qualified without test reports must meet

STEP 2.1.2 Processing Application Package.

STEP 2.1.2.1 Performance Certification Agreement for Original Equipment Manufacturer

STEP 2.1.3 Selection and Acquisition of Test Samples.

STEP 2.1.3.2 Acquisitions of Qualification Test Samples/Selection Criteria. Within 30

STEP 2.1.4.1.1 Maximum GPM. Required on all Instantaneous Water Heaters.

STEP 2.1.4.1.2.1 Models Qualified Using Test Reports. For qualification

STEP 2.1.4.1.2.2 Electric Storage Models Qualified Using an AEDM. For

STEP 2.1.4.1.3.1 UEF Test Procedure

STEP 2.1.4.1.3.1.1 UEF Test Following Confirmed Draw Pattern.

STEP 2.1.4.1.3.1.2 UEF Test following Failed Draw Pattern.

STEP 2.1.4.1.3.2 UEF Pass/Fail Criteria. For qualification testing,

STEP 2.2.2 Processing Application Package.

3. Equipment Selection and Testing

3.8.1 Maximum GPM. Required on all Instantaneous Water Heaters.

3.8.3 Uniform Energy Factor (UEF). Required on all Water Heaters.

3.8.3.1 UEF Test Procedure

3.9 Test Failures.

3.9.1 Options Following First Sample Failure.

Figure 1. RWH Electric Storage AEDM Certification Test

3.10 Discontinuing or Changing Ratings for a Basic Model.

3.10.1 Voluntarily Changed Rating.

5. AHRI Directory of Certified Product Performance

• AHRI Certified Reference Number

1 Required on all Storage Water Heaters

6. Assessment and Payment of Certification Fees

Refer to Section 12 of the AHRI General Operations Manual.

7. Issuance of Violations and/or Termination

Refer to Section 14 of the AHRI General Operations Manual.

8. Program Hierarchy, Complaints, and the Appeals Process

Refer to Section 15 of the AHRI General Operations Manual.

9. Proper Use of the AHRI Certification Mark and Claims to Certification

Refer to Section 8 of the AHRI General Operations Manual.

9.1 Advertising with Metrics Not Certified by AHRI

Ratings Not Certified by AHRI