POWERED DIRECT VENT SERIES GAS-FIRED

COMMERCIAL WATER HEATER

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance

- WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.

 Do not touch any electrical switch; do not use any phone in your building.

 Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

 If you cannot reach your gas supplier, call the fire department.

- For your family’s comfort, safety and convenience, it is recommended this water heater be installed and serviced by a plumbing professional.

INSTALLATION/OPERATION MANUAL

WITH TROUBLESHOOTING GUIDE

PLACE THESE INSTRUCTIONS ADJACENT TO WATER HEATER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

238-47676-00B 6/12

SECTION I: IMPORTANT INFORMATION

READ CAREFULLY

This gas-fired water heater is design certified by CSA International under the American National Standard, Z21.10.3 and CAN/CGA 4.3-M (as indicated on the rating plate). These standards are available from CSA Standards

Association, 5060 Spectrum Way Mississauga, Ontario L4W 5N6 CANADA.

This water heater must be installed in accordance with local codes. In the absence of local codes, it must be installed in compliance with the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA

B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest

Edition).

The following terms are used throughout this manual to bring attention to the presence of hazards at various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation, which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation, which, if not avoided, could result in death, serious injury or substantial property damage.

CAUTION

Indicates potentially hazardous situation, which, if not avoided, may result in moderate or minor injury or property damage.

NOTICE

Indicates special instructions on installation, operation or maintenance, which are important but not related to personal injury hazards.

NOTICE

This water heater has a limited warranty. The warranty for this water heater is valid only if the water heater has been installed, maintained and operated in accordance with these instructions. The warranty does not cover damage or injury caused by the use of any energy-saving devices (other than those authorized by the manufacturer) in conjunction with this water heater. The use of unauthorized energy-saving devices may decrease the life of the water heater and endanger life and/or property. The manufacturer will not be liable for any damage, injury, or loss of life resulting from alteration and/or failure to comply with these instructions.

IMPORTANT-Before proceeding, please inspect the water heater and components for possible damage. DO NOT install damaged components. If damage is evident, please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

TABLE OF CONTENTS

VIII ELECTRICAL CONNECTIONS.....................22

II SPECIFICATIONS............................................5 IX OPERATING INSTRUCTIONS......................24

III GENERAL MAINTENANCE.............................................32

DIAGNOSTIC AND TROUBLESHOOTING

V VENTING........................................................11

VI WATER XIII

GUIDE............................................................35

XII PARTS

INSTALLATION FOR POTABLE

WATER AND SPACE HEATING....................57

2

DANGER

DO NOT store or use gasoline or other flammable, combustible, or corrosive vapors and/or liquids in the vicinity of this or any other appliance.

This water heater is equipped with an adjustable thermostat to control water temperature. Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and/or death. The temperature at which injury occurs varies with the person’s age and the time of exposure. The slower response time of disabled persons increases the hazards to them. NEVER allow small children to use a hot water tap, or to draw their own bath water. NEVER leave a child or disabled person unattended in a bathtub or shower.

Toxic chemical, such as those used for boiler treatment, must not be introduced into potable water used for space heating.

This water heater must not be connected to an existing heating system or component(s) previously used with a nonpotable water heating appliance.

All piping components connected to this water heater for space heating applications must be suitable for use with potable water.

WARNING

Improper installation, adjustments, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this manual and literature in legible condition with this water heater for reference by owner and service technician.

This water heater requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

Installation, maintenance, and service must be performed only by a qualified, skilled and knowledgeable installer or service provider.

Installation is not complete unless a temperature and pressure relief valve is installed into the proper location at the top of this water heater.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are properly operating when the installation is complete.

DO NOT operate this water heater without first being certain it is filled with water.

DO NOT tamper with or alter the water heater and/or controls.

DO NOT operate water heater with jumpered or absent controls or safety devices.

DO NOT operate water heater if any external part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system including gas controls, which has been under water.

DO NOT attempt to use this water heater with any gas other than the type listed on the rating plate. Do not attempt to convert this water heater for use with a gas other than the type for which it is equipped. Failure to use the proper gas can create an unsafe condition resulting in property damage, bodily injury, or death. Consult your local gas supplier or gas company if there are any questions.

For installations in high altitude regions, this water heater must be ordered from the supplier to the manufacturer’s specifications for that particular altitude. Contact the company listed on the rating plate when ordering high altitude constructed water heaters.

Incorrect operation of this appliance may create a hazard to life and property and will nullify the warranty.

DO NOT operate this water heater if the input rate exceeds the rate shown on the water heater rating plate.

This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect any components of this water heater without positively assuring the water is cool and is not under pressure. Always wear protective clothing and equipment when installing, starting up or servicing this water heater to prevent scald injuries. Do not rely on the temperature gauges to determine the temperature. Do not touch any components unless they are cool.

This water heater must be properly vented and connected to an approved vent system in good condition. DO NOT operate water heater with the absence of an approved vent system. A clean and unobstructed vent system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the water heater’s efficiency.

3

WARNING

This water heater needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. Insufficient air supply will cause a recirculation of combustion products resulting in contamination that may be hazardous to life. This will result in carboning or sooting of the combustion chamber, burners, and flue tubes and creates a risk of asphyxiation.

Water heater materials of construction, products of combustion and the fuel contain carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby this water heater.

Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the water heater. Open containers of flammable material should not be stored or used in the same room with this water heater.

Insulation blankets are not required for this water heater. This water heater meets or exceeds the ASHRAE/IES

90.1b (latest edition) standards with respect to insulation and standby loss requirements.

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. See following section in this Installation/Operation Manual to change the maximum setpoint limit (max setpoint). Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance, which is connect to the hot water system. If hydrogen is present, there will be unusual sounds such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

WARNING

Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak.

Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

IF YOU SMELL GAS:

 DO NOT try to light any appliance.

 DO NOT touch any electric switch; do not use any telephone in your building.

 Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s instructions.

 If you cannot reach your gas supplier, call the fire department.

DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!

To comply with NSF requirements this water heater is to be: a) Sealed to the floor with sealant, in a smooth and easily cleanable way, or b) Installed with an optional leg kit that includes legs and/or extensions that provide a minimum clearance of 6” beneath the water heater.

4

SECTION II: SPECIFICATIONS

Figure 1

Model Description Dimensions for Figure 1

Input

(Gal) Nat. LP (in.) (in.) (in.) (in.) (in.)

100

80

360,000 360,000 72 7/8 60 7/16 78 11/16 56 15/16 74 13/16

300,000 300,000 63 7/8 51 7/16 69 11/16 47 15/16 65 13/16

Model Description Dimensions for Figure 1

Input

(Liter) Nat. LP (cm) (cm) (cm) (cm) (cm)

378.5 105.5 105.5 185.1 153.5 199.9 144.7 190.0

302.8 88.0 88.0 162.3 130.7 177.0 121.8 167.2

5

SECTION III: GENERAL INFORMATION

FEATURES

1. Porcelain enamel lined tank provides corrosion protection with a tough glass lining on the interior of the tank.

2. Magnesium anodes provide an extra measure of protection and extends tank life.

3. Direct Vent design with an induced draft blower. Flue gases are exhausted and combustion air is taken from outside the building through coaxial vent pipe (exhaust flue pipe inside combustion air intake pipe). Maximum venting distance is 19 ½ feet with one elbow. May be horizontally or vertically vented. See venting section for complete details.

4. Hand Hole Cleanout allows inspection of tank interior and allows the removal of lime and sediment deposits.

5. Honeywell Integrated Water Heater has the following features:

 Attractive digital water heater display on control panel for precisely setting and displaying the temperature setpoint.

Pressing temperature up and down buttons changes the temperature setpoint. Temperature format may be displayed in degrees F or degrees C.

 Single control board with plug in wiring controls temperature, ignition, and induced draft blower operation.

 Reduced number of parts for servicing and wiring.

 Plug in wiring reduces chance of miswiring.

 Water heater display will show diagnostic codes in the event the water heater needs servicing. Aids in diagnosing and servicing the water heater. Temperature of the tank sensors can be monitored in the Service Mode.

 Water heater display can show up to 10 previous error codes to further aid in servicing the water heater.

WARNING

Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be hot enough to cause scald injury. The water is under pressure and may splash.

For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot

Water Supply Systems, ANS Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and

Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve must be marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The combination temperature and pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not less than the hourly rating of the water heater.

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater.

Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve.

Verify that the combination temperature and pressure relief valve complies with local codes. If the combination temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the installation instructions above on this page.

Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.

DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches

(10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

Do not place a valve between the combination temperature and pressure relief valve and the tank.

6

DISHWASHING MACHINE REQUIREMENTS

All dishwashing machines meeting the National Sanitation Foundation requirements are designed to operate with water flow pressures between 15 and 25 pounds per square inch. Flow pressures above 25 pounds per square inch, or below

15 pounds per square inch, will result in improperly sanitized dishes.

The National Sanitation Foundation also recommends circulation of 180°F water. Where this is done, the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater. The circulation should be just enough to provide 180°F water at the point of take-off to the dishwashing machine. Adjust flow by means of the valve in the circulation line.

7

SECTION IV: INSTALLATION INSTRUCTIONS

WARNING

INSTALLATION OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED

TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING, GAS SUPPLY AND

ELECTRICAL WORK ARE REQUIRED.

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING:

 Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in detection of the gas.

 Most people recognize this odor as a “sulfur” or “rotten egg” smell.

 Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or “fade”, and not be as readily detectable.

 If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a telephone in another building.

 Gas detectors are available. Contact your gas supplier or plumbing professional for more information.

Liquefied petroleum gases/propane gas is heavier than air and will remain at floor level if there is a leak.

Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

IF YOU SMELL GAS:

 Do not try to light any appliance.

 Do not touch any electric switch; do not use any telephone in your building.

 Immediately call your gas supplier from a telephone in another building. Follow the gas supplier’s instructions.

 If you cannot reach your gas supplier, call the fire department.

DO NOT OPERATE THE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!

This water heater must be located in an area where leakage of the tank, water line connections, or the combination temperature and pressure relief valve will not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, a suitable drain pan must be installed under the water heater. The drain pan depth must be suitable for draining and collecting water, and have a minimum length and width of at least four (4) inches (10.0 cm) measured from the jacket of the water heater. The drain pan, as described above, can be purchased from your plumbing professional. The drain pan must be piped to an adequate drain. The piping must be at least 3/4 inch (2.0 cm) in diameter and pitched for proper drainage.

Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater components. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE

OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE

SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR

INTAKE SYSTEM.

Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty.

Minimum Clearances

CAUTION

The National Fuel Gas Code (ANSI Z233.1- latest edition) or in Canada The National Gas or Propane

Installation Code CAN/CGA (B149.1, B149.2- latest edition), expressly prohibits the following: a. Installation of a water heater in a bathroom, bedroom, or any occupied room normally kept closed. b. Installation of a water heater in a garage, unless the unit is installed so that the burner and ignition devices are at least eighteen (18) inches (45.8 cm) above floor level and protected to avoid damage by a moving vehicle.

If the buildings cold water supply has a back-flow preventer, check valve or water meter with check valve, provisions for thermal expansion of water in the hot water system must be provided.

8

The location of this water heater is of the utmost importance. Before installing this water heater, you should read the

Installation section of these instructions. After reading these Installation and Operating Instructions, select a location for the water heater where the floor is level and is easily accessible to water lines, gas supply (type identified on the rating plate), an adequate open drain, and within the maximum specified venting distance to an outside wall or roof for the direct vent terminal. DO NOT locate the water heater where water lines could be subjected to freezing temperatures.

Make sure the cold water pipes are not located directly above the gas control so that condensate during humid

weather does not drip or accumulate on the controls.

WARNING

IF COMBUSTIBLE FLOORING IS USED, A THERMAL BREAK LEG KIT MUST BE INSTALLED BEFORE

SETTING WATER HEATER IN PLACE. THE APPROPRIATE LEG KIT HAS BEEN INCLUDED WITH THIS

WATER HEATER.

This installation must allow access to the front of the water heater and adequate clearance must be provided for servicing and operating this water heater. The water heater may be installed on either a combustible or non-combustible floor. If the water heater is to be installed directly on carpeting, it must be installed on top of a metal or wood panel (or equivalent) extending beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the appliance is to be installed in an alcove or closet, the entire floor must be covered by the panel. The panel must be strong enough to support the weight of the water heater when full of water.

This water heater MUST be installed indoors out of the wind and weather.

Note: For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from DSA Headquarters Office, 1102 Q Street, Suite 5100, Sacramento, California 95811.

Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical

vapors. Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence.

NOTICE

DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED

BY THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE HAS OR WILL OCCUR. DO

NOT STORE ANY POTENTIALLY CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER OR

THE DIRECT VENT TERMINAL.

In order to provide clearance for the burner panel access screws to be removed, use a slab inside the drain pan to raise the water heater 1” (2.5 cm) so that the burner access panel clears the lip of the drain pan. There must be access to the burner assembly for servicing. Be sure the water heater remains level.

This water heater may be installed in an alcove on combustible flooring with clearances from combustible materials as shown in the following clearances illustration of this Installation and Operation Instruction Manual.

UNPACKING

INSPECT SHIPMENT carefully for any signs of damage.

1. All equipment is carefully manufactured, inspected and packed.

2. Any claims for damage or shortage in shipment must be filed immediately with the manufacturer noted on the rating plate label.

LOCATE WATER HEATER in front of final position before removing crate.

1. LOCATE so that venting connections will be short and direct.

2. THIS WATER HEATER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR. The thermal break leg kit supplied with the water heater must be used.

3. Proper venting practices must be considered when selecting a location for this water heater. For exact venting specifications, please consult the Venting section of these Installation and Operating Instructions.

4. It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

9

5. The minimum clearances to combustibles for this water heater are: two (2) inches (5.1 cm) from the sides and rear, two (2) inches (5.1 cm) from the front of the burner access box, sixteen (16) inches (40.6 cm) from the top jacket, zero (0) inch (0 cm) from the air intake boot and vent tubes and twelve (12) inches (30.5 cm) in any direction from the direct vent terminal. A minimum of 30 inches (76.2 cm) front clearance from the burner access panel is necessary for inspection and servicing.

6. Increase distances to provide clearance for servicing.

Minimum Clearances

Figure 2

REMOVE CRATE

1. Remove all banding and pry off crate sides carefully so as not to damage the water heater.

2. Carefully roll/lift the water heater from the crate base.

MOVE WATER HEATER TO PERMANENT POSITION by sliding or walking. Place drain pan underneath water heater

INSTALL TEMPERATURE AND PRESSURE RELIEF VALVE (if not already installed).

This water heater must be located in an area where the general public does not have access to set temperatures.

10

SECTION V: VENTING

WARNING

The venting system must be installed properly following all local codes or in the absence of local codes, the latest edition of the National Fuel Gas Code (ANSI Z223.1- latest edition), or in Canada, The Natural Gas and Propane

Installation Code (B149.1-00 latest edition). Failure to properly install the venting system could result in property damage, personal injury, or death.

Carefully inspect the venting system of a replacement water heater installation before connecting to the venting system. All joints in the vent connector must be securely fastened with screws and fit tightly together. Inspect the venting system for signs of deterioration (rust and perforation) and replace any sections that are not in good condition.

The direct vent system must be properly installed. Failure to properly install the direct vent system could result in property damage, personal injury, or death.

DO NOT install any damaged direct vent system components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for

replacement parts.

This is a Powered Direct Vent Gas Water Heater where all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere. The venting system is a coaxial (pipe within a pipe) design where the flue products are discharged through the inside flue tube and the combustion air supply surrounds the flue tube enclosed by the outside pipe. The venting system incorporates both the combustion air supply and the flue exhaust. The venting system component, which is outside the building and takes in the combustion air supply and discharges the flue products, (while keeping them separate) is referred to as the “direct vent terminal”.

Note: Provide protection of the building materials from degradation by flue gases from the direct vent terminal.

Figure 3

11

A=

B=

C=

D=

Direct Vent Terminal Clearances

Canadian Installations 1 Installations 2

Clearance above grade, veranda, porch, deck or balcony 12 inches (30 cm)

12 inches

(30 cm)

Clearance to widow or door that may be opened 36 inches (91 cm) 12 inches (30 cm)

*b *b Clearance to permanently closed widow

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

Clearance to unventilated soffit

Clearance to outside corner

12 inches (30 cm) *a

12 inches (30 cm) *a

*b

12 inches (30 cm) *a

12 inches (30 cm) *a

*b

E=

F=

G=

H=

Clearance to inside corner

Clearance to each side of center line extended above meter/regulator assembly

*b

3 feet (91 cm) within a height 15 feet (4.6 m) above the meter/regulator assembly

36 inches (91 cm)

*b

*b

I=

J=

K=

Clearance to service regulator vent outlet or oil tank vent

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

Clearance to a mechanical air supply inlet

36 inches (91 cm)

6 feet (1.83 m)

*b

12 inches (30 cm)

3 feet (91 cm) above if within 10 feet horizontally

*b L= Clearance above paved sidewalk or paved driveway located on public property 7 feet (2.13 m)†

M= Clearance under a veranda, porch, deck, or balcony 12 inches (30 cm) ‡ *b

1 In accordance with the current CAN/CGA-B149 Installation Codes.

2 In accordance with the current ANSI Z223.1-(Latest edition)/NFPA 54 National Fuel Gas Code.

† A vent must not terminate directly above a sidewalk or paved driveway that is located between two single-family dwellings and serves both dwellings.

‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

*a) A minimum clearance value determined by testing in accordance with section 2.20.

*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.

The vent system must terminate so that proper clearances are maintained as cited in local codes or the latest edition of the National

Fuel Gas Code, ANSI Z223.1.73.4e and 7.8a, b as follows:

1. Do not terminate near soffit vents or crawl space or other area where condensate or vapor could create a nuisance or hazard or cause property damage.

2. Do not terminate the exhaust vent terminal where condensate or vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

3. Do not terminate the exhaust vent terminal over public area or walkways where condensate or vapor can cause nuisance or hazard.

4. The vent must terminate a minimum of 12 inches above expected snowfall level to prevent blockage of vent termination.

Vent pipes serving power vented appliances are classified by building codes as “vent connectors”. Required clearances from combustible materials must be provided in accordance with information in this manual under LOCATION OF

WATER HEATER and CLEARANCES, and with National Fuel Gas Code and local codes.

12

Horizontal And Vertical Direct Vent Lengths

This Powered Direct Vent Gas Water Heater comes with one (1) direct vent kit. The venting system supplied with this water heater is a coaxial (pipe within a pipe) design with the flue discharge tube on the inside and combustion air supply on the outside. Optional direct vent components are available that can extend the horizontal length and/or vertical height of the direct vent system to the maximum distances listed in the table below. This water heater must be installed using the supplied or optional listed components without modifications. Reference the Venting Component Tables listed in the

Installation (Direct Vent System Installation) for the various system components.

Note: The supplied horizontal vent terminal may be used to vent through outside walls up to 24 in. (61 cm) thick.

Maximum Venting Distances (Horizontal, Vertical, or Combined)

Number of 90° Elbows Maximum distance of straight pipe (excluding vent terminal) to exterior wall

0 22 ft. 9 in. (7 m)

1

2

19 ft. 6 in. (6 m)

16 ft. 3 in. (5 m)

Note: Each 45° elbow reduces the maximum venting distance by 19 1/2 in. (50 cm).

NOTICE

IMPORTANT - Do not exceed the venting distances or the number of elbows listed above. Exceeding the maximum venting distances may cause the water heater to malfunction or cause an unsafe condition.

Direct Vent System Installation

WARNING

The direct vent system must be properly installed. Failure to properly install the direct vent system could result in property damage, personal injury or death.

Do not install any damaged direct vent system components. Contact the manufacturer of the water heater for replacement parts.

The flow of combustion air must not be restricted. Keep the direct vent terminal openings clear of objects, shrubs, snow and debris.

Tools Required For Direct Vent Installation

The following minimum tools are required to properly install the direct vent system. Note: Wall construction will determine tool usage.

 Tape Measure

 Drill

 3/16 inch Diameter Drill Bit(s)

 1/8 inch Diameter Drill Bit(s)

 Masonry Drill Bit(s) (For Poured Concrete, Concrete Block and Brick Wall Construction)

 Reciprocating Saw w/appropriate Blade(s) (Dependent on Wall Construction)

 Chisel (For Poured Concrete, Concrete Block and Brick Wall Construction)

 Hammer (For Poured Concrete, Concrete Block and Brick Wall Construction)

 1/4 & 5/16 inch Nut Drivers (Preferred) or Slotted Head Screwdriver

 Phillips Head Screwdriver

Materials:

 Metal strapping to support vent piping.

13

Installation Procedure

A. Determine where the vent terminal will exit through the wall or roof.

1. The supplied vent kit includes a horizontal (through the wall) vent terminal, an elbow, a condensate trap, vent connector clamps, and 6 1/2 ft. (2 m) of coaxial vent pipe. The 6 in. (15.3 cm) diameter venting system also is supplied with an 8 in. (20.3 cm) to 6 in. (15.3 cm) reducer for the water heater vent connection. The coaxial vent pipe includes both the flue exhaust (inside pipe) and combustion air intake (outside pipe). The coaxial vent pipe may be cut on the unflared end (end without gasket) as required for the installation.

2. Determine if additional venting components are required for the venting installation. Refer to the venting component table listed in the Direct Vent Installation section for available optional venting components.

3. Make sure the vent terminal location complies with the requirements described earlier and referenced in the latest edition of the National Fuel Gas Code.

4. Measure the vertical and horizontal distance from the water heater vent connection to determine the number of vent pipes needed.

Venting Component Table for 8 in. (20.3 cm) Diameter Vent Size

Supplied Kit Components

Quantity

2

1

1

1

1

Vent Length Part Description

39 3/8 in. (100 cm) Coaxial vent pipe, straight section with gasket and clamp

Flue Exhaust Cap

23 5/8 in. (60 cm) Horizontal vent Terminal

Vent Adapter Connection Clamp

7 1/4 in. (18.5 cm) Condensate Trap Tee

Part Number

239-41593-00

239-41584-00

239-41676-00

239-41589-00

239-41459-00

239-41597-00

B. Install Vent Terminal

Note: The supplied horizontal vent terminal may be used to vent through outside walls up to 24 in. (61 cm) thick.

1. Horizontal Vent Terminal (Through the Wall) (Supplied)

(a) Cut an opening of at least 8 1/2 inch (21.6 cm) in diameter. (See Figure 4).

Figure 4

(b) Slide the vent terminal through the wall opening until the rib closest to the intake air openings of the terminal is even with the outside wall.

14

Figure 5

(c) Slide the outside wall plate over the vent terminal and fasten to the wall with 4 screws. Depending upon the wall construction, wall anchors may be required to reinforce the screws.

(d) Install the flue cap over the outside of the angled flue discharge tube of the vent terminal. Rotate the cap so that the vent discharge opening is in line with the angled opening of the vent terminal. The vent and air intake openings must both be aligned to face the ground. Tighten the screw clamp so that the cap remains firmly in place.

NOTICE

IMPORTANT - The flue cap must be installed over the angled flue discharge tube with the direct vent openings facing directly down for the water heater to operate properly during rain and wind conditions.

Figure 6

(e) Install inside wall plate on the inside wall and fasten with 4 screws. Depending upon the wall construction, wall anchors may be required to reinforce the screws.

15

Figure 7 (Inside Wall)

2. Vertical Vent Terminal (Through the Roof - Optional)

(a) Determine the exact location where the roof vent terminal will exit the roof, making sure the venting system clears all obstructions. For pitched roofs, the vent cap must be the distance above the roofline as specified in the local codes, or in the absence of local codes refer to the latest edition of the National Fuel Gas Code. The top of the roof terminal may extend up to 2 1/2 ft. (76.2 cm) above the roofline as needed.

(b) Run the coaxial venting system to the proper distance below the roof sheathing required for the correct distance of the roof terminal above the roof surface. See the following sections on installing the rest of the venting system.

(c) Cut a minimum 8 1/2 inch (21.6 cm) minimum diameter hole centered in the desired location for the roof terminal. (See Figure 8).

(d) Center the roof flashing over the hole using either the flat roof flashing or universal flashing for pitched roofs.

(e) Slip the storm collar supplied with the roof flashing kit over the outside of the vent terminal and align with the vent pipe end below roof opening. Insert the terminal into the vent pipe.

(f) Fasten the roof flashing to the roof with nails. Seal the vent terminal and flashing to the roof.

(g) Install the gasketed clamp around the joint between the vent terminal and vent pipe.

Figure 8

16

C. Install Vent Piping Sections

1) The coaxial vent pipe sections are designed to fit tightly together and seal with the integral flue pipe seal and supplied pipe clamps. No silicone caulk or special tools are required.

General Notes:

(2) All venting sections and fittings come complete with silicone flue pipe gaskets and outside gasketed pipe clamps for making airtight connections between the venting pipe connections.

(3) Wetting the silicone gaskets with a solution of soapy water will make the pipe connections slide together easier.

(4) The internal flue pipe of the straight vent pipe is not fastened to the outside pipe so that the last vent section can be cut to length. Remove the internal flue pipe from the outside pipe for easier handling during installation. Complete one section at a time by installing the outside pipe, then the inside flue pipe.

Installation Procedure:

(a) Raise the outside vent pipe to the vent terminal connection with the flared (female) end of the pipe toward the vent terminal. Insert the outside pipe into the vent terminal connection and grasp the end of the vent pipe while twisting and pushing the pipe until inserted all the way into the vent terminal.

Figure 9

(b) Connect the outside pipes together using the gasketed clamps provided. The outside vent pipes have ribs located on the female end. When connecting the vent piping, the gasketed clamps must cover the ribs and joints of the connecting vent tubes (See Figure 10). Support each pipe section with hangers attached to supporting joists in the wall or ceiling.

Figure 10

(c) Insert the inside flue pipe into the outer pipe with the female gasketed end toward the vent terminal. Push and twist on the end of the flue pipe until the flue pipe from the vent terminal is completely seated inside the female gasketed end.

17

(d) Continue connecting pipe sections together with clamps and supporting with hangers. Follow the same procedure described in the previous steps for inserting and connecting the flue tubes inside the outer vent pipes.

Install one section at a time with the outside pipe first, followed by the inside flue pipe.

(e) The last pipe section may be cut to fit the distance required to reach the water heater vent connections. First, install the supplied condensate trap with the crimped end into the gasketed end of the elbow (horizontal vent installations) and clamp the condensate tee and elbow together. Then install the crimped end of the elbow into the vent connection of the water heater. On vertical vent installations, install the crimped end of the condensate trap directly onto the water heater vent connection.

NOTICE

IMPORTANT - In order for the condensate trap to collect and dispose of the condensate from the vent pipe, the venting system must have a downward slope of 1/4 in. per ft. (21 mm/m) toward the condensate trap. The condensate trap must be installed as close as possible to the vent adapter to prevent condensate from accumulating and draining into the vent adapter or blower.

(f) Carefully measure the length of straight vent pipe needed allowing for about 2 in. (5.1 cm) insertion into the elbow. Mark the ungasketed end of the pipe to be cut and carefully make a straight cut on the outside pipe to the desired length. Remove the inside flue tube and cut each pipe separately. Then cut the inside flue pipe about 1 in. (2.5 cm) longer than the outside pipe so that the flue pipe protrudes slightly beyond the outside pipe.

Reinsert the inside flue pipe into the outside vent pipe. Connect the outside vent pipe and clamp at each end.

(g) Use the large clamp supplied in the vent kit with the stepped gasket to seal the elbow or condensate trap to the blower vent connector. The larger step of the gasket seals the vent pipe to the cast vent adapter.

(h) Condensate disposal: Connect either a 1 1/4 inch (3.2 cm) slip joint drain connection or a 1 inch (2.5 cm) PVC compression coupling from the condensate trap nipple to 1” (2.5 cm) PVC piping to a drain or condensate disposal pump. Install a drain trap after the condensate fitting to seal the venting system. Some local codes may require a condensate neutralizer before allowing the condensate to be disposed down the drain. Contact your plumbing professional.

CAUTION

A trap or loop must be installed for the condensate drain to prevent leakage of potentially hazardous flue products from being discharged into the room.

Figure 11

18

SECTION VI: WATER CONNECTIONS

NOTE: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.

After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top and front of the water heater. Make sure the diptube is in place before making the cold water connection. Make the proper plumbing connections between the water heater and the plumbing system to the house. Install a shut-off valve in the cold water supply line.

CAUTION

If sweat fittings are to be used, DO NOT apply heat to the nipples on top or side of the water heater. Sweat the tubing to the adapter before fitting the adapter to the water heater connections. It is imperative that heat is not applied to the nipples containing a plastic liner.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED TEMPERATURE AND PRESSURE RELIEF VALVE WILL

RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE

TEMPERATURE AND PRESSURES

.

NOTICE

If this water heater is installed in a closed water supply system, such as the one having a back-flow preventer in the cold water supply, provisions must be made to control thermal expansion. DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion. Warranties do not cover damages from thermal expansions such as pressure bulges and/or deformities. Your water supplier or local plumbing inspector should be contacted on how to control this situation.

After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER

HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER.

APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

120°F (49°C) More than 5 minutes

125°F (52°C)

130°F (54°C)

1½ to 2 minutes

About 30 seconds

135°F (57°C)

140°F (60°C)

145°F (63°C)

150°F (66°C)

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1½ seconds

155°F (68°C) About 1 second

19

WARNING

Keep clear of combination temperature and pressure relief valve discharge line outlet. The discharge may be hot enough to cause scald injury. The water is under pressure and may splash.

For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot

Water Supply Systems, ANS Z21.22 and the Standard CAN1-4.4 Temperature, Pressure, Temperature and

Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve must be marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The combination temperature and pressure relief valve must also have an hourly rated temperature steam BTU discharge capacity not less than the hourly rating of the water heater.

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater.

Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve.

Verify that the combination temperature and pressure relief valve complies with local codes. If the combination temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the installation instructions above on this page.

Install a discharge line so that water discharged from the combination temperature and pressure relief valve will exit within six (6) inches (15.2 cm) above, or any distance below the structural floor and cannot contact any live electrical part. The discharge line is to be installed to allow for complete drainage of both the combination temperature and pressure relief valve and the discharge line. The discharge opening must not be subjected to blockage or freezing.

DO NOT thread, plug or cap the discharge line. It is recommended that a minimum clearance of four (4) inches

(10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

Do not place a valve between the combination temperature and pressure relief valve and the tank.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury.

Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the manufacturer of this water heater or a local plumbing supplier. Please consult with a plumbing professional. For information regarding space heating water connections and plumbing arrangements, refer to the section at the end of this manual.

20

SECTION VII: GAS CONNECTIONS

The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in

Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.2 Propane Installation Code

(Latest Edition).

The minimum permissible gas supply pressure for the purpose of input adjustment is one (1.0) inch (0.25 kPa) water column above the operating manifold pressure. See the rating plate and gas valve for the manifold pressure and gas type. The maximum permissible gas supply pressure is fourteen (14.0) inches (3.5 kPa) water column for natural gas and liquefied petroleum gases/propane gas.

1. Connect this water heater only to the type of gas (Natural or Propane gas) as shown on the rating plate. Use clean black iron pipe or equivalent material approved by local codes and ordinances. (Dirt and scale from the pipe can enter the gas valve and cause it to malfunction). The inlet gas line must have a minimum length of three (3) inches (7.6

cm) drip leg (sediment trap) installed as close to the water heater’s gas valve as possible. A ground joint union must be installed as close to the water heater as possible in the gas supply line feeding the water heater to permit servicing of the water heater. Compounds used on the threaded joints of the gas piping must be resistant to the action of liquefied petroleum gases/propane gas. DO NOT apply pipe dope to the gas valve inlet and make certain that no pipe dope has become lodged in the inlet screen of the gas valve. Extreme care must be taken to ensure no pipe dope enters the gas valve. Avoid excessive torque when tightening the gas supply line to the gas valve. Excessive torque may result in cracking of the gas valve housing and could create a gas leak. The suggested maximum torque is 31.5 ft. lbs. (4.4 kg-m).

WARNING

The manufacturer of this water heater will not be liable for any damage or injury caused as a result of a cracked gas inlet as a result of excessive torque.

2. This water heater and its gas connection must be leak tested before placing the water heater in operation. Check for gas leaks with a soap and water solution and a brush or a commercial leak detector fluid. NEVER USE A MATCH OR

OPEN FLAME FOR TESTING!

CAUTION

The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply system at test pressures equal to or less than 1/2 psi (3.5 kPa). The supply line must be capped when not connected to the water heater.

3. While checking for leaks care must be taken to prevent solution from contacting the electrical connections at the control. If electrical connections at the control become wet, they must be thoroughly dried before attempting to operate the water heater.

WARNING

Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved. Plumbing, air supply, venting, gas supply and electrical work are required.

Light the unit in accordance with the operating instructions label attached to the water heater.

Under no circumstances should the input rate exceed the input rate shown on the water heater rating plate. Over firing could result in damage or sooting of the water heater.

If the unit is exposed to the following, do not operate water heater until all corrective steps have been made by a factory authorized independent service contractor or qualified service professional.

1. Flooding to or above the level of the burner or controls

2. External

3. Damage

4. Firing without water

5. Sooting

21

SECTION VIII: ELECTRICAL CONNECTIONS

WARNING

Turn off or disconnect the electrical power supply to the water heater before servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

All electrical wiring must be installed and grounded in accordance with local codes, or in the absence of local codes, the National Electrical Code, ANSI/NFPA 70 and/or CSA C22.2 Electrical Code.

The water heater must be wired to a 115 volt, 60

Hz, AC power supply. The water heater should be wired on a separate circuit and breaker. If a flexible line cord and plug is permitted by local code, then provide a three wire grounding type receptacle within reach of the line cord provided on the control box. Do not plug the line cord into a receptacle that can have the power supply interrupted by a switch that is used to control lights or another appliance.

If wiring in conduit is required, cut the line cord close to the control board and make the appropriate wiring connections.

CAUTION

This water heater must be wired on a separate circuit. Failure to wire on a separate circuit may cause improper operation or failure of the electrical components of the water heater.

Refer to the “Electrical Connections” section of the Installation and Operating Instructions

Manual for complete instructions on electrical wiring and connections to the water heater.

Do not energize the electric circuit before the water heater tank is filled with water.

Wiring Diagram (to the right)

22

TYPICAL INSTALLATION

WARNING

Water heaters are heat-producing appliances. To avoid damage or injury there must be no materials stored against the water heater or direct vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and direct vent system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS

WATER HEATER OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.

NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A

TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE

WATER HEATER.

23

SECTION IX: OPERATING INSTRUCTIONS

Lighting and Shutdown Instructions

24

TEMPERATURE ADJUSTMENT

APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS

120°F (49°C) More than 5 minutes

125°F (52°C)

130°F (54°C)

1½ to 2 minutes

About 30 seconds

135°F (57°C)

140°F (60°C)

145°F (63°C)

150°F (66°C)

155°F (68°C)

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1½ seconds

About 1 second

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of 140 F (60 C). To protect against hot water injury, install an ASSE approved mixing valve in the water system.

This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines. A licensed plumbing professional or local plumbing authority should be consulted.

This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance and call a qualified service technician.

CAUTION

This water heater, when set at a lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes.

NOTICE

Whenever the water heater is filled with cold water, condensate will form on the cool tank surface and drops of water will fall on the hot burner and combustion chamber surfaces producing a “sizzling” noise. Condensation is normal and does not indicate a leak. It will disappear when the tank becomes heated.

The lower the temperature setting, the greater the energy efficiency, both to heat the water and to maintain the storage temperature during standby periods. Lower water temperatures also extend tank life. Remember, no water heating system will provide exact temperatures at all times. Allow a few days of operation at this setting to determine the correct temperature setting consistent with the requirements for the installation.

The water heater temperature setting is adjusted by using the control display mounted to the front of the control panel of the water heater. The water heater thermostat is set at the lowest setpoint of 70 F when shipped from the factory. The control display shows the temperature setpoint in degrees Fahrenheit ( F) or degrees Celsius (C), and the status of the water heater (“Idle” or “Heating”). If the water heater is functioning normally, the display will also show “Operational”.

For energy efficient operation of your water heater, the suggested initial temperature setting is 120 F (49C). During the winter season, or any cold period, you may desire a higher temperature setting to adjust for the colder incoming water.

This adjustment, however, may cause additional condensation to form on the cooler tank surface. This does not mean the tank is leaking. During summer months, the warmer incoming water temperatures will benefit the performance of your water heater and reduce the amount of condensation developed.

Condensation does not mean your tank is leaking. Over 40% of reported tank leaks on installation are proven to be condensation. To avoid unnecessary expense and inconvenience, make sure the tank is leaking before calling a service person.

25

Shown flashing in display only when temp is adjusted

Sequence of operation Indicator

Reads "Idle” or “Heating"

Status Indicator

Read "Operational" or "Service Needed"

Select button

Water Heater Display and Control Buttons

°F setpoint idle

Status Operational

SELECT SET

Temperature

Up Button

Temperature Setpoint in Degrees F or Degrees C

Range 70 - Max °F

Range 21 - Max °C

Temperature

Down Button

Set button

WARNING

If the water heater display does not show “Operational” in the “Status” indicator, there may be an operating malfunction with the water heater. If this is the case, a numeric code will be displayed. Refer to the label next to the display for the definition of the error code and call your plumbing professional or service agent to service the water heater. Do not try to reset the water heater without having a qualified service person to diagnose and correct the problem. If the display is blank or does not show an error code, make sure there is power to the water heater.

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. See following section to change the maximum setpoint limit (max setpoint). Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

See previous warning on scalds and an ASSE approved mixing valve.

NOTICE

When the maximum setpoint is reached, the display will show “Max Setpoint” without the setpoint value. The maximum setting is equal to approximately 180˚F (82˚C).

The default temperature setpoint from the factory is 70˚F (21˚C).

26

To Increase Setpoint Temperature

Step 1: Depress and hold “Temperature Up” button until desired setpoint temperature appears in the display.

°F idle

Status Operational

SELECT SET



Step 1

Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Up” button.

"Setpoint" flashes

idle

Status Operational

SELECT

°F setpoint

SET



Step 2

Step 3: Press “SET” button for new setting to take effect immediately. “Setpoint” will stop flashing. If the “SET” button is not pressed, the new temperature setting will take effect in approximately 10 seconds.

"Setpoint" flashes for 10 seconds

°F setpoint idle

Status Operational

SELECT

Step 3

SET



Press SET Button for setting to to take effect immediately

27

To Decrease Setpoint Temperature

Step 1: Depress and hold “Temperature Down” button until desired setpoint temperature appears in the display.

°F idle

Status Operational

SELECT SET



Step 1

Step 2: “Setpoint” indicator begins flashing in the display after pressing “Temperature Down” button.

"Setpoint" flashes

setpoint

°F idle

Status Operational

SELECT SET



Step 2

Step 3: Press “SET” button for new setting to take effect immediately. The setpoint will stop flashing. If the “SET” button is not pressed, the new temperature setting will take effect in approximately 10 seconds.

"Setpoint" flashes for 10 seconds

°F setpoint

SELECT idle

Status Operational

Step 3

SET



Press SET for setting to take effect immediately

28

To Change Temperature Format in Display from F to C or ˚C to ˚F:

Step 1: Press “SELECT” button until F/C is displayed.

°F °F/°C idle

Status Operational

SET



SELECT

Step 2: Press “SET” button to change temperature format. Symbol F/C will flash.

Press select

Step 1

°F °F/°C idle

Status Operational

SELECT SET



Step 3a: Press “Temperature Up” button to change temperature format to C.

Changes to "°C"

Step 2

°F/°C Flashes

°C °F/°C idle

Status Operational

SELECT SET



°F/°C Flashes

Step 3a

29

Step 3b: Press “Temperature Down” button to change temperature format to F.

Changes to "°F"

°F/°C Flashes

°F °F/°C idle

Status Operational

SELECT SET



Step 3b

Step 4: Press “SET” button to confirm ˚F or ˚C format. F/C will stop flashing. Setpoint display will appear in the format selected (˚F or ˚C) in 10 seconds.

Symbol "°F/°C" Stops Flashing

°F °F/°C idle

Status Operational

SELECT

Step 4

SET



Press Set

Step 5: Pressing “SELECT” button will return display to setpoint in format selected (˚F or ˚C) immediately.

Setpoint shown in °F

idle

Status Operational 

SELECT

Press select

Step 5

SET

30

°F

An automatic gas shut-off device (ECO) is incorporated in the sensor and control board which will shut off all gas supply to the burner and pilot if the water heater temperature exceeds 200°F (93°C). Should the ECO function (open), the water temperature should be reduced to approximately 120°F

(49°C) and follow applicable Lighting Instructions to place the water heater in operation. The water heater must have the problem corrected by a qualified service person before putting the water heater back in operation. It is recommended that all service work be performed by a qualified service agency.

If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off, the water heater and piping should be fully drained (See “To Drain the Water Heater”) and the drain valve should be left fully open.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

Burner Flame Check

At the time of installation and at periodic intervals (about every 3 months), a visual check of the pilot and burner flames should be made to determine if they are burning properly. No adjustment to the air shutter should be required for this heater. The burner flames should be blue with yellow tips. A blueorange flame is characteristic of operation on liquefied petroleum (LP) gas. If the burner flame does not appear as described, an air shutter adjustment may be required. The burner tube flames should light smoothly from the pilot.

NOTICE

IMPORTANT- In the event of an emergency, turn off the gas and electric (if applicable) to the appliance.

IMPORTANT- The water heater should be inspected at a minimum annually by a qualified service technician for damaged components and/or joints not sealed. DO NOT operate this water heater if any part is found damaged or if any joint is found not sealed.

Figure 8

WARNING

Do not run out of propane gas. Damage to the water heater may occur.

WARNING

Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS

WATER HEATER, VENT SYSTEM OR IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER

HEATER OR VENT SYSTEM.

31

SECTION X: MAINTENANCE

NOTICE

The water heater should be inspected at a minimum annually by a qualified service technician for damaged venting system components and/or vent and combustion air supply joints not sealed. DO NOT operate this water heater if any part is found damaged or if any joint is found not sealed.

1. A qualified service technician should perform the following maintenance at the minimum periodic intervals suggested below. In some installations, the maintenance interval may be more frequent depending on the amount of use and the operating conditions of the water heater. Regular inspection and maintenance of the water heater will help to insure safe and reliable operation.

2. Annual checks of the ignition systems, temperature controls and any other water heater controls are necessary to ensure proper operation. Also, all safety shut-off valves must be checked to verify proper operation and tightness.

3. The entire combustion system must be sealed for this water heater to function properly. Make sure the burner access panel is kept tightly sealed. The combustion air supply pipe at the rear of the water heater must be tightly clamped to the vent adapter and combustion air box boot. Replace any damaged parts. The entire venting system and combustion air supply parts must be inspected at least annually for integrity of all joints and gaskets.

WARNING

The ventilation air system may be HOT.

4. The flow of combustion and ventilation air MUST NOT be restricted. Keep the direct vent terminal openings clear of objects, shrubs, snow, and debris. Check to make sure the vent terminal is not damaged.

5. At all times keep the water heater area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

WARNING

Do not run out of propane gas. Damage to the water heater may occur.

6. Annually conduct a visual check of the pilot and burner flames to determine that they are burning properly. See

“Burner Flame Check” section for an illustration of the proper burner flame pattern.

7. At annual intervals check the flue baffles for deterioration and scale or carbon deposits. Clean if necessary and brush the flue tubes if excessive scale or deposits are found on the baffles. Replace any baffles that have become excessively warped or deteriorated. Check the flue collector gasket for integrity and replace if necessary. Cleaning of the flue baffles and flue tubes should be done prior to cleaning the burners, since deposits may fall on the burners during cleaning or checking the baffles.

8. Annually remove the main burner rack assembly to clean orifices and related parts of any dirt or other foreign material. Inspect the burner ports for obstructions or debris and clean with a wire brush, vacuum, or use a mild detergent solution to clean as needed. Inspect the pilot. Carefully clean the electrode and flame sensor rod with emery cloth. The spark electrode (rod closest to the pilot hood) gap should be 1/8”.

NOTICE

It is imperative for proper operation of the water heater that the main burner rack be replaced in the original location.

32

To remove the burner rack assembly, follow the procedure outlined below: a) Shut off the gas and electrical supply to the water heater. b) Remove the pilot tube fittings at the gas valve and combustion box. c) Disconnect wires to gas valve. Open control box and disconnect pilot spark and flame sensor wires. Remove the wire raceway cover below the control box. d) Disconnect the gas pipe union below the gas valve. e) Remove the three screws securing the gasketed manifold pipe flange on the left side of the combustion box. f) Remove the burner access panel from the front of the combustion box. g) Carefully remove and push the pilot wire grommet into the combustion box with the pilot wires. h) Disconnect the pilot tube fitting on the inside bulkhead fitting of the combustion box.

I) Un-thread the gas pipe assembly from the manifold inside the combustion box. j) Remove the screw securing the burner rack on the top right panel of the combustion box. k) Slide out the burner rack assembly.

To reinstall the burner rack, reverse the above procedure.

9. At least once a year, check the combination temperature and pressure relief valve to insure that the valve has not become encrusted with lime. Lift the lever at the top of the valve several times until the valve seats properly without leaking and operates freely.

WARNING

When lifting lever of the combination temperature and pressure relief valve, hot water will be released under pressure. Be careful that any released water does not result in bodily injury or property damage.

Keep clear of the combination temperature and pressure relief valve discharge line outlet. The discharge may be hot enough to cause scald injury. The water is under pressure and may splash.

10. Monthly drain off a gallon of water to remove silt and sediment.

WARNING

THIS WATER MAY BE HOT!

11. If the combination temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the combination temperature and pressure relief valve outlet.

12. All models are equipped with a cleanout opening to aid in removal of hard water deposits from the tank bottom. If this water heater operates under hard water conditions, the following should be performed at least every 3 months:

Drain the water heater. Remove the cleanout jacket cover and tank cover. When cleaning the tank, care must be taken to avoid trying to break deposits loose as this could damage the glass lining and shorten the life of the water heater. After cleaning, replace the cleanout tank cover and jacket cover, and refill with water. Refer to filling and draining the water heater.

13. Four sacrificial anode rods have been installed in the tank head to extend tank life. The anode rods should be inspected annually for corrosion and replaced when necessary to prolong tank life. Water conditions in your area will influence the time interval for inspection and replacement of the anode rod. The use of a water softener may increase the speed of anode consumption. More frequent inspection of the anode is needed when using softened

(or phosphate treated) water. Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information.

14. Oil the induced draft blower motor in the ports of the front and rear motor bearings every 6 months with 4 drops each of SAE 20 motor oil.

15. The vent system must be inspected at least once a year to ensure against leakage of exhaust products.

CAUTION

FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION GAS CONTROL, BURNERS OR GAS

PIPING. REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN.

33

TO FILL THE WATER HEATER

1. Close the water heater drain valve by turning the knob or valve stem clockwise. If alternative water connections are provided but not used, make certain they are plugged (i.e. rear connections).

2. Open the cold water supply shut-off valve.

3. Open several hot water faucets to allow air to escape from the system.

4. When a steady stream of water flows from the faucets, the water heater is filled. Close the faucets and check for water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold water connections.

5. To restore operation of the water heater, refer to operating instruction label on the water heater.

TO DRAIN THE WATER HEATER

Should it become necessary to completely drain the water heater, make sure you follow the steps below:

1. Reduce the thermostat to the lowest setting. Depress the control panel rocker switch on the top of the control box to the “OFF” position. Disconnect power to the water heater.

2. Rotate and partially depress gas control knob clockwise to the “OFF” position.

3. Shut off the gas supply to the water heater.

4. Close the cold water supply shut-off valve.

5. Open the drain valve or valve stem on the water heater by turning the knob counter-clockwise. The drain valve has threads on the end that will allow the connection of a standard hose coupling.

6. Open a hot water faucet to allow air to enter the system.

To refill the water heater, refer to “To Fill the Water Heater.”

Contact your supplier, plumbing professional or contact the company at the address given on the rating plate of the water heater for replacement parts.

Provide the part name as well as the model and serial number(s) of the water heater(s) when ordering parts.

READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF TIME THAT PARTS AND THE WATER

HEATER ARE WARRANTED.

Manufactured under one or more of the following U.S. Patents: RE.34,534; B1 5,341,770; 4,416,222; 4,628,184; 4,669,448;

4,672,919; 4,808,356; 4,829,983; 4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519; 5,115,767;

5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952; 5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492;

5,988,117; 6,142,216; 6,395,280 6,684,821; 7,063,132; 7,007,748

Other U.S. and Foreign patent applications pending. Current Canadian Patents: 1,272,914; 1,280,043; 1,289,832; 2,045,862;

2,092,105; 2,107,012; 2,108,186; 2,112,515

Complete the following information and retain for future reference:

Model No:

Serial No:

Service Phone

Days: Nights:

Address:

Supplier:

Supplier Phone No:

34

SECTION XI: DIAGNOSTIC AND TROUBLESHOOTING GUIDE

DIAGNOSTIC GUIDE FOR HONEYWELL INTEGRATED CONTROL SYSTEM

SEQUENCE OF OPERATION FOR PDV MODELS

1. When the tank temperature drops below the temperature setpoint on the display, the control sends power to the induced draft blower to start the ignition sequence.

2. When blower reaches the full operating speed, the pressure switch closes, completing the 24 volt circuit to the safety circuit of the control. If the exhaust vent becomes blocked or the blower fails, the pressure switch will open, the gas valves close, and the blower stops after a 5 second post-purge. The blower will restart and continue to operate in the lockout condition until the blockage is removed or the venting problem is corrected.

Error code 29 will appear on the water heater display.

3. The control will continue to operate the blower for 15 seconds to “prepurge” any flue products remaining before starting the ignition sequence.

4. After the prepurge period, the control sends 24 volt power to the pilot valve “PV” terminals on the gas valve allowing pilot gas to flow to the pilot. The control also sends high voltage through the pilot electrode to spark to the pilot hood and ignite the pilot gas. If the pilot does not ignite within 90 seconds, the pilot valve is denergized and the sparking stops for 75 seconds. The control will attempt to ignite the pilot two more times. If the pilot does not light on the 3 rd

attempt, the control will go into “soft lockout” for 1 hour and then will repeat the 3 ignition attempts. The blower is off during the “soft lockout” period.

5. When the pilot is lit, the flame is sensed by the flame sense rod. The flame sense signal received by the control board causes the sparking to stop and the main gas valve to open. The main burners ignite from the pilot flame.

The pilot is continually monitored by the flame sensing circuit. If for any reason, the pilot flame is not sensed by the flame sensing circuit, the gas valves close. After a 75 second delay, the pilot valve opens and the pilot electrode sparks to relight the pilot. The same sequence will occur in the event of a power supply or gas supply interruption.

6. The main burners continue to operate until the water temperature in the tank increases past the control setpoint, which will cause the gas valve to close. The blower stops operating 5 seconds after the gas valve closes. The water heater remains in the standby mode until the temperature drops below the setpoint and initiates another heating cycle.

7. If for some reason, the tank temperature should reach or exceed 200˚F, then the control closes the gas valve and goes into a “hard lockout” state and will not operate until reset by a qualified service person. The display will read

“error code 65”, which indicates the tank high limit temperature has been exceeded. No attempt should be made to reset the control until a service person has corrected the cause of the high limit condition. Refer to the diagnostic service section at the end of this Installation and Operating Instructions Manual.

35

ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY)

The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater. This procedure is for service and installation personnel only. To enter the Service Mode, follow the steps illustrated below:

WARNING

The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition.

Step 1: Press “Select” and “Temperature Up” buttons together and hold for 3 seconds until “Max Setpoint” is shown in the display.

"Max Setpoint" next to Temperature

Setpoint value.

Max

Setpoint idle

Status Operational 

SELECT

NOTICE

SET



30 Seconds after the last button press, the display will automatically return to the “User Mode”. Simultaneously pressing the “Select” and “Temperature Up” buttons will switch the display immediately to the “User Mode”.

Step 2: Pressing “Select” button will change display to next mode



SELECT idle

Status Operational

°F

Water

Temp

SET

36

The following is the sequence of modes available in “Service Mode” by pressing the “Select” button:

Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”.

Error Code Shown in Water Heater Display

Status Service Needed

SELECT Lockout RESET

1. Max Setpoint (Display/Change)

Max Setpoint value

Water Heater Display

°F

Max

Setpoint idle

Status Operational

SET



SELECT

2a. Water Temperature Average (Displays average if there are two sensors – sensor temperature displayed if single sensor is used).



SELECT idle

Status Operational

37

°F

Water Temp

SET

2b. Water Temperature - Upper Sensor (Displays if there is an upper sensor – some models)

°F idle

Operational Status

Upper Sensor 

SELECT

2c. Water Temperature - Lower Sensor (Displays if there are two sensors)

SET

°F idle

Status Operational

SET

 Lower Sensor

SELECT

3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle)



SELECT

µA

Heating

Status

Flame Current

Operational

SET

38

4. Setpoint (Display/Change)

5. ˚F/˚C (Display/Change)



SELECT idle

Status Operational

SET

°F setpoint

°F °F/C°



SELECT idle

Status Operational

6. Differential (Display only – shows the differential of the thermostat)

SET



SELECT idle

Status Operational

°F Differential

SET

39

7. Software Version (Display only)

Soft idle

Status Operational

SET



SELECT

8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show -- if there are no error codes.

No current error codes

idle

Status Operational

SELECT SET



To change the Maximum Setpoint Limit (Max Setpoint) for the temperature setpoint:

WARNING

Setting the water temperature to the maximum set point can result in scalding hot water delivered to the faucets. It is highly recommended that the maximum setpoint be adjusted to the lowest temperature possible for the needs of the installation. See following section to change the maximum setpoint limit (max setpoint). Make sure the water heater control display is not in a public area that can result in the temperature settings being improperly adjusted.

See previous warning on scalds and an ASSE approved mixing valve.

Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed.



SELECT idle

Status Operational

40

°F

Max

Setpoint

SET

Step 2: Press “Set” button to enter setting mode. “Max Setpoint” will flash to indicate setting mode.

"Max Setpoint" Flashes

°F

Max

Setpoint idle

Status Operational

SELECT SET



Step 3: Press the “UP” or “DOWN” buttons to change the maximum setpoint value. This will limit the maximum setpoint the user can select. Note: The maximum setpoint is approximately 180˚F.

"Max Setpoint" continues to flash while making adjustments

°F idle

Status Operational

Max

Setpoint

SELECT SET



Step 4: Press “Set” button to confirm new “Max Setpoint” value and stop setting mode.

"Max Setpoint" stops flashing

41

SELECT

°F

Max

Setpoint idle

Status Operational

SET



Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max

Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting. The Water Heater

Display can be set back to the “User Mode” immediately by pressing both the “Temperature Up” and “Select” buttons together for 3 seconds.

Max

Setpoint



SELECT idle

Status Operational

SET

Exiting Service Mode



Display of Water Temperature:

Step 1: In Service Mode, Press the “Select” button until “Water Temp” is displayed in the upper right section of the water heater display. For water heaters using two temperature sensors in the tank, this will be the average reading between the two sensors. For water heaters using a single sensor, this is the reading for the sensor.



SELECT idle

Status Operational

°F

Water

Temp

SET

42

Step 2: For water heaters using two temperature sensors, pressing the “Select” button again displays the Upper Sensor temperature reading. “Upper Sensor” will be displayed in the lower right side of the status window of the water heater display.

°F idle

Operational Status

Upper Sensor

SET



SELECT

Step 3: For water heaters using two temperature sensors, pressing the “Select” button again displays the Lower Sensor temperature reading. “Lower Sensor” will be displayed in the lower left side of the status window of the water heater display.

°F idle

Status Operational

SET

 Lower Sensor

SELECT

To Display Flame Sense Current of the Pilot Flame Sensor:

The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays

“Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode” described previously. Step 3:

Press the “Select” button until a number value is displayed with “Flame Current” to the right of the number. The value displayed is in microamps (µA).



SELECT

µA

Heating

Status Operational

43

Flame

Current

SET

To Display and Change Temperature Setpoint:

Step 1: In “Service Mode” press the “Select” button until “Setpoint” is shown in the water heater display.

°F setpoint idle

Status Operational

SET



SELECT

Step 2: Press the “Set” button to enter the setting mode. “Setpoint” will flash in the water heater display.

"Setpoint" Flashes

°F setpoint idle

Status Operational

SELECT SET



Step 3: To raise the temperature setpoint, press the “Temperature Up” button until the desired temperature is shown on the water heater display.

NOTICE

Note: The maximum temperature that can be set in the Water Heater Display is limited to the “Max Setpoint” described previously. To change the “Max Setpoint”, refer to the procedure “To Change the Maximum Setpoint

Limit…” described previously under “Accessing the Service Mode on the Water Heater Display”.

"Setpoint" Flashes

°F setpoint idle

Status Operational

SELECT SET



44

Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on the water heater display.

"Setpoint" Flashes

setpoint

°F idle

Status Operational

SELECT SET



Step 5: When the desired setpoint is reached on the water heater display, press the “Set” button to confirm the new setpoint. “Setpoint” stops flashing in the water heater display.

"Setpoint" Stops Flashing

°F setpoint idle

Status Operational

SELECT

To Display and Change Temperature Format (˚F/˚C):

SET



To Change Temperature Format in Display from ˚F to ˚C or ˚C to ˚F:

Step 1: While in “Service Mode”, press “Select” button until “˚F/˚C” is shown in the upper right portion of the water heater display.



SELECT idle

Status Operational

°F °F/C°

SET

45

Step 2: Press “Set” button to change temperature format. “˚F/˚C” symbol will flash in the water heater display.

"°F/°C" Flashes

°F °F/C° idle

Status Operational

SELECT SET



Step 3a: Press “Temperature Up” button to change temperature format to ˚C

Changes to "°C"

"°F/°C" Flashes

°C °F/C° idle

Status Operational

SELECT SET



Step 3b: Press “Temperature Down” button to change temperature format to ˚F.

Changes to "°F"

"°F/°C" Flashes

46

°F °F/C° idle

Status Operational

SELECT SET



Step 4: Press “Set” button to confirm ˚F or ˚C format. ˚F/˚C will stop flashing.

"°F/°C" Symbol Stops Flashing

idle

Status Operational

SELECT SET



Step 5: Pressing “Select” button will return display to setpoint in format selected (˚F or ˚C) immediately.

Setpoint shown in °F

 Lower Sensor

SELECT idle

Status Operational

°F

SET

47

How to reset the control from Lockout Conditions:

WARNING

The following procedure is for service and installation personnel only. Resetting lockout conditions without correcting the malfunction can result in a hazardous condition.

If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition” with the water heater display showing the error code number and “Service Needed” in the status section of the display window. Error codes 62 (maximum number of retries detected) and 63 (maximum number if ignition recycles detected) are “Soft Lockouts” in which the control can be reset in the “User Mode” by pressing the lower right button under “Lockout

Reset” shown in the lower right portion of the display. The control will also go through 3 attempts to relight the burners every hour in the soft lockout condition.

Resetting Error Codes in Soft Lockout Condition

Error Code Shown in

Water Heater Display

Status Service needed

SELECT Lockout RESET



Press for 2 seconds

All other error codes will put the water heater into a “Hard Lockout” condition, in which the water heater will not operate and cannot be reset in the “User Mode”. To reset a hard lockout, first enter the “Service Mode” described earlier by pressing both the “Temperature Up” and “Select Buttons” at the same time for 3 seconds. Then press the lower right button under “Lockout Reset” in the water heater display and hold for 3 seconds.

Resetting Error Codes in Hard Lockout Condition

Error Code Shown in

Water Heater Display

Status Service Needed

SET



SELECT

Step 1: Press for 3 seconds to enter service mode.



Status Service Needed

SELECT Lockout RESET

Step 2: Press for 3 seconds to reset control in service mode.

48

Error Codes and Error History Display:

If there is an operating problem with the water heater, an error code number will appear on the water heater display with

“Service Needed” to the right of the “Status” indicator. The error code label is located below the water heater display and the following section in this Installation and Operating Instruction Manual explains the error codes with corrective actions to repair the water heater.

Example of Error Code in the Display: idle

Service Needed

SELECT SET

Error Code History:

In “Service Mode” pressing the “Select” button after the “Software Version” (item 8 in the previously described sequence of service modes) will show an error code history, if there have been any previous operating problems with the water heater. If the display shows --, there is not a current error code.

The Water Heater Display will provide up to 10 previous error codes. The oldest error code will be stored in code index

#1 and the most recent in code index #10 (if there are 10 error codes).

To view previous error codes:

Step 1:

In “Service Mode” press the “Select” button until the next display after the “Software Version”. If there are no current error codes, the display will show -- .

No Current Error Code



SELECT idle

Status Operational

°F

SET

49

Step 2:

Press the “Temperature Down” button to select the error code index, starting with the most recent error code “10”.

Error Code Index

idle

Status Operational

SELECT SET



Step 3:

Press the “Select” button to view the error code for “code 10”. If there is a number displayed, note what the number is.

The label next to the water heater display will identify the code number. If no number is displayed with only a “--“ in the water heater display, then there has not been an error code for error code index 10.

No Error Code Shown for Code Index 10



SELECT idle

Status Operational

SET

50

Step 4:

Press the “Temperature Down” button to change to the previous code index, code #9.

Error Code Index

idle

Status Operational

SELECT SET



Step 5:

Press the “Select” button for code index #9 to view if there are any code numbers.

Stored Error Code

For Code Index #9



SELECT idle

Status Operational

SET

51

Step 6:

Continue pressing the “Temperature Down” button to change to the next error code index and press “Select” to view the error code number, if any, for that index number. Continue on to index #1, the oldest error code index. The water heater display will store up to 10 error codes with the oldest code starting in code index #1 with the most recent code in code index #10.

Step 7: 10 seconds after the last button press, the Water Heater Display will revert back to the current error code display.

To exit Service Mode, either wait 30 seconds or press Temperature Up button and Select Button for 3 seconds.

6

4

2

29

Error

Code idle

°F

Operational setpoint

Status

SET





SELECT

Exiting Service Mode

DIAGNOSTIC ERROR CODES AND TROUBLESHOOTING PROCEDURES FOR HONEYWELL INTEGRATED

CONTROLS (PDV AND INDUCED DRAFT MODEL SERIES)

Definition of Code Cause of Problem and Actions Taken to Correct

Low Flame Sense

Current

Pressure Switch

Failed to Open (Stuck

Closed)

Pressure Switch

Failed to Close

Determine flame sense current in the Service Mode with the water heater operating. If less than 1.0 microamps, check pilot flame sense rod and wire.

Clean flame sense rod with emery cloth. If problem is not solved, replace pilot.

The pressure switch contacts did not return back to the normally open position at the end of the last heating cycle. The control checks to make sure the pressure switch is in the normally open position before allowing the blower to start the ignition sequence. Check to make sure the pressure switch tubing is not blocked.

If the pressure switch tubing is clear, replace the pressure switch.

The pressure switch contacts did not close after the blower was energized. Check to make sure the blower is energized at the beginning of the heating cycle. If the blower did not start, check to make sure there is power to the motor. Replace blower or control board if defective. Check to make sure the venting system is not blocked. Make sure the vent length does not exceed the specified limits. Make sure the vent terminal is not blocked. Check to make sure the pressure switch tubing is clear. Replace the pressure switch if the venting system has checked out

O.K. Control will reset once problem is corrected.

Flame Sensed Out of

Normal Sequence

(Before Opening Gas

Valve or After Closing

Gas Valve)

Check to make sure gas valve has closed. No voltage should be present at the gas valve before or after ignition cycle. Make sure wire positions on the wire harness are correct. If gas valve is stuck open, replace.

52

Error

Code

23

24

31

32

57

58

59

61

62

63

64

65

Definition of Code Cause of Problem and Actions Taken to Correct

Flame Detected

Before Ignition

Flame Detected After

Heating Cycle

Completes

Upper Sensor

Readings Faulty

Lower Sensor

Readings Faulty

Flame Rod Shorted to Ground

Check to make sure gas valve has closed. No voltage should be present at the gas valve before the ignition cycle. Make sure wire positions on the wire harness are correct. If gas valve is stuck open, replace.

Check to make sure gas valve has closed. No voltage should be present at the gas valve before the ignition cycle. Make sure wire positions on the wire harness are correct. If gas valve is stuck open, replace.

Resistance of upper sensor out of operating range. Check continuity of wire harness to upper sensor, and if O.K., replace upper sensor.

Resistance of lower sensor out of operating range. Check continuity of wire harness to lower sensor, and if O.K., replace lower sensor.

Pilot flame sensor rod is shorted to ground. Check to see if flame sensor wire has bare spots touching metal parts of if flame sensor rod is touching the pilot shield or other metal parts. Replace pilot if flame sense wire is damaged or flame rod is bent. Make sure pilot shield is not touching the pilot flame sensor.

AC Line Frequency

Error – Signal Too

Noisy or Frequency

Incorrect

Line Voltage Too Low or High

DC Output Voltage

Unstable

Maximum Number of

Retries Detected

Check line voltage frequency to the water heater. Determine if there are wide fluctuations. Call an electrician if the problem persists. The water heater should be on a separate line.

Check line voltage to the water heater. Determine cause of low or high voltage.

Call an electrician or your utility. The water heater should be on a separate line.

Check line voltage to the water heater for erratic readings. Also check wiring to make sure there are no shorts. If power supply and wiring are O.K., replace control board.

Pilot is either not lighting or not staying lit during ignition cycle. Check inlet gas pressure for minimum pressure on rating label. Is pilot electrode sparking? Check gas valve wire harness for broken wires or shorts. If 24 volts is present between

PV and PV/MV terminals at the gas valve, replace gas valve. Check for voltage output to the yellow and red gas valve wires on the control board pins. If during the ignition trial period, there is no voltage present at the control board pin terminal for the red and yellow wires leading to the gas valve, then replace the control board. Replace pilot if wires are damaged or electrode is damaged.

Maximum Number of

Ignition Recycles

Detected

Pilot flame is lost during run cycle, then restablished on ignition cycle. Check inlet gas pressure. Is gas pressure dropping below the minimum operating pressure on the rating label after the main gas valve opens? Is the gas pipe size to the water heater adequate? Check the pilot shield position and condition of the burners.

Clean or replace as needed. Check the pilot flame and observe the microamp output on the run cycle. Check the pilot tubing to the pilot and replace if crimped or damaged. Replace pilot if wires, flame sensor, or electrode is damaged.

Electronics Failure Replace control board.

Water temperature in tank has exceeded 200˚F. Check lower sensor. Make sure

High Water

Temperature (Over

200˚F) sensor is fully inserted into the well (clip on sensor wire secures sensor in place).

Check lower and upper (where used) sensor readings. If not within specifications, replace sensor. If sensor and wire harnesses check O.K., replace control board.

53

Procedure for Checking Thermostat Sensors

Set the thermostat above water temperature (See temperature adjustment section) and observe system through one (1) complete cycle. Make sure system operates as desired.

To check the upper sensor or lower sensor assembly, compare the resistance of the sensor terminals (blue leads for upper sensor, yellow and black lead for lower sensor) as measured by an ohmmeter to the water temperature as measured by an accurate thermometer. Thermistor resistance increases as the temperature decreases. The tables below show the correct sensor resistance at various temperatures. Replace the sensor if the ohm reading in the chart does not approximate the reading from the sensor at the temperature measured in the tank.

In Degrees F

°F 0 1 2 3 4 5 6 7 8 9

40 26109 25400 24712 24045 23399 22771 22163 21573 21000 20445

50 19906 19383 18876 18383 17905 17440 16990 16553 16128 15715

60 15314 14925 14548 14180 13823 13477 13140 12812 12494 12185

70 11884 11592 11308 11032 10763 10502 10248 10000 9760 9526

80 9299 9078 8862 8653 8449 8250 8057 7869 7685 7507

90 7333 7165 7000 6839 6683 6531 6383 6238 6098 5961

100 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767

110 4663 4562 4464 4368 4274 4183 4094 4006 3922 3839

120 3758 3679 3602 3527 3453 3382 3312 3244 3177 3112

130 3048 2986 2925 2866 2808 2752 3697 3643 2590 2538

140 2488 2439 2391 2344 2298 2253 2209 2166 2124 2083

150 2043 2004 1966 1928 1891 1856 1820 1786 1753 1720

160 1688 1656 1625 1595 1566 1567 1509 1481 1454 1427

170 1402 1376 1351 1327 1303 1280 1257 1235 1213 1191

180 1170 1150 1129 1110 1090 1071 1053 1035 1017 999

190 982 965 949 933 917 901 886 871 857 842

200 828 814 801 788 775 762 749 737 725 713

In Degrees C

°C 0 1 2 3 4 5 6 7 8 9

0 32648 31026 29495 28049 26682 25389 24166 23010 21915 20879

10 19898 18968 18088 17253 16461 15710 14998 14322 13680 13071

20 12492 11942 11419 10922 10450 10000 9572 9165 8778 8409

30 8057 7722 7403 7099 6808 8532 6268 6016 5775 5546

40 5327 5117 4917 4726 4543 4368 4201 4042 3889 3742

50 3602 3468 3340 3217 3099 2986 2878 2774 2675 2579

60 2488 2400 2316 2235 2157 2083 2011 1942 1876 1813

70 1752 1693 1637 1582 1530 1480 1432 1385 1340 1297

80 1256 1216 1177 1140 1105 1070 1037 1005 974 944

90 916 888 861 835 810 786 763 741 719 698

54

SECTION XII: PARTS LIST

8” (20.3 cm) VENT KIT

55

REPLACEMENT PARTS LIST FOR POWERED DIRECT VENT

MODELS

Contact your supplier, plumbing professional or the company listed on the rating plate of the water heater for replacement parts.

Provide the part name as well as the model and serial number(s) of the water heater(s) when ordering parts. When applicable, the following information must be provided: type of gas, voltage and amperage, item number (from the following list) and description (from the following list).

PART NAME AND DESCRIPTION

1. Induced Draft Blower Assembly

2. Diptube

3. Pressure Switch

4. T&P Valve

5. Flue Baffle

6. Cleanout Access (Jacket) Cover

7. Drain Valve

8. Cleanout Cover

8a. Cleanout Cover O-Ring

8b. Cleanout Cover Gasket

9. Main Burner Tubes

10. Pilot Assembly

11. Pilot Supply Tube (Control Side)

12. Pilot Supply Tube (Burner Side)

13. Main Burner Manifold

14. Gas Valve

15. Main Burner Orifice

16. Transformer

17. Integrated control board

18. On/Off Switch

19. Temperature Display

20. Utility Cover

21. Anode Rods (Not Pictured)

22. Tank Leg Thermal Break

23. Blower Wiring harness

24. Secondary T’former Wire Assy

25. Primary T’former Wire Assy

26. Power Cord Wiring Harness

27. Control/Gas Valve Harness

28. Lower Sensor

29. Upper Temperature Sensor

30. Lower Sensor Retaining Clip

31. Outlet Nipple

32. Collector Head

33. Pilot Shield

34. Combustion Air Intake Pipe

35. Pressure Switch Cover

36. Burner Access Panel

37. Sight Glass

38. Sight Glass Backing Plate

39. Sight Glass Gasket

40. Gas Manifold Flange

41. Pressure Tube

42. Hose Barb

43. Pressure Tube Retaining Nut

44. Collector Transition

45. Blower Transition

46. Vent Adapter

47. Rubber Grommet

48. Sealing Flange Gasket

49. Combustion Air Transition

50. Lower Thermostat Well

51. Upper Sensor Wire Harness

52. Pressure Switch Wire Harness

56

`

SECTION XIII: INSTALLATION FOR POTABLE WATER AND SPACE HEATING

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:

GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING

1. All piping components connected to this water heater for space-heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet.

2. Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space heating.

3. This water heater must not be connected to an existing heating system or component(s) previously used with a nonpotable water heating appliance.

4. When the system requires water for space heating at temperatures higher than required for other uses, such as an

ASSE approved mixing valve must be installed to temper the water for those uses in order to reduce the scald hazard potential.

Please refer to the illustrations below and on the following pages for suggested piping arrangements.

Suggested Piping Arrangement For Side Connections

57

`

Suggested Piping Arrangement For Top & Side Connections

Suggested Piping Arrangement For Top Connections

58

SECTION XIV: NOTES

59

NOTES

60