Installation and Operating Manual
RESIDENTIAL GAS WATER HEATERS
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1210
322151-001
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE
GENERAL SAFETY
INTRODUCTION
2
3
4
6
Qualified Installer Or Service Agency . . . . . . . . . . . . 6
Preparing For The Installation . . . . . . . . . . . . . . . . . . 6
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS
TYPICAL INSTALLATION
7
9
Get To Know Your Water Heater - Gas Models
(List Referencing Figures 1-7). . . . . . . . . . . . . . . . . . 9
Replacement Parts And Deliming Products . . . . . . 10
Combo Heating Inlet And Outlet Side Taps . . . . . . . 10
Water Piping - Mixing Valve Usage . . . . . . . . . . . . . .11
Mixing Valves
Water Heater Operation . . . . . . . . . . . . . . . . . . . . . 12
Electrical Requirements & Wiring Diagram . . . . . . . 13
SAFETY LOCKOUTS
14
High Limit Controls (TCO) . . . . . . . . . . . . . . . . . . . . 14
Thermostat/Water Temperature
Blower High Limit Switch
Blower Air Pressure Switch . . . . . . . . . . . . . . . . . . . 14
Flammable Vapor Sensor . . . . . . . . . . . . . . . . . . . . 14
LOCATING THE NEW WATER HEATER
15
Facts To Consider About The Location . . . . . . . . . . 15
Storage Of Flammable Liquids . . . . . . . . . . . . . . . . 15
Clearances To Combustibles
Floors With Carpeting
Clearance For Servicing
Important Notes And Warnings
Venting Terminations And Sizing
Vent Screen Installation
Calculating Equivalent Feet
Venting Instructions
Vent Pipe Connection To Blower
Different Coupling Installations According To Vent Sizes
Blower Exhaust Direction . . . . . . . . . . . . . . . . . . . . 35
Vent Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . 35
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 38
LIGHTING INSTRUCTIONS
OPERATING THE TEMPERATURE
CONTROL SYSTEM
INSTALLING THE NEW WATER HEATER
17
17
17
17
17
18
18
18
19
20
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Space Heating And Potable Water Systems . . . . . . 20
Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
System Requirements
Installation
Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 22
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 22
Temperature-Pressure Relief Valve. . . . . . . . . . . . . 23
T&P Valve Discharge Pipe Requirements:
Temperature-Pressure Relief Valve And Pipe Insulation
High Altitude Installation . . . . . . . . . . . . . . . . . . . . .
Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sediment Traps/Dirt Leg . . . . . . . . . . . . . . . . . . . . .
Filling The Water Heater . . . . . . . . . . . . . . . . . . . . .
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Termination Clearances Sidewall Power Vent. . . . .
Blower Assembly Installation. . . . . . . . . . . . . . . . . .
Installation Of Vent System . . . . . . . . . . . . . . . . . . .
Planning The Vent System . . . . . . . . . . . . . . . . . . .
High Ambient Temperature Installations . . . . . . . . .
24
24
25
26
26
27
28
28
28
28
39
40
Gas Control Valve/Thermostat . . . . . . . . . . . . . . . . 41
FOR YOUR INFORMATION
42
Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 42
Condensate
Thermal Expansion
Closed Water Systems
Smoke/Odor
Strange Sounds
Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 42
Smelly Water
“Air” In Hot-water Faucets . . . . . . . . . . . . . . . . . . . . 43
High Water Temperature Shut-off System. . . . . . . . 43
PERIODIC MAINTENANCE
Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . .
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .
Unconfined Space. . . . . . . . . . . . . . . . . . . . . . . . . .
Unusually Tight Construction . . . . . . . . . . . . . . . . .
Confined Space. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Vent Appliances . . . . . . . . . . . . . . . . . . . . . .
Exhaust Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fresh Air Openings For Confined Spaces. . . . . . . .
Chemical Vapor Corrosion . . . . . . . . . . . . . . . . . . .
2
Polypropylene Vent Systems . . . . . . . . . . . . . . . . . 29
Condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting System Inspection . . . . . . . . . . . . . . . . . . .
Blower Maintenance . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning The Blower. . . . . . . . . . . . . . . . . . . . . . . .
Burner Operation And Inspection . . . . . . . . . . . . . .
Combustion Chamber And Burner Cleaning . . . . . .
Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anode Rod Inspection. . . . . . . . . . . . . . . . . . . . . . .
Anode Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
44
44
44
44
45
46
46
46
46
Removing Anode Rod:
Installing Anode Rod:
Temperature-Pressure Relief Valve Test . . . . . . . . . 47
Draining And Flushing . . . . . . . . . . . . . . . . . . . . . . . 48
To Drain The Water Heater Storage Tank:
To Flush The Water Heater Storage Tank:
LEAKAGE CHECKPOINTS
49
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REFERENCE PARTS LISTING
TROUBLESHOOTING GUIDELINES
50
52
Resetting The Heater Control . . . . . . . . . . . . . . . . . 54
TCO Resettable Lockout. . . . . . . . . . . . . . . . . . . . . 54
Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Soft Lockout
Hard Lockout
Ignition State And Timing . . . . . . . . . . . . . . . . . . . . 55
System Status And Error Codes . . . . . . . . . . . . . . . 55
LIMITED WARRANTY
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58
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use or service this water heater.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or injury.
WARNING
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could
result in property damage
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message
and how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects or other reproductive harm and requires businesses to warn
of potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.
This appliance can cause low level exposure to some of the substances listed in the Act.
IMPORTANT DEFINITIONS
Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this
Installation and Operating manual.
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air
supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code
as it relates to the installation of gas fired water heaters. The service agency must also have a thorough understanding
of this Installation and Operating manual, and be able to perform repairs strictly in accordance with the service guidelines
provided by the manufacturer.
Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances
within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping
up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service
and inspection of appliances within the building.
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3
GENERAL SAFETY
4
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GENERAL SAFETY
DANGER
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with codes.
• Do not operate water heater if flood damaged.
• For operation above 10,100’ (3,079 m), a high
altitude orifice must be installed.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake with
insulating jacket.
FLAMMBLE
Flammable Vapors
• Do not obstruct blower air intake.
• Do not place chemical vapor emitting products
near water heater.
• Gas and carbon monoxide detectors are
available.
• No vent damper installation is compatible with
this power vented water heater.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
Vapors from flammable
liquids may explode and
catch fire causing death or
severe burns.
Do not use or store
flammable products such as
gasoline, solvents or adhesives in the same room or
area near the water heater.
Keep flammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
4. out of children's reach.
Water heater has a main
burner and hot surface igniter.
The hot surface igniter:
1. can be triggered at any
time and
2. the hot surface will ignite
flammable vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the floor
and
4. can be carried from other
rooms to the the
electodes by air currents.
Installation: Do not install the water heater where flammable
products will be stored or used.
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5
INTRODUCTION
Thank You for purchasing this water heater. Properly
installed and maintained, it should give you years of trouble
free service.
Abbreviations found in this Installation and Operating
manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
• UL - Underwriters Laboratories Inc.
• AHRI - Air Conditioning, Heating and Refrigeration
Institute.
This gas-fired water heater is design certified by CSA
International, under Water Heater Standard ANSI
Z21.10.1 • CSA 4.1 (current edition).
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by
ANSI below) in the field involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical
supply are required in addition to electrical testing skills
when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in
person or through a representative is engaged in and is
responsible for (a) the installation, testing or replacement
of gas piping or (b) the connection, installation, testing,
repair or servicing of appliances and equipment; that
is experienced in such work; that is familiar with all
precautions required and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualified (as defined by ANSI above) and
licensed or certified as required by authority having
jurisdiction to perform a given task, do not attempt to
perform any of the procedures described in this manual.
If you do not understand the instructions given in this
manual do not attempt to perform any procedures outlined
in this manual.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety Information” section of this
manual first and then entire manual carefully. If you
don’t follow safety rules, the water heater will not
operate properly. It could cause DEATH, SERIOUS
BODILY INJURY AND/OR PROPERTY DAMAGE.
This manual contains instructions for installation,
operation, and maintenance of the gas-fired water
heater. It also contains warnings throughout the
manual that you must read and be aware of. All
warnings and instructions are essential to proper
operation of the water heater and your safety. Since
6
we cannot put everything on the first few pages,
READ ENTIRE MANUAL BEFORE ATTEMPTING TO
INSTALL OR OPERATE THE WATER HEATER.
2. The installation must conform with these
instructions and local code authority having
jurisdiction. In absence of local codes, installation
must comply with current editions of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and
National Electrical Code, NFPA 70. All documents
are available from:
CSA International,
8501 East Pleasant Valley Road,
Cleveland, Ohio, United States
44131-5575.
NFPA documents are also available from:
National Fire Protection Association,
1 Batterymarch Park,
Quincy, MA 02269.
3. The water heater, when installed, must be electrically
grounded in accordance with the local codes or in the
absence of local codes: the National Electrical Code
(NFPA 70).
4. If after reading this manual you have any questions or
do not understand any portion of the instructions, call
the local gas utility or the manufacturer whose name
appears on the rating plate.
5. Carefully plan the place where you are going to put
the water heater. Correct combustion, vent action, and
vent pipe installation are very important in preventing
death from possible carbon monoxide poisoning and
fires (see Figures 15 & 16). Examine the location to
ensure the water heater complies with the “Locating
the New Water Heater” section in this manual.
6. For installation in California, 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:
California Office of the State Architect,
400 P Street,
Sacramento, CA 95814.
7. Massachusetts Code requires this water heater to be
installed In accordance with Massachusetts 248CMR 2.00: State Plumbing Code and 248-CMR
5.00.
8. Complies with California Health and Safety code
116875 (known as AB-1953) and with weighted
average maximum of 0.25% lead.
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INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters
installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned
or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above
finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall
be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated
or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or
structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner
to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and
be ANSI/ UL 2034 listed and CSA certified.
SIGNAGE
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign shall read, in print size no less than one- half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with
the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS
The following equipment is exempt from 248 CMR 5.08(2) (a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from
the dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system
design or venting system components with the equipment, the instructions provided by the manufacturer for installation
of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by
the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
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7
INSTALLATION GRAPHIC: GAS-FIRED POTABLE
WATER HEATING/SPACE HEATING SYSTEM
•
If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following
graphic during installation and during modifications to the water supply system.
TYPICAL MIXING VALVE INSTALLATION
COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM
EXPANSION TANK
TEMPERED WATER
TO FIXTURES
(MUST MEET TEMPS LISTED
IN MASS. CODE 248 CMR † )
CHECK
VALVE †
COLD WATER INLET
CHECK VALVE †
(1/8” HOLE
DRILLED IN CLAPPER)
VACUUM
RELIEF
VALVE
SHUT-OFF
VALVE
FLOW CONTROL
VALVE
UNION
HOT
WATER
OUT
OUT
SEE
NOTE ‡
SHUT-OFF
VALVE *
IN
COIL
TO
AIR
HANDLER
WATER HEATER ACCEPTED
BY THE BOARD FOR
INSTALLATION IN
MASSACHUSETTS. †
*
PUMP *
TEMP/
PRESSURE
RELIEF
VALVE
MUST BE VERTICAL TO
REMOVE AIR BUBBLES
MIXING VALVE
(MUST BE INSTALLED BELOW
TOP OF WATER HEATER
AS PER MANUFACTURER’S
RECOMMENDATIONS)
UNION
AIR
HANDLER
100’-0” MAXIMUM DISTANCE
FROM WATER HEATER TO FAN
COIL AND BACK. (DEVELOPED
LENGTH) NOT INCLUDING COIL
IN HEATING UNIT †
MASSACHUSETTS INSTALLATION REQUIREMENTS:
1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS
FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.
2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR
& 780 CMR).
3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.
8
†
REQUIRED FOR MASSACHUSETTS.
‡
PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS (list referencing Figures 1-7)
1. Vent Termination Elbow with Rodent
Screen
2. *Vent Pipe
3. *Vent Pipe Coupling (if required)
4. *Vent Pipe Elbow (long radius)
5. Blower High Limit Switch (see Figure
6)
6. T&P Valve
7. Cold-Water Inlet Nipple/Diptube
8. Baffle Assembly
9. * Discharge Pipe
10. Gas Control Valve/Thermostat
(Honeywell)
11. Gas Valve Electronic Control Module
And Cover (Honeywell)
12. Drain Valve
13. Outer Gas Door
14. Manifold Door Assembly (behind
outer door) (see Figures 3 & 4)
15. *Floor Drain
16. *Metal Drain Pan
17. Flammable Vapor Sensor (under
cover) (see Figure 5)
2
1
3
4
18. **Combo Heating System Return
Inlet (Optional)
19. Air Inlet Snorkel
20. **Combo Heating System Supply
Outlet (Optional)
21. Blower with Power Cord (see also
Figure 6)
22. Air Switch (inside box) (see Figure
6)
23. Junction Box (see Figure 6)
24. Junction Box Cover (see Figure 6)
25. Air Tubing (see Figure 6)
26. Rubber Coupling (see also Figure
6)
27. Gear Clamp (see also Figure 6)
28. Flue Collector
29. Hot-Water Outlet Nipple
30. Anode (under cap)
31. ***Control Harness
32. Flexible Manifold Tube (see Figures
3 & 4)
33. Viewport (see Figures 3 & 4)
27
34. Flame Sensor Rod (see Figures 3 &
4)
35. Gas Orifice (see Figures 3 & 4)
36. Sheet Metal Burner (see Figures 3 &
4)
37. Gas Manifold (see Figures 3 & 4)
38. Hot-Surface Igniter (see Figures 3 &
4)
39. Manifold Door Gasket (see Figures 3
& 4)
40. Manifold Door (see Figures 3 & 4)
41. Two Piece Grommet With Clip (see
Figures 3 & 4)
42. *Inlet Water Shut-off Valve
43. *Gas Supply*
44. *Main Manual Gas Shut-off Valve
45. *Ground Joint Union (gas
connection)
46. *Sediment Trap/Dirt Leg
47. *Union (water connection)
48. Rating Plate
49. *Thermal Expansion Tank (required
for all closed systems)
*, **, ***, **** see notes on following
page
42
27
26
49
6
21
7
48
30
7
9
10 11
8
Blower
Dilution Air
Inlets
Combustion
Air Inlets
18
43
44
19
31
45
12
46
32
13 14
17
16
29
28
20
21
47
47
15
Front View
Figure 1
Rear View
Figure 2
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9
Natural gas and Propane main
burner with igniter assembly for
40k to 50k Btu/hr models
22
25
26
23
34
35
32
27
24
36
37
21
38
33
39
41
5
Figure 6
Vacuum relief valve
install per local
codes (not supplied
with heater).
40
Figure 3
Natural gas and Propane
main burner with igniter
assembly for 60k to 75k
Btu/hr models
32
Figure 7
34 35
36
37
38
33
39
41
Figure 4
40
Notes:
* Items not supplied with the water heater.
** The side recirculation loop connections may not be
used as the primary water inlet and outlet connections.
See “Combo Heating Inlet And Outlet Side Taps”
below.
*** Caution harness has 120 VAC In operation.
**** See “Planning The Vent System”, “Condensate” and
“Blower Assembly Installation” for more information.
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be
ordered through authorized servicers or distributors. When
ordering parts, provide complete model and serial numbers
(see rating plate), quantity and name of part desired.
Standard hardware items may be purchased locally.
COMBO HEATING INLET AND OUTLET SIDE TAPS
Models equipped with Combo Heating capabilities are
shipped with the two side plumbing taps OPEN (items
18 and 20 in Figure 1 and see also Figures 8 & 26). If
the heater is to be operated without using the side taps,
these openings must be closed with the two pipe plugs
supplied with the heaters.
17
Figure 5
10
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WATER PIPING - MIXING VALVE USAGE
Mixing Valves
DANGER
Water temperature over
125°F (52°C) can cause
severe burns instantly
resulting in severe injury or
death.
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
HOT
BURN
Temperature limiting devices
such as mixing must be
installed when required by
codes and to ensure safe
temperatures at fixtures.
Water heated to a temperature which satisfies space
heating, clothes washing, dish washing, and other
sanitizing needs can scald and cause permanent injury
upon contact. Short repeated heating cycles caused by
small hot-water uses can cause a temperature increase
of the hot water by 20F° (11C°) higher than the heater’s
temperature settings.
TEMPERED
POTABLE WATER
MIXING VALVE
SUGGESTED PlPING
ARRANGEMENT FOR
TOP CONNECTIONS
SHUT-OFF
VALVE
COLD-WATER
INLET
MASSACHUSSETTS:
INSTALL A VACUUM
RELIEF IN COLD
WATER LINE PER
SECTION 19 MGL
142.
CERTAIN
MODELS ARE
EQUIPPED WITH
SIDE PLUMBING
CONNECTIONS
FOR SPACE
HEATING. THE HOT
AND COLD FITTING
ASSEMBLlES
(PART #9001262)
CAN BE ORDERED
THROUGH THE
MANUFACTURER
TEMERATUREPRESSURE
RELIEF VALVE
are considered suitable for Water (Potable) Heating and
Space Heating. Note: Do not use in space heating only
applications.
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures.
SUGGESTED PlPING
ARRANGEMENT FOR
TOP CONNECTIONS
COLD-WATER
INLET
NON-TEMPERED
WATER RETURN
NON-TEMPERED
WATER SUPPLY
TEMERATUREPRESSURE
RELIEF VALVE
MASSACHUSSETTS:
INSTALL A VACUUM
RELIEF IN COLD
WATER LINE PER
SECTION 19 MGL
142.
DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
GAS
SUPPLY
DRAIN
VALVE
TO SUITABLE
DRAIN
6” (150mm)
MAX. AIR
GAP*
METAL DRAlN
PAN 1.75”
(45mm) MAX.
DEPTH.
AT LEAST
2” (50mm)
GREATER THAN
THE DIAMETER
OF THE WATER
HEATER.
DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
GAS
SUPPLY
DRAIN
VALVE
TO SUITABLE
DRAIN
* NOTE: THE
T&P VALVE
CAN BE PIPED
DIRECTLY TO
THE DRAIN
Figure 9
TEMPERED
POTABLE WATER
NON-TEMPERED
WATER SUPPLY
COLD-WATER
INLET
6” (150mm)
MAX. AIR
GAP*
METAL DRAlN
PAN 1.75”
(45mm) MAX.
DEPTH.
AT LEAST
2” (50mm)
GREATER THAN
THE DIAMETER
OF THE WATER
HEATER.
SHUT-OFF
VALVE
TEMPERED
POTABLE WATER
MIXING VALVE
* NOTE: THE
T&P VALVE
CAN BE PIPED
DIRECTLY TO
THE DRAIN
ALTERNATIVE PlPING
ARRANGEMENT
FOLLOW THE
MIXING VALVE
MANUFACTURER’S
INSTRUCTIONS
MASSACHUSSETTS:
INSTALL A VACUUM
RELIEF IN COLD
WATER LINE PER
SECTION 19 MGL
142.
MIXING
VALVE (SET
TO 120°F
(49°C))
Figure 8
TEMERATUREPRESSURE
RELIEF VALVE
This appliance has been design certified as complying
with American National Standard/CSA Standard for water
heaters and certain models with side plumbing connections
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DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
Figure 10
11
Some people are more likely to be permanently injured
by hot water than others. These include the elderly,
children, the infirm and the physically/mentally disabled.
Table 1 (published by U.S. Government Memorandum,
1978) shows the approximate time-to-burn relationship
for normal adult skin. If anyone using hot water provided
by the water heater being installed fits into one of these
groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special
precautions must be taken.
WATER HEATER OPERATION
Figure 11 shows the water heater’s sequence of operation
when a call for heat is initiated. The ignition control module
will attempt to light the burner three times. If the ignition
control does not detect ignition it will enter lockout mode
and flash the corresponding error code.
Time for Permanent
Burns 2nd & 3rd
Degree (Most
Severe Burns)
Water
Temperature
°F (°C)
Time for 1st
Degree Burns
(Less Severe Burns)
110 (44)
(normal shower temp.)
116 (47)
(pain threshold)
116 (47)
35 minutes
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
154 (68)
instantaneous
1 seconds
IGNITER IS ENERGIZED
AND MAIN GAS VALVE
IS OPENED
HEATER CONTROL
CHECKS TO ENSURE
BLOWER PRESSURE
SWITCH IS OPEN
Table 1
In addition to using lowest possible temperature setting
that satisfies demand of application, a mixing valve should
be installed at water heater (see Figures 8-10) or at hotwater taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores.
Consult a Qualified Installer or Service Agency. Follow
mixing valve manufacturer’s instructions for installation
of the valves. Before changing the factory setting on the
thermostat, read the “Operating The Temperature Control
System” section in this manual.
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MAIN BURNER COMES
ON AND THE FLAME IS
SENSED BY CONTROL
MAIN BURNER CONTINUES TILL THE WATER
IN THE TANK REACHES
THERMOSTAT SETTING
BLOWER IS
ENERGIZED
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)
12
HEATER
THERMOSTAT
CALLS FOR
HEAT
CONTROL CHECKS
TO ENSURE PRESSURE SWITCH CLOSES
INDICATING BLOWER
IS OPERATING AND
THERE ARE NO
VENTING BLOCKAGES
(INLET OR OUTLET)
MAIN BURNER SHUTS
OFF. BLOWER
CONTINUES FOR A
POST PURGE TIME
Figure 11
HEATER
REMAINS ON
STANDBY UNTIL
NEXT CALL FOR
HEAT
ELECTRICAL REQUIREMENTS & WIRING DIAGRAM
WARNING
Electric Shock Hazard
Disconnect power before
servicing.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN
CAUSE IMPROPER AND DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER SERVICING.
POWER VENT WIRING SCHEMATIC.
NOTE: REFER TO THE “INSTALLATION CHECKLIST”
BEFORE OPERATING THIS HEATER.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electrical shock.
1
N
1
L1
EARTH GND
CAPACITOR
Before plugging in the water heater, always make sure:
• The voltage and frequency correspond to that specified
on the water heater wiring diagram.
• The electrical outlet has the proper overload fuse or
breaker protection.
1. The unit must be connected to a dedicated power
supply.
2. The unit must be connected to a 120VAC power
supply.
3. The water heater must be properly grounded.
4. This water heater is a polarity sensitive appliance
and will not operate if the power supply polarity is
reversed.
Note: Always reference the wiring diagram for the correct
electrical connections.
6
3
5
2
4
1
P1
4
3
2
4
2
1
After making all electrical connections, completely fill the
tank with water and check all connections for leaks. Open
the nearest hot-water faucet and let it run for 3 minutes to
purge the water lines of air and sediment and to ensure
complete filling of the tank. The electrical power may then
be turned on. Verify proper operation after servicing. See
also “Installation Checklist”.
BLOWER
7
FLAME SENSOR
6
HOT SURFACE IGNITER
5
PRESSURE SWITCH
3
HIGH LIMIT SWITCH
2
FLAMMABLE VAPOUR SENSOR
P2
1
3
4
P3
P4
Circled numbers indicate
sequence of operation.
Figure 12
Figure 13
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13
SAFETY LOCKOUTS
This water heater has several lockout features designed to
prevent the heater from operating in unsafe conditions.
HIGH LIMIT CONTROLS (TCO)
Thermostat/Water Temperature
This feature is a part of the gas control valve/thermostat
(see Figure 1, item 10) and limits the maximum water
temperature. In the event of the water overheating, this
safety feature shuts off the fuel supply to the burner. If the
high limit is tripped, it requires manual resetting (see “TCO
Resettable Lockout”).
If there is a problem with the wiring of the flammable
vapor sensor or the flammable vapor interface, the LED
will flash the failure status code (see “System Status And
Error Codes”).
* ROTATE LEFT (CCW)
TO REMOVE
Blower High Limit Switch
This device is located on the blower (see Figure 6, item
5) and limits the maximum temperature of the blower.
If the blower temperature rises above the temperature
setting, the switch opens causing the heater to shut down.
The switch will auto reset once the temperature drops
sufficiently.
BLOWER AIR PRESSURE SWITCH
This device, located in the junction box, monitors the air
pressure produced by the blower. In the event that the
exhaust venting becomes blocked or sufficently restricted,
the switch will shut the heater down (see Figure 6, item
22).
FLAMMABLE VAPOR SENSOR
When using a gas fired water heater there is a risk of
flammable vapors entering the combustion chamber, being
ignited by the burner flame and causing a flashback. In
order to detect such flammable vapors before they enter
the combustion chamber, this water heater is equipped
with a flammable vapor sensor (FVS). It is a chemicalabsorption based sensor that is connected to the gas
control/thermostat (see Figure 14). When exposed to
flammable vapors it will trigger the control to stop the
flow of gas and enter the FVS lockout state. While in the
FVS lockout state the LED on the control will flash the
gas lockout code. (Refer to the “System Status And Error
Codes” section of this manual for an explanation of the
codes applicable to the control installed on your water
heater.) If this error occurs, check around the water heater
for sources of chemical contamination such as: flammable
vapors including gas vapors, solvents, paint and thinners
as well as sources of water and detergents.
Note: Resetting the heater will reset the FVIR circuit if
all sources of contamination have been removed and the
sensor clears. If all sources of contamination have been
removed and the system will not reset, the sensor will need
to be replaced (see “Resetting the Heater Control”).
14
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COVER*
MOUNTING
BRACKET
FLAMMABLE
VAPOR SENSOR
(PULL TO REMOVE)
Figure 14
LOCATING THE NEW WATER HEATER
FACTS TO CONSIDER ABOUT THE LOCATION
Carefully choose an indoor location for the new water
heater because the placement is a very important
consideration for the safety of the occupants in the building
and for the most economical use of the appliance. This
water heater is not for use in manufactured (mobile) homes
or outdoor installation.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must
be observed:
1. Select a location indoors as close as practical to the
vent termination or location to which the water heater
vent piping is going to be connected, and as centralized
with the water piping system as possible.
2. Selected location must provide adequate clearances
for servicing and proper operation of the water
heater.
3. Ensure the area has a continuous supply of air for
combustion dilution and ventilation.
4. Avoid locations that could cause the water heater to
freeze from outside air.
5. Selected location must provide access to a properly
grounded electrical branch circuit. A dedicated circuit
is preferred. Do not use a GFI outlet.
6. Avoid locations that expose the water heater to direct
sunlight.
7. Keep combustibles such as boxes, magazines,
clothes, etc., away from the water heater area.
Important: Do not use an extension cord to connect the
water heater to an electrical outlet.
Important: this heater has special venting requirements
when installed in areas where the ambient temperatures
exceed 110°F (43°C) (see “High Ambient Temperature
Installaions”).
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
Installation of the water heater must be accomplished
in such a manner that if the tank or any connections
should leak, the flow of water will not cause damage to
the structure. For this reason it is not advisable to install
the water heater in an attic or upper floor. In all cases, a
metal drain pan should be installed under the water heater.
Metal drain pans are available at your local hardware store.
Such a metal drain pan must have a clearance of at least
1” (2.5cm) greater than any point on the water heater’s
outer jacket and must be piped to an adequate drain. The
pan must have a maximum depth of 1.75” (4.5cm).
Water heater life depends upon water quality, water
pressure and the environment in which the water heater
is installed. Water heaters are sometimes installed in
locations where leakage may result in property damage,
even with the use of a metal drain pan piped to a drain.
However, unanticipated damage can be reduced or
prevented by a leak detector or water shut-off device used
in conjunction with a piped metal drain pan. These devices
are available from some plumbing supply wholesalers
and retailers, and detect and react to leakage in various
ways:
• Sensors mounted in the metal drain pan that trigger an
alarm or turn off the incoming water to the water heater
when leakage is detected.
• Sensors mounted in the metal drain pan that turn off
the water supply to the entire building when water is
detected in the metal drain pan.
• Water supply shut-off devices that activate based on
the water pressure differential between the cold-water
and hot-water pipes connected to the water heater.
• Devices that will turn off the gas supply to a gas water
heater while at the same time shutting off its water
supply.
STORAGE OF FLAMMABLE LIQUIDS
Flammable liquids (such as gasoline, solvents, propane
(LP or butane, etc.) and other substances (such as
adhesives, paints, etc.) emit flammable vapors which can
be ignited by a gas water heater’s hot surface igniter (HSI)
or main burner. The resulting flashback and fire can cause
death or serious burns to anyone in the area.
This water heater is equipped with a FV (Flammable Vapor)
sensor for detecting the presence of flammable vapors.
When the sensor detects those vapors, the unit will shut
down and not operate. Should this happen, please refer
to the “Troubleshooting Guidelines” section of this manual.
Even though this water heater is a flammable vapors
ignition resistant (FVIR) water heater and is designed to
reduce the chances of flammable vapors being ignited,
gasoline and other flammable substances should never
be stored or used in the same vicinity or area containing a
gas water heater or other open flame or spark producing
appliance. Examples of such locations are garages,
storage and utility areas.
The water heater must be located and/or protected so it is
not subject to physical damage by a moving vehicle.
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15
Clearance for servicing
Adequate clearance of 24” (61cm) for servicing this
appliance should be considered before installation, such
as changing the anodes, etc.
WARNING
Fire or Explosion Hazard
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
A minimum clearance of 5.5” (14cm) must be allowed for
access to replaceable parts such as thermostats, drain
valve and relief valve.
When installing the heater, consideration must be given to
proper location. Location selected should be as close to
the wall as practicable and as centralized with the water
piping system as possible.
Read instruction manual before
installing, using or servicing
water heater.
TOP VIEW
OF CLOSET
WITHOUT DOOR
AIR INTAKE*
TOP VIEW OF
CLOSET WITH
DOOR
0” MIN.
WARNING
0” MIN.
0” MIN.
5.5” (14cm)
MIN.
* DO NOT BLOCK THE AIR INTAKES AT THE BACK OF THE WATER HEATER.
FLAMMABLES
Flammable Vapors
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance. Storage or
use of gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in serious injury
or death.
WARNING
Figure 15
A gas water heater cannot operate properly without the
correct amount of air for combustion and ventilation. Do
not install in a confined area such as a closet unless you
provide air as shown below and described in the “Air
Requirements” section (see Figure 16). Never obstruct the
flow of ventilation air for dilution and combustion. If you
have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amount of combustion air
can result in a fire or explosion and cause death, serious
bodily injury, or property damage.
WARNING
Fire Hazard
For continued protection against
risk of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
Clearances to combustibles
Minimum clearances between water heater and
combustibles are 0” at the sides and rear, 5.5” (14cm) from
the front and 12” (300mm) from top (standard clearance.)
If clearances stated on the heater differ from standard
clearances, install water heater according to clearances
stated on the heater (see Figure 15).
Breathing Hazard - Carbon Monoxide Gas
• Install water heater in accordance with the
instruction manual and NFPA54.
• To avoid injury, combustion and ventilation air
must be taken from outdoors.
• Do not place chemical vapor emitting products
near water heater.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
FLAMMABLE
Floors with carpeting
This water heater must not be installed directly on
carpeting. Carpeting must be protected by a metal or wood
panel beneath the appliance extending beyond the full
width and depth of the appliance by at least 3” (76mm) in
every direction, or if the appliance is installed in an alcove
or closet, the entire floor must be covered by the panel.
Failure to heed this warning may result in a fire hazard.
16
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Figure 16
If this water heater will be used in beauty shops, barber
shops, cleaning establishments, or self-service laundries
with dry cleaning equipment, it is imperative that the water
heater or water heaters be installed so that combustion
and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
react to form corrosive hydrochloric acid when exposed to
the combustion products of the water heater. The results
can be hazardous, and also cause product failure.
INSULATION BLANKETS
Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary
with these products. The purpose of an insulation blanket
is to reduce standby heat loss encountered with storage
tank heaters. Your water heater meets or exceeds
the current standards with respect to insulation and
standby loss requirements, making an insulation blanket
unnecessary.
Should you choose to apply an insulation blanket to
this heater, you should follow these instructions (For
identification of components mentioned below, see Figures
1-7). Failure to follow these instructions will restrict the air
flow required for proper combustion and dilution, potentially
resulting in fire, asphyxiation, serious personal injury or
death.
• Do not apply insulation to the top of the water heater,
•
•
•
•
as this will interfere with safe operation of the blower
assembly.
Do not cover the outer door, thermostat or T&P relief
valve, FV sensor, or Air Intake Snorkel.
Do not cover the “Installation And Operating manual”.
Keep it on the side of the water heater or nearby for
future reference.
Do obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over
the existing labels.
Do inspect the insulation blanket frequently to make
certain it does not sag, thereby obstructing combustion
air flow.
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Do not obstruct water heater air intake(s) with
insulating jacket.
• Gas and carbcn monoxide detectors are available.
• Install water heater in accordance with the
instruction manual and NFPA54.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
AIR REQUIREMENTS
For safe operation an adequate supply of fresh,
uncontaminated air for combustion dilution and ventilation
must be provided.
Note: Contaminated or dusty air may cause build-up on
the blower wheel resulting in nuisance shut downs.
An insufficient supply of air can cause recirculation of
combustion products resulting in contamination that may
be hazardous to life. Such a condition often will result in
a yellow, luminous burner flame, causing sooting of the
combustion chamber, burners and flue tubes and creates
a risk of asphyxiation.
Do not install the water heater in a confined space unless
an adequate supply of air for combustion dilution and
ventilation is brought into that space using the methods
described in the “Confined Space” section that follows.
Never obstruct the flow of dilution/ventilation air. If you
have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amounts of air can result in
a fire or explosion and cause property damage, serious
bodily injury or death. The combustion and dilution air
inlets are shown in Figure 2.
Important: Power Vented water heaters require air for
combustion and dilution air for the blower.
UNCONFINED SPACE
An Unconfined Space is one whose volume is not less
than 50 cubic feet per 1,000 Btu/hr (4.8m3/kW) of the
total input rating of all appliances installed in the space.
Rooms communicating directly with the space in which the
appliances are installed, through openings not furnished
with doors, are considered a part of the unconfined
space.
Makeup air requirements for the operation of exhaust
fans, kitchen ventilation systems, clothes dryers and
fireplaces should also be considered in determining the
adequacy of a space to provide combustion, ventilation
and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconfined spaces in buildings, infiltration may be
adequate to provide air for combustion, ventilation and
dilution of flue gases. However, in buildings of unusually
tight construction (e.g., weather stripping, heavily
insulated, caulked, vapor barrier, etc.) additional air must
be provided using the methods described in the “Confined
Space” section that follows.
CONFINED SPACE
A Confined Space is one whose volume is less than 50
cubic feet per 1,000 Btu/hr (4.8m3/kW) of the total input
rating of all appliances installed in the space.
Openings must be installed to provide fresh air for
combustion, ventilation and dilution in confined spaces.
The required size for the openings is dependent on the
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17
method used to provide fresh air to the confined space
and the total Btu/hr input rating of all appliances installed
in the space.
DIRECT VENT APPLIANCES
Other appliances installed in a Direct Vent configuration
that derive all air for combustion from the outdoor
atmosphere through sealed intake air piping are not
factored in the total appliance input Btu/hr calculations
used to determine the size of openings providing fresh
air into confined spaces.
EXHAUST FANS
Where exhaust fans are installed, additional air should be
provided to replace the exhausted air. When an exhaust
fan is installed in the same space with a water heater,
sufficient openings to provide fresh air must be provided
that accommodate the requirements for all appliances
in the room and the exhaust fan. Undersized openings
will cause air to be drawn into the room through the
water heater’s vent system causing poor combustion.
Sooting, serious damage to the water heater and the risk
of fire or explosion may result. It can also create a risk of
asphyxiation.
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions should be used to calculate the
size, number and placement of openings providing fresh air
for combustion, ventilation and dilution in confined spaces.
The illustrations shown in this section of the manual are
a reference for the openings that provide fresh air into
confined spaces only. Do not refer to these illustrations
for the purpose of vent installation. See “Installation of
Vent System” section for complete venting installation
instructions.
Figure 17
B. ALL AIR FROM OUTDOORS: (See Figures 18-20)
The confined space shall be provided with two
permanent openings, one commencing within 12”
(30cm) of the top and one commencing within
12“ (30cm) from the bottom of the enclosure. The
openings shall communicate directly, or by ducts,
with the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
1. When directly communicating with the outdoors,
each opening shall have a minimum free area of 1
square inch per 4,000 Btu/hr (5.5 cm2/kW) of total
input rating of all equipment in the enclosure (see
Figure 18).
Chemical vapor corrosion of the flue, blower assembly and
vent system may occur if the air supply contains certain
chemical vapors. Spray can propellants, cleaning solvents,
refrigerator and air conditioner refrigerants, swimming pool
chemicals, calcium and sodium chloride (water softener
salt), waxes, bleach and process chemicals are typical
compounds which are potentially corrosive.
A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 17)
The confined space shall be provided with two
permanent openings communicating directly with an
additional room(s) of sufficient volume so that the
combined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utilization
equipment installed in the combined space shall be
considered in making this determination. Each opening
shall have a minimum free area of one square inch per
1,000 Btu/hr (22 cm2/kW) of the total input rating of all
gas utilization equipment in the confined space, but not
less than 100 square inches (645cm2). One opening
shall commence within 12” (30cm) of the top and one
commencing within 12” (30cm) of the bottom of the
enclosures.
18
Figure 18
2. When communicating with the outdoors through
vertical ducts, each opening shall have a minimum
free area of 1 square inch per 4,000 Btu/hr (5.5
cm2/kW) of total input rating of all equipment in the
enclosure (see Figure 19).
3. When communicating with the outdoors through
horizontal ducts, each opening shall have a
minimum free area of 1 square inch per 2,000 Btu/hr
(11 cm2/kW)) of total input rating of all equipment in
the enclosure (see Figure 20).
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Figure 19
4. When ducts are used, they shall be of the same
cross-sectional area as the free area of the openings
to which they connect. The minimum short side
dimension of rectangular air ducts shall not be less
than 3” (76mm) (see Figure 20).
Figure 20
5. Alternatively a single permanent opening may
be used when communicating directly with the
outdoors, or with spaces that freely communicate
with the outdoors. The opening shall have a
minimum free area of 1 square inch per 3,000 Btu/hr
(8.3 cm2/kW) of total input rating of all equipment in
enclosure (see Figure 21).
Figure 21
6. Louvers and Grilles: In calculating free area,
consideration shall be given to the blocking effect
of louvers, grilles or screens protecting openings.
Screens used shall not be smaller than 1/4” (6.4mm)
mesh. If the free area through a design of louver
or grille is known, it should be used in calculating
the size opening required to provide the free area
specified. If the design and free area is not known,
it may be assumed that wood louvers will be 20-25
percent free area and metal louvers and grilles will
have 60-75 percent free area. Louvers and grilles
shall be fixed in the open position or interlocked with
the equipment so that they are opened automatically
during equipment operation.
7. Special Conditions Created by Mechanical
Exhausting or Fireplaces: operation of exhaust fans,
ventilation systems, clothes dryers or fireplaces may
create conditions requiring special attention to avoid
unsatisfactory operation of installed gas utilization
equipment.
CHEMICAL VAPOR CORROSION
CORROSION OF THE FLUEWAYS AND VENT SYSTEM
MAY OCCUR IF AIR FOR COMBUSTION CONTAINS
CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY
RESULT IN FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and
air conditioning refrigerants, swimming pool chemicals,
calcium and sodium chloride (water softener salt), waxes,
and process chemicals are typical compounds which
are potentially corrosive. Do not store products of this
sort near the heater. Also air which is brought in contact
with the heater should not contain any of the chemicals.
If necessary, uncontaminated air should be obtained
from remote or outside sources. The Limited Warranty is
voided when failure of water heater is due to a corrosive
atmosphere. See “Limited Warranty” for complete terms
and conditions.
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19
INSTALLING THE NEW WATER HEATER
WATER PIPING
DANGER
HOT
BURN
Water temperature over
125°F (52°C) can cause
severe burns instantly
resulting in severe injury or
death.
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing valves must
be installed when required
by codes and to ensure safe
temperatures at fixtures.
Read instruction manual for
safe temperature setting.
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures.
HOT WATER CAN SCALD:
Water heaters are intended to produce hot water.
Water heated to a temperature which will satisfy space
heating, clothes washing, dish washing, cleaning and
other sanitizing needs can scald and permanently injure
you upon contact. Some people are more likely to be
permanently injured by hot water than others. These
include the elderly, children, the infirm, or physically/
mentally handicapped. If anyone using hot water fits into
one of these groups or if there is a local code or state law
requiring certain temperature water at the hot-water tap,
then you must take special precautions. In addition to
using lowest possible temperature setting that satisfies
your hot water needs, a means such as a mixing valve,
should be used at hot-water taps used by these people or
at the water heater (see Figures 8-10). Valves for reducing
point of use temperature by mixing cold and hot water are
also available.
SPACE HEATING AND POTABLE WATER SYSTEMS
This appliance has been design certified as complying
with American National Standard/CSA Standard for water
heaters and are considered suitable for Water (Potable)
Heating and Space Heating. Note: Water heaters used
in combination water/space heating shall not be used in
space heating only applications.
WARNING
Toxic Chemical Hazard
Consult a Qualified Installer or Service Agency. Follow
manufacturer’s instructions for installation of valves.
Before changing the factory setting on thermostat, read
“Operating The Temperature Control System” section in
this manual.
• This water heater should not be connected to any
heating systems or components previously used with
a non-potable water heating appliance.
• All piping components connected to this unit for space
heating applications should be suitable for use with
potable water.
• Toxic chemicals, such as those used for boiler treatment
shall not be introduced into the potable water used for
space heating.
• When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a mixing valve must be installed. Please refer
to Figures 8-10 for suggested piping arrangement.
Note: Water piping and vent piping occupy the space
above the water heater. Plan the water piping to ensure
it does not cause interference with the vent piping (see
“Planning the Vent System”).
If this water heater is to be used to supply both space
heating and potable water, the instructions listed below
must be followed:
• Be sure to follow the manual(s) shipped with the air
handler or other type heating system.
• This water heater is not to be used as a replacement
for an existing boiler installation.
• Do not use with piping that has been treated with
chromates, boiler seal or other chemicals and do not
add any chemicals to the water heater piping.
• If the space heating system requires water temperatures
in excess of 120°F (49°C), a mixing valve must be
installed, per the manufacturer’s instructions, in the
potable hot-water supply to limit the risk of scald
injury.
• Pumps, valves, piping and fittings must be compatible
with potable water.
• A properly installed flow control valve is required to
prevent thermosiphoning. Thermosiphoning is the
result of a continuous flow of water through the air
handler circuit during the off cycle. Weeping (blow off)
of the temperature-pressure relief valve (T&P) or higher
than normal water temperatures are the first signs of
thermosiphoning.
• The hot-water line from the water heater should
be vertical past any mixing valve or supply line to
the heating system to remove air bubbles from the
system.
• Do not connect the water heater to any system or
components previously used with non-potable water
heating appliances when used to supply potable
water.
• Do not connect to non-potable water system.
20
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COMBO HEATING
This section serves as a guide for the installation and use
of “Combo” heating systems utilizing a domestic water
heater that has been specifically approved for such use.
It is written for those knowledgeable in the required trades
and professionals involved in the design and installation
of Combo Heating Systems.
It is the responsibility of the installer/designer to follow all
applicable codes to ensure the effectiveness and safety
of the installation.
System Requirements
The following requirements must be met for the installation
of Combo Heating Systems:
1. All components used for the distribution of water in
the heating loop must be suitable for potable water.
These include all piping, fittings, solder and fluxes,
pumps for circulation of water, valves, etc.
2. The water heater must not be connected to a hydronic
heating system that has been used previously.
3. No boiler treatment chemicals of any kind shall be
introduced into the system.
4. The Combo System components must be selected
and sized to meet and maintain the total calculated
demands for both domestic service hot water
and space heating requirement. The sizing and
installation must be performed in accordance with
good engineering practice such as “ASHRAE
Handbooks”, HRAI’s Unified Combo Guidelines,
“Hydronics Institute Manuals”, ANSI Z223.1, CSA
F280, National/Provincial Building Codes, ANSI
and/or codes having jurisdiction.
5. The air handler (fan coil) and/or the circulating pump
in a baseboard hydronic loop will require a dedicated
120V circuit. This must be provided and identified for
this purpose.
6. All piping between the water heater and the air handler
or hydronic baseboard loop must be adequately
insulated to reduce heat loss.
7. If the local jurisdiction requires a back-flow preventer
in the cold water line, an expansion tank of adequate
size must be installed.
8. “Combo” Heating Systems require higher water
temperatures than other applications. When the
system is used to supply water for Combo Heating
applications, a means, such as mixing valve, must be
installed to temper the water in order to reduce scald
hazard potential (see Figures 22 & 23).
2. Install a drain valve at the lowest point of the heating
loop so that water can be drained from the heating
module without affecting the water heater.
3. If the air handler does not have a venting means at
the highest point of the piping arrangement, install
an air bleed at the highest point of the plumbing
arrangement.
HOT WATER
TO HOUSE
FIXTURE
EXPANSION TANK
(OPTIONAL)
COLD SUPPLY
(see also
Massachussetts
code requirements
on pg 8)
CHECK VALVE (IF USED
REQUIRES EXPANSION TANK)
MIXING
VALVE
C
H
M
CHECK
COLD INLET VALVE
8 in TO
12 in MAX.
FLOW
CONTROL
HOSE BIB
(OPTIONAL)
HOT
OUTLET
EXTERNAL
CIRCULATOR
RETURN
WATER
HEATER
DRAIN/
PURGE
VALVE
SUPPLY
INTERNAL
CIRCULATOR
AIR
HANDLER
Figure 22
HOT WATER
TO HOUSE
FIXTURE
EXPANSION TANK
(OPTIONAL)
COLD SUPPLY
(see also
Massachussetts
code requirements
on pg 8)
CHECK VALVE (IF USED
REQUIRES EXPANSION TANK)
MIXING
VALVE
M
C
H
CHECK
COLD INLET VALVE
8 in TO
12 in MAX.
FLOW
CONTROL
HOSE BIB
(OPTIONAL)
HOT
OUTLET
Installation
The heating mode may be one of the following options:
A. A fan coil/air handler (Figure 22).
B. A hydronic baseboard (finned tube) loop/In floor heating
(Figure 23).
The following is a list of requirements for the installation
of option A or B.
1. Install shut-off valves and unions so that the water
heater can be isolated from the heating module should
servicing of the water heater become necessary.
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EXTERNAL
CIRCULATOR
RETURN
SUPPLY
WATER
HEATER
HYDRONIC
BASEBOARDS
(SERIES
CONNECTED
SHOWN)
Figure 23
21
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements
or such conditions as high line pressure, among others,
have installed devices such as pressure-reducing valves,
check valves, and back flow preventers. Devices such as
these cause the water system to be a closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will increase. As the
volume of water increases, there will be a corresponding
increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure
(leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause
intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure
build up. The temperature-pressure relief valve is not
intended for the constant relief of thermal expansion. This
condition is not covered under the limited warranty.
HOT-WATER
OUTLET
SHUT-OFF VALVE
UNION
UNION
3/4” SWEAT
FITTING
3/4” SWEAT
FITTING
TEMPERATUREPRESSURE
RELIEF VALVE
SOME
COMPONENTS
NOT SHOWN
FOR CLARITY.
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
DRAIN
VALVE
A properly-sized thermal expansion tank should be
installed on all closed systems to control the harmful
effects of thermal expansion. Contact a plumbing service
agency or your retail supplier regarding the installation of
a thermal expansion tank.
6” (15cm) MAX.
AIR GAP
METAL
DRAIN
PAN
Note: To protect against untimely corrosion of hot and cold
water fittings, it is recommended that di-electric unions or
couplings be installed on this water heater when connected
to copper pipe.
CAUTION
Property Damage Hazard
• Avoid water heater damage.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold water inlet.
• Contact qualified installer or service agency.
22
COLDWATER
INLET
FLOOR
DRAIN
Figure 24
Figure 22 shows typical attachment of water piping to the
water heater. The water heater is equipped with 3/4” NPT
water connections.
Note: If using copper tubing, solder tubing to an
adapter before attaching the adapter to the water heater
connections. Do not solder the water lines directly to the
water heater connections - it will harm the dip tube and
heat traps and damage the tank.
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TEMPERATURE-PRESSURE RELIEF VALVE
WARNING
Explosion Hazard
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperaturepressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
This water heater is provided with a properly rated/sized
and certified combination Temperature-Pressure Relief
Valve (T&P valve) by the manufacturer. The valve is
certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed
equipment of materials as meeting the requirements for
Relief Valves for Hot Water Supply Systems, ANSI
Z21.22-CSA 4.4, and the code requirements of ASME.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination temperaturepressure relief valve rated/sized and certified as indicated
in the above paragraph. The new valve must be marked
with a maximum set pressure not to exceed the marked
hydrostatic working pressure of the water heater (150 psi
= 1,035 kPa) and a discharge capacity not less than the
water heater Btu/hr or kW input rate as shown on the water
heater’s model rating plate.
For safe operation of the water heater, the temperaturepressure relief valve must not be removed from its
designated opening nor plugged. The T&P valve must
be installed directly into the fitting of the water heater
designed for the relief valve. Install discharge piping so
that any discharge will exit the pipe within 6” (15cm) above
an adequate floor drain, or external to the building. In
cold climates it is recommended that it be terminated at
an adequate drain inside the building. Be certain that no
contact is made with any live electrical part.
The discharge opening must not be blocked or reduced
in size under any circumstances. Excessive length (over
30 feet (9.14m)), or use of more than four elbows can
cause restriction and reduce the discharge capacity of
the valve.
No valve or other obstruction is to be placed between
the T&P valve and the tank. Do not connect discharge
piping directly to the drain unless a maximum of 6”
(15cm) air gap is provided. To prevent bodily injury,
hazard to life, or property damage, the relief valve must
be allowed to discharge water in adequate quantities
should circumstances demand. If the discharge pipe is not
connected to a drain or other suitable means, the water
flow may cause property damage.
CAUTION
Water Damage Hazard
• Temperature-pressure relief valve discharge pipe
must terminate at an adequate drain.
T&P valve discharge pipe requirements:
• Shall not be smaller in size than the outlet pipe size
•
•
•
•
•
•
of the valve, or have any reducing couplings or other
restrictions.
Shall not be plugged or blocked.
Shall not be exposed to freezing temperatures.
Shall be of material listed for hot water distribution.
Shall be installed so as to allow complete drainage
of both the temperature-pressure relief valve and the
discharge pipe.
Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated
at an adequate drain inside the building
Shall not have any valve or other obstruction between
the relief valve and the drain.
DANGER
• Burn hazard.
• Hot water discharge.
HOT
• Keep clear of
temperature-pressure
relief valve discharge.
BURN
The T&P valve must be manually operated at least once
a year. Caution should be taken to ensure (1) no one is
in front of or around the outlet of the discharge line, and
(2) the water manually discharged will not cause any
bodily injury or property damage because the water may
be extremely hot. If after manually operating the valve, it
fails to completely reset and continues to release water,
immediately close the cold-water inlet to the water heater,
follow the draining instructions in this manual, and replace
the temperature-pressure relief valve with a properly
rated/sized new one.
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23
Note: The purpose of a temperature-pressure relief valve
is to prevent excessive temperatures and pressures in
the storage tank. The T&P valve is not intended for the
constant relief of thermal expansion. A properly sized
thermal expansion tank must be installed on all closed
systems to control thermal expansion, see “Closed Water
Systems” and “Thermal Expansion” section.
Temperature-Pressure Relief Valve and Pipe
Insulation
The T&P valve installed on this water heater is covered by
insulation to minimize heat loss. The insulation has a hole
on the bottom side to accommodate the valve outlet and
allow for the piping connection. Do not restrict the outlet
opening of the T&P valve.
T&P Relief Valve Insulation
(Outlet opening on underside)
WARNING
Breathing Hazard - Carbon Monoxide Gas
• For operation above 10,100 ft.
(3,079 metres) a high altitude
orifice must be installed.
• Contact a qualified installer or
service agency.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
This heater is approved for operation up to 10,100 feet
(3,079 m) without alteration.
Failure to replace standard orifice with a high altitude
orifice when installed above 10,100 feet (3,079 m) could
result in improper and inefficient operation of the appliance,
producing carbon monoxide gas in excess of safe limits,
which could result in serious injury or death. Contact
your gas supplier for any specific changes which may be
required in your area.
Manual Relief Lever
T&P Relief Valve
T&P Relief Valve
Drain Line
Figure 25
GAS PIPING
Locate the temperature and pressure relief valve on the
water heater (also known as a T&P relief valve). See
Figure 25.
1. Locate the slit running the length of the T&P relief
valve insulation.
2. Spread the slit open and fit the insulation over the T&P
relief valve. See Figure 25. Apply gentle pressure to
the insulation to ensure that it is fully seated on the T&P
Relief Valve. Once seated, secure the insulation with
duct tape, electrical tape, or equivalent. IMPORTANT:
The insulation and tape must not block the discharge
opening or hinder access to the manual relief lever
(Figure 25). Ensure a discharge pipe is installed into
the T&P valve discharge opening per the instructions
in this manual.
3. Locate the hot water (outlet) & cold water (inlet) pipes
to the water heater.
4. Locate the slit running the length of a section of pipe
insulation.
5. Spread the slit open and slip the insulation over the
cold water (inlet) pipe. Apply gentle pressure along
the length of the insulation to ensure that it is fully
seated around the pipe. Also, ensure that the base
of the insulation is flush with the water heater. Once
seated, secure the insulation with duct tape, electrical
tape, or equivalent.
6. Repeat steps 5 and 6 for the hot water (outlet) pipe.
7. Add additional sections of pipe insulation as
needed.
24
HIGH ALTITUDE INSTALLATION
WARNING
Fire and Explosion Hazard
• Do not use water heater with
any gas other than the gas
shown on the rating plate.
• Excessive pressure to gas
control valve can cause serious
injury or death.
• Turn off gas lines during
installation.
• Contact qualified installer or
service agency.
WARNING
Explosion Hazard
Have a qualified technician make sure that the L.P.
gas operating pressure does not exceed 13" water
column (3.237 kilopascals).
Failure to do so can result in death, explosion, or
fire.
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Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
14 inch w. c. (3.5 kPa) for natural gas and propane gas.
The minimum inlet gas pressure shown on the rating plate
is that which will permit firing at rated input.
All gas piping must comply with local codes and ordinances
or with the National Fuel Gas Code (ANSI Z223.1/ NFPA54). Copper or brass tubing and fittings (except tin lined
copper tubing) should not be used.
If the gas control valve/thermostat is subjected to pressures
exceeding 1/2 psi (3.5 kPa), the damage to the gas control
valve/thermostat could result in a fire or explosion from
leaking gas.
excess of 1/2 psi (3.5 kPa). It should be isolated from the
gas supply piping system by closing its individual manual
shut-off valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than 1/2
psi (3.5 kPa).
Connecting gas piping to the gas control valve/thermostat
of water heater can be accomplished by either of two
methods shown in Figures 26 & 27.
If the main gas line shut-off serving all gas appliances is
used, also turn “OFF” the gas at each appliance. Leave
all gas appliances shut “OFF” until the water heater
installation is complete.
A gas line of sufficient size must be run to the water heater.
Consult the current edition of National Fuel Gas Code
(ANSI Z223.1/NFPA 54) and your gas supplier concerning
pipe size.
Figure 26
There must be:
• A readily accessible manual shut-off valve in the gas
supply line serving the water heater, and
• A sediment trap (dirt leg) ahead of gas control valve/
thermostat to help prevent dirt and foreign materials
from entering the gas control valve/thermostat.
• A flexible gas connector or a ground joint union between
the shut-off valve and gas control valve/thermostat to
permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting
the water heater. Use a soapy water solution, not a match
or open flame. Repair and retest as required. When
finished, rinse off soapy solution and wipe dry.
Figure 27
SEDIMENT TRAPS/DIRT LEG
WARNING
WARNING
Fire and Explosion Hazard
Fire and Explosion Hazard
• Contaminants in gas lines can
cause fire or explosion.
• Use joint compound or tape
compatible with propane.
• Clean all gas piping before
installation.
• Leak test before operating
heater.
• Disconnect gas piping and
shut-off valve before pressure
testing system.
Use pipe joint compound or Teflon tape marked as being
resistant to the action of gases.
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
The appliance and its individual shut-off valve should be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
• Install sediment trap in accordance with NFPA54.
A sediment trap should be installed as close to the inlet of
the water heater as practical at the time of water heater
installation. The sediment trap should be either a tee fitting
with a capped nipple in the bottom outlet or other device
recognized as an effective sediment trap. If a tee fitting is
used, it should be installed in conformance with one of the
methods of installation shown in Figures 26 & 27.
Contaminants in the gas lines may cause improper
operation of the gas control valve/thermostat that may
result in fire or explosion. Before attaching the gas line be
sure that all gas pipe is clean on the inside. To trap any
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25
dirt or foreign material in the gas supply line, a sediment
trap (sometimes called a dirt leg) must be incorporated in
the piping. The sediment trap must be readily accessible.
Install in accordance with the “Gas Piping” section. Refer to
the current edition of the National Fuel Gas Code (ANSI
Z223.1/NFPA 5 4).
HOT-WATER
OUTLET
SHUT-OFF VALVE
COLDWATER
INLET
UNION
SIDE TAP
(OUTLET)
SOME
COMPONENTS
NOT SHOWN
FOR CLARITY.
TEMPERATUREPRESSURE
RELIEF VALVE
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
SIDE TAP
(INLET)
To fill the water heater with water:
1. Close the water heater drain valve by turning handle
to the right (clockwise). The drain valve is on the lower
front of water heater (see Figure 28).
2. If the heater is equipped with plumbing side taps and
they are not connected to piping, ensure that the side
taps have been closed with pipe plugs.
3. Open all hot-water faucets served by the water heater to
allow air to escape from the tank and the water piping.
Ensure any shut-off valves between the heater and the
faucets are the open position.
4. Open the cold-water supply valve to the water heater.
Notes:
• The cold-water supply valve must be left open when
the water heater is in use.
• Avoid water leakage when filling the tank. Do
not allow the insulation of the water heater to get
wet as water can reduce the effectivness of the
insulation.
5. To ensure complete filling of the tank, allow air to exit
by opening nearest hot-water faucet. Allow water to run
until a constant flow is obtained. This will let air out of
the water heater and the piping.
6. Check all water piping and connections for leaks. Repair
as needed.
VENTING
DRAIN
VALVE
WARNING
6” (150mm) MAX.
AIR GAP BELOW
DISCHARGE PIPE
Breathing Hazard - Carbon Monoxide Gas
METAL
DRAIN
PAN
• Install vent system In accordance with codes.
• Do not operate water heater if flood damaged.
• Install water heater in accordance with the
instruction manual.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake(s) with
insulating blanket.
• Do not place chemical vapor emitting products near
water heater.
• Gas and carbon monoxide detectors are available.
• Never operate the heater unless it is vented to the
outdoors and has adequate air supply to avoid risks
of improper operation, fire, explosion or asphyxiation.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
FLOOR
DRAIN
Figure 28
FILLING THE WATER HEATER
CAUTION
Property Damage Hazard
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Avoid water heater damage.
• Fill tank with water before operating.
• Do not insert the power cord into the electrical
•
26
receptacle until the heater has been fully installed.
Never use this water heater unless it is completely full
of water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot-water
faucet before turning “ON” gas to the water heater.
Important: DO NOT common vent this water heater with
any power vented appliance. DO NOT vent into a common
chimney.
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TERMINATION CLEARANCES SIDEWALL POWER VENT
R
RNE
E CO
INSIDDETAIL
V Vent terminal
X Air supply inlet
G
Area where is not permitted
V
A
D
E
V
B
B
V
C
V
L
B
V
B
D
FIXE D
SE
CLO
RA
OPE
E
ERABL
OP
F
D
FIXE ED
LOS
BLE C
B
I
M
V
X
V
B
V
V
X
K
J
A
Gas meter / regulator
Figure 29
Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion.
Clearance above grade,
A veranda, porch, deck or
balcony
12 in. (30cm)
Clearance to each side of
H center line extended above
meter/regulator assembly
to window or door
B Clearance
that may be opened
4 ft. (1.2m) below or
to side of opening;
1 ft. (30cm) above
opening
I
Clearance to service regulator
vent outlet
3 ft. (91cm)*
Clearance to permanently
C closed window
12 in. (30cm)*
J
Clearance to a non
mechanical air supply inlet into
building or combustion air inlet
to any other appliance
4 ft. (1.2m) below or
to side of opening;
1 foot (30cm) above
opening.
Vertical clearance to ventilated
soffit located above the
D terminal within a horizontal
12 in. (30cm)*
distance of 2 ft. (61cm) from
the center line of the terminal
to a mechanical air
K Clearance
supply inlet
to unventilated
E Clearance
soffit
12 in. (30cm)*
L
F Clearance to outside corner
2 ft. (60cm)*
under veranda,
M Clearance
porch, deck, or balcony
G Clearance to inside corner
18 in. (45cm)*
Clearance above paved
sidewalk or paved driveway
located on public property
N/A
3 ft. (91cm) above
if within 10 ft. (3m)
horizontally
7 ft. (2.13m) †
12 in. (30cm) ‡
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the
manufacturer’s installation instructions.
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27
BLOWER ASSEMBLY INSTALLATION
1. This power vented water heater comes with blower
assembly installed (see Figure 30).
2. After unit is set in place, make sure blower assembly is
still mounted securely. Make sure there is no damage
to blower.
HOSE
CONNECTION
PORT FOR
CONDENSATE
DRAIN
DILUTION
AIR
INLETS
INSTALLATION OF VENT SYSTEM
Before beginning installation of piping system, thoroughly
read the “Vent Pipe Preparation” section of this manual.
BLOWER
ASSEMBLY
8 in.
(200mm)
LOOP
TO
DRAIN
Figure 30
3. Make sure there is no packing material in the inlet or
discharge of the blower.
4. Make sure that the plastic tubing is still attached
from the air pressure switch to the port on the blower
housing. Make sure the plastic tubing is not folded
anywhere between the pressure switch and the blower
housing (see Figures 38-42).
5. This water heater is a polarity sensitive appliance and
will not operate if the power supply polarity is reversed.
Power to this water heater must be wired properly
(correct polarity).
6. Do not plug in power cord until vent system is
completely installed. The Power Vent operates on 110
-120 VAC. therefore a grounded outlet must be within
reach of the 6 foot (1.8 m) flexible power cord supplied
with the heater. The power cord supplied may be used
on a unit only where local codes permit. If local codes
do not permit use of flexible power supply cord:
a. Make sure the unit is unplugged from the wall outlet.
Remove the screw and open panel on the front of
the junction box on the blower.
b. Cut the flexible power cord, leaving enough to be
able to make connections. Remove the strain relief
fitting from the box.
c. Install a suitable conduit fitting inside the
enclosure.
d. Splice field wiring into existing wiring using code
authorized method (wire nuts, etc).
e. Be certain that the neutral and line connections are
not reversed when making these connections.
f. Ground heater properly. This water heater must
be grounded in accordance with the National
Electrical Code NFPA 70 and/or local codes. These
must be followed in all cases.
The water heater must be connected to a grounded
metal, permanent wiring system or an equipment
grounding conductor must be run with the circuit
conductors and connected to the equipment
28
grounding terminal or lead on the water heater (see
Figure 13; the wiring diagram).
g. Close the panel on the junction box. Make sure that
the access panel is secured shut.
7. The blower discharge boot is made to accept only
straight sections of 2” or 3” pipe. To start off with an
elbow, a short section of the straight pipe must be cut
and glued into the end of the elbow that will mount on
the discharge boot.
PLANNING THE VENT SYSTEM
Plan the layout of the vent system from the vent termination
to the water heater considering all of the 90 degree and 45
degree elbows plus the number of feet of pipe that would
be needed to install the total vent system. The water heater
must be vented to the outdoors as described in these
instructions. This water heater must be vented separately
from all other appliances.
The unit may be vented horizontally through a wall or
vertically through the roof. Pipe runs must be adequately
supported along both vertical and horizontal runs.
Note: Do not use an elbow as a support point. Elbows are
not designed to cary the load or stresses of the venting
system if they are rigidly held.
It is imperative that the first hanger (or support) be located
on the horizontal run immediately adjacent to the first 90degree elbow from the vertical rise. Support method used
should isolate the vent pipe from the floor joists or other
structural members to prevent the transmission of noise
and vibration. Do not support, pin, or otherwise secure
the venting system in a way that restricts the normal
thermal expansion and contraction of the chosen venting
material.
If the water heater is being installed as a replacement for
an existing power vented heater in pre-existing venting,
a thorough inspection of existing venting system must be
performed prior to any installation work. Verify that correct
material, as detailed in below, has been used, and that the
minimum or maximum vent lengths and terminal location
as detailed in this manual have been met.
HIGH AMBIENT TEMPERATURE INSTALLATIONS
This heater requires room air to lower the flue gas
temperatures before the gases pass through the vent
system. The dilution air inlets are located on the rear of
the blower assembly (see Figures 2 & 30).
As the room temperature rises, the ability to lower the flue
gases lessens so special attention to the choice of venting
material is required. Establishing the ambient temperatures
where the heater and the venting is installed is very
important, especially in regions with warmer climates
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or any region that experiences hot summers. Ambient
conditions hotter than 110°F (43°C) require that the venting
material be either CPVC or polypropylene. Areas that can
experience high ambient environments include closets,
alcoves, areas under staircases, attics-especially in metal
roofed buildings, areas with restricted air movement,
rooms with large solar gains, metal sheds, industrial or
commercial enterprises and venting systems exposed to
direct sunlight. For high temperature environments, obtain
high limit switch upgrade Kit # 9008306015 and use the
higher rated vent piping.
Note: This unit can be vented with the following piping:
PVC pipe
materials
DWV ASTM-D2665
Schedule 40, 80* & 120* ASTM-D1785,
SDR Series ASTM-D2241
CPVC pipe
materials
CPVC 41 ASTM-D2846
Schedule 40, 80* & 120* ASTM-F441
SDR Series ASTM-F442,
ABS pipe
materials
DWV ASTM-D2661
Schedule 40
Polypropylene UL-1738
vent system
* NOTE: USING SCHEDULE 80 OR 120
SIGNIFICANTLY REDUCES THE VENT LENGTH.
Note: If local codes require venting to be marked suitable
for use as gas venting, type BH venting may be used.
The fittings, other than the Termination should be
equivalent to:
PVC pipe
PVC DWV ASTM D-2665
CPVC pipe
CPVC ASTM F-438
ABS pipe
ABS ASTM D-2661/3311
Polypropylene UL-1738
vent system
If CPVC or ABS pipe and fittings are used, the proper
cement must be used for all joints, including joining the
pipe to Termination (PVC Material). If local codes do not
allow the use of the PVC termination when a material
other than PVC is used for venting, an equivalent fitting of
that material may be substituted if the screen in the PVC
terminal is removed and inserted into the new fitting.
This water heater is supplied with a 45 degree PVC
termination elbow and the applicable vent screens. A 90
degree termination elbow is optional.
ASTM D-2564 Grade Cement should be used on PVC
Materials and ASTM F-493 Grade Cement on CPVC
Materials.
POLYPROPYLENE VENT SYSTEMS
Polypropylene vent systems do not use cement to connect
the pipe and elbow sections but use a push together gasket
seal method. Do not attempt to connect polypropylene
with sealant cement.
Polypropylene vent systems are designed to use specific
adaptors to connect into the rubber coupling on the top
of the blower. Thse are available through your venting
supplier.
The PVC vent termination elbow supplied with this heater
has been certified to be used with polypropylene vent
systems. A polypropylene to PVC end connection is
required and is available through your supplier.
Optional wall plates that fit the polypropylene venting are
also available through your supplier.
Carefully inspect the entire venting system for any signs of
cracks or fractures, particularly at joints between elbows
and other fittings and straight runs of vent pipe. Check
system for signs of sagging or other stresses in joints as
a result of misalignment of any components in the system.
If any of these conditions are found, they must be corrected
in accordance with the venting instructions in this manual
before completing installation and putting the water heater
into service.
The vent piping shall be connected to the blower with
the rubber coupling and secured with gear clamps. The
coupling and clamps are provided with the heater.
Even though the flue gas temperature leaving the blower
is hot, some installations will have water condense in
the vent piping. If this occurs, then adequate means of
draining and disposing of the condensate shall be made
by the installer.
CONDENSATE
Condensate formation does not occur in all installations
of power vented water heaters, but should be drained
on installations where it can form in the venting system.
Condensation in the venting system of power vented
water heaters is dependent upon installation conditions
including, but not limited to, ambient temperature and
humidity of installation location, ambient temperature
and humidity of venting space, vent discharge and slope,
and product usage. In certain conditions, installations in
unconditioned space or having long horizontal or vertical
vent runs can accumulate condensate. Long lengths of
venting that pass through cool/cold areas will experience
condensation. The vent pipe should be sloped upwards
away from the blower assembly, then adequate means
for draining and disposing of the condensate needs to
be made by the installer. If installation conditions cause
condensation, install a condensate trap loop approximately
8 in. (200mm) in diameter using 3/8” plastic hose. Connect
the hose to the built-in drain port of the rubber coupling
of the blower assembly (see Figure 30). Loop the hose
in a vertical position as shown. The tube loop must be
filled with water at least half way prior to operating the
heater. Ensure the end of the tube has access to a drain
as condensate will flow from the end. Secure the tubing to
the side of the heater. Prior to operating the water heater,
make sure the removable cap is installed on the drain port
(if a drain hose is not needed).
Note: This cap must remain in place if a drain hose is not
installed.
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29
EXHAUST VENTING
This heater is designed to exhaust the products of
combustion (flue gases) to the outdoors using a sealed
piping system. Table 2 lists the allowable vent materials
and sizing information. Figure 34 shows the general venting
layout while Figures 38-42 show various end termination
details and clearances. Connection of the venting piping
to the blower is shown in Figures 38-42.
Important Notes and Warnings
• This heater is certified to be installed using PVC, CPVC,
•
•
Correct installation of the venting system is essential to
the safe and efficient operation of this water heater. Vent
piping must be installed in accordance with all applicable
codes. All installations shall meet the requirements as
stated in the current edition of the “National Fuel Gas
Code, ANSI Z223.1/NFPA 54”.
Note: The information provided in Figure 29 is intended
as a guideline for good vent installation practices only
and is not intended to restrict venting options beyond
those restrictions established by the current edition of the
“National Fuel Gas Code, ANSI Z223.1/NFPA 54” or any
applicable local and state codes.
•
•
•
STREET ELBOW
NORMAL ELBOW
6 in.
(150mm)
min.
ABS or polypropylene plastic vent material. Only use
approved material. All venting material and components
must be joined with the approved primer/cleaner and
solvent cement.
Do not common vent this heater with any other
appliance.
During operation the plastic piping will expand as it
heats up and contract as it cools down. This is normal
for this type of venting. Rigidly fastening the vent piping
can cause undue stress that may result in the cracking
or fracturing the vent piping material. A fracture of
the venting pipe may pose a serious safety hazard.
To prevent stressing of the vent system, all hangers
and supports must allow the vent piping freedom to
move.
Use long sweep elbows wherever possible. Closelycoupled elbows and short radius elbows can reduce
the venting capacity.
All power vented water heaters generate a certain
amount of operational noise. In order to minimize noise
transmission to the support structure, use isolation pads
between the pipe hangers and the vent pipe.
Most power vent installations develop some
condensation in the vent piping. When using long runs
of venting or when the venting passes through cold or
unheated areas, considerable amounts of condensate
from the flue gases can develop. Provision must be
made for the condensate to drain freely from the
system or to be collected in a condensate trap(s) that
can be drained. Damage or fracture of the vent piping
may occur if the condensate is allowed to collect and
freeze. Pooling of condensate can restrict airflow and
can cause nuisance failures of the system.
BACK TO BACK ELBOWS
PREFERRED PRACTICE
90° SHORT SWEEP ELBOW
(MORE RESTRICTIVE)
90° LONG SWEEP ELBOW
(LESS RESTRICTIVE)
Figure 31
30
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• 50 and 75 gallon heaters with a rated input of 60k Btu/
Venting terminations and sizing
• Refer to Figure 34 and Table 2 for vent pipe materials
•
and sizing. Examples of the vent terminations are
shown in Figures 35 & 36. If the installation requires
a vent riser, suitable drainage must be provided to
ensure condensation does not accumulate. Termination
through a roof is shown Figure 37.
40, 50 and 60 gallon heaters with rated inputs of 50k
Btu/hr or less are supplied with a 2”-3” rubber coupling
to attach the venting to the blower and a 2”, 45° vent
termination elbow.
For heaters with rated inputs of 50k Btu/hr or less:
with 2 in. venting (short)
with 2 in. venting (long)
•
hr or more are supplied with a 3”-3” rubber coupling
to attach the venting to the blower and a 3”, 45° vent
termination elbow.
Supplied with this heater are several vent termination
screens (see Figures 32 & 33).
Installed in the vent termination elbow, the vent screen
is required to keep foreign objects, rodents and small
birds from entering the venting system. These screens
have been sized to ensure maximum energy efficiency of
the vent system based on the “equivalent length” of the
vent piping. CHOOSE ONLY the ONE SCREEN THAT
MATCHES YOUR VENTING CONFIGUARATION (see
Figures 32 & 33). How to determine the “equivalent length”
is shown in Figure 34 and in Table 2.
Vent screen installation
• Install the appropriate vent screen into the vent
termination elbow.
• Gently push the screen into the termination elbow until
it sits against the inside shoulder.
• The metal wire screens are self-securing.
• Plastic screens must be secured with (2) drops of
VENT LENGTH LESS THAN OR
EQUAL TO 20 EQUIVALENT FT.
(6.1 METRES) USE THIS SCREEN
(SUPPLIED).
VENT LENGTH GREATER THAN
20 EQUIVALENT FT.
(6.1 METRES) USE THIS SCREEN
(SUPPLIED).
with 3 in. venting
with 3 in. venting
VENT LENGTH LESS THAN OR
EQUAL TO 50 EQUIVALENT FT.
(15.2 METRES) USE THIS SCREEN
(SUPPLIED).
VENT LENGTH GREATER THAN
50 EQUIVALENT FT.
(15.2 METRES) USE THIS SCREEN
(SUPPLIED).
silicone sealant. This will allow for easy removal for
inspection and cleaning.
For heaters with rated inputs of 60k Btu/hr or more:
with 3 in. venting (short)
with 3 in. venting (long)
VENT LENGTH LESS THAN OR
EQUAL TO 20 EQUIVALENT FT.
(6.1 METRES) USE THIS SCREEN
(SUPPLIED).
VENT LENGTH GREATER THAN
20 EQUIVALENT FT.
(6.1 METRES) USE THIS SCREEN
(SUPPLIED).
with 4 in. venting
with 4 in. venting
VENT LENGTH GREATER THAN
125 EQUIVALENT FT.
(38.1 METRES) USE THIS SCREEN
(SUPPLIED).
VENT LENGTH GREATER THAN
50 EQUIVALENT FT.
(15.2 METRES) USE THIS SCREEN
(SUPPLIED).
Figure 33
Figure 32
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31
Calculating Equivalent Feet
WATER
HEATER
MODEL
HEATER VENT SIZE
INPUT
(Inside
(Btu/hr)
Diam)
PRESSURE
SWITCH
SETTING
MAXIMUM EQUIVALENT
VENT LENGTH
40 & 50 gal.
40,000
- 0.27 in. w.c.
60 gal.
42,000
40 & 50 gal.
50,000
- 0.37 in. w.c
40 & 50 gal.
40,000
- 0.27 in. w.c.
60 gal.
42,000
40 & 50 gal.
50,000
2” (50mm)
3” (76mm)
- 0.27 in. w.c.
- 0.27 in. w.c.
- 0.37 in. w.c.
50 gal. (short)
62,000
50 gal. (tall)
65,000
- 0.99 in. w.c.
75 gal.
72,000
- 0.99 in. w.c.
40 & 50 gal.
40,000
- 0.27 in. w.c.
60 gal.
42,000
40 & 50 gal.
50,000
- 0.37 in. w.c.
50 gal. (short)
62,000
- 0.99 in. w.c.
50 gal. (tall)
65,000
75 gal.
72,000
3” (76mm)
4” (102mm)
4” (102mm)
- 0.99 in. w.c.
- 0.27 in. w.c.
- 0.99 in. w.c.
- 0.99 in. w.c.
MINIMUM EQUIVALENT
VENT LENGTH
50 ft. (15.2m) +
termination elbow
7 ft. (2.1m) +
termination elbow
125 ft. (38.1m) +
termination elbow
7 ft. (2.1m) +
termination elbow
50 ft. (15.2m) +
termination elbow
7 ft. (2.1m) +
termination elbow
180 ft. (54.9m) +
termination elbow
125 ft. (38.1m) +
termination elbow
125 ft. (38.1m) +
termination elbow
50 ft. (15.2m) +
termination elbow
Equivalent lengths of straight pipe for various elbows using Schedule 40 PVC, CPVC and polypropylene.
Size
Type
Short Sweep/
Short Radius
Long Sweep/
Long Radius
2” (50mm)
3" (76mm)
4" (102mm)
90° elbow
8 ft. (2.44m)
5 ft. (1.52m)
2” (50mm)
3" (76mm)
4" (102mm)
45° elbow
4 ft. (1.22m)
2.5 ft. (0.76m)
Notes:
1. Use long radius elbows where
possible. Minimum distance between
90º elbows should be 6” (150mm)
wherever possible.
2. Venting systems may use a maximum
of five (5) 90° elbows.
3. Use proper screen termination (see
Figures 32 & 33).
Table 2
COVER PLATE
(OPTIONAL)
TERMINATION
ELBOW
RODENT
SCREEN
(INSTALL INTO
ELBOW)
12” (305mm) MIN. OR
ABOVE ANTICIPATED
SNOW LEVEL.
GROUND LEVEL
Note: The vent pipe must be supported every 4 ft. (1.2M). To prevent vibration and sagging, it is recommended
to use isolation pads when attaching straps to floor joists, walls or ceilings. PVC and CPVC vent pipe should be
sloped upwards away from the blower assembly at a pitch of 1/8 in. (3mm) rise per 4 ft. (1.2M). Polypropylene
vent systems require a 1/4” (6mm) per 1 ft. (0.3M) upward slope to ensure proper drainage.
45° SHORT
ELBOW
STRAP
Example for calculating equivalent feet.
Section “A”
0.5 ft.
(0.15m)
90° elbow
8.0 ft.
(2.44m)
Section B
1.0 ft.
(0.31m)
45° elbow
4.0 ft.
(1.22m)
Section C
1.5 ft.
(0.46m)
45° elbow
4.0 ft.
(1.22m)
Section D
15.0 ft.
(4.57m)
Total Equivalent 34.0 ft.
(10.37m)
Based on this example use the (fully open) rodent
screen for vent length greater than 20 equivalent ft.
(6.1 equivalent metres) (see Figures 32 & 33).
Figure 34
32
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90° SHORT
ELBOW
Venting instructions
1. Plan the venting layout starting at the vent termination
and work back toward the heater. Take into consideration
the style and position of the vent termination, the vent
pipe routing, elbows and connectors required and the
necessary support hangers.
2. Venting should be as direct as possible with the fewest
number of fittings. Use long radius 45 degree and long
radius 90 degree elbows wherever possible.
3. Avoid using 90 degree elbows “back to back” and do
not use street elbows. Maintain a minimum 6” (152mm)
straight section between elbows. Closely coupled and
short radius elbows reduce the venting capacity. Figure
31 shows examples of vent pipe connections.
4. DO NOT USE AN ELBOW AS A SUPPORT POINT.
Elbows are not designed to carry the weight of the
venting system.
5. Calculate “Equivalent Vent Length” before starting. Do
not exceed the values shown in Table 2. An example
of how this length is determined is shown in Figure 34.
The value from your calculations should also be used
to determine which rodent screen to install into the vent
termination elbow.
6. Measure the vent piping and cut to required lengths.
Pipes must be cut at right angles and deburred to
ensure a good smooth fit with sufficient overlap for the
glue joints. Correct any interference conditions.
7. Provide support hangers for horizontal vent piping every
4 ft. (1.2m) to prevent sagging and stress. Provide a
minimum of 1/8” (3mm) rise per 4 ft. (1.2m) of vent
piping to ensure adequate drainage (polypropylene
vent systems require a 1/4 in. (6mm) rise per 1 ft.
(0.3m) of vent pipe). Horizontal vent piping must not
sag to form valleys where condensate can collect.
Vertical venting shall be supported every 5 ft. (1.5m).
Use appropriate support straps and vibration isolators
(foam pads) on straight sections only. Allow sufficient
clearance for expansion and contraction of the venting
system.
8. At the point where the venting exits the building, cut
a 2-1/2” (64mm) hole for 2” (51mm) venting, a 3-1/2”
(89mm) hole for 3” (76mm) venting or a 4-1/2” (114mm)
hole for 4” (102mm) venting. For sidewall applications,
use the appropriate metal cover plate as a template to
mark the hole for the vent pipe to pass through the wall.
BEWARE OF CONCEALED WIRING AND PIPING
INSIDE THE WALL.
9. Insert the vent piping through this hole and secure into
position. Connect the vent pipe to the end termination
elbow as shown in Figures 35-37.
10. Dry fit all vent pipes, elbows, connectors and fittings
before joining any parts with solvent cement. PARTS
MUST FIT WITHOUT STRESS OR BENDING OF
ANY SECTION and each connection must overlap a
minimum of 1/2” (13mm). Do not force fit any of the
connections. Use only the appropriate solvent cement.
Caution: Solvent cements may produce
flammable vapors. Use only in well-ventilated
areas and keep away from all sources of ignition.
Note: DO NOT use solvent cement on polypropylene
vent systems.
11. Install the properly sized rodent screen into the outlet
elbow and secure with a small quantity of silicone
sealant. Refer to Figures 32 & 33 to determine the
proper screen.
12. Do not seal the vent piping to the wall until the venting
is properly connected to the blower assembly.
13. Complete the venting installation by sealing around
the termination assembly where it passes through
the outside wall, inside and out, with silicone or other
suitable sealant. Apply enough sealant to secure the
(optional) cover plate to the wall.
CAUTION
Use of Solvent Cement and Primer
• Use only in well-ventilated areas.
• Do not use near flame or open fire.
• Use only the Solvent Cement and Primer appropriate for
the venting material being used.
• Solvent cements for plastic pipe are flammable liquids and
must be kept away from all sources of ignition.
ATTACH
TERMINATION 6” (152mm)
ELBOW (MAY
ALSO BE 90°)
12”
(305mm)
MIN.*
RODENT
SCREEN
(INSTALL
INTO
ELBOW)
SEALANT
COVER PLATE
(OPTIONAL)
SEALANT
(UNDER
PLATE)
GROUND
LEVEL*
* WHERE SNOW COVER IS NORMAL DURING
WINTER, ENSURE OUTLET IS INSTALLED
ABOVE ANTICIPATED SNOW LEVEL.
VENT PIPING MAY
BE SLOPED IN ANY
DIRECTION, AS
LONG AS A WATER
TRAP IS NOT
CREATED IN THE
VENTING SYSTEM.
THE SLOPE
SHOULD BE KEPT
TO A MINIMUM
SO AS NOT TO
EXERT ANY UNDUE
STRESS ON THE
PIPE.
Figure 35
ATTACH
TERMINATION
ELBOW (MAY
ALSO BE 90°)
BRACKET
EQUIVALENT
VENT LENGTH
MEASURED
FROM THIS
POSITION
RODENT
SCREEN
(INSTALL
INTO
ELBOW)
12”
(305mm)
MIN.*
SEALANT
VENT
RISER
COVER PLATE
(OPTIONAL)
GROUND
LEVEL*
SEALANT
(UNDER
PLATE)
* WHERE SNOW COVER IS NORMAL DURING
WINTER, ENSURE OUTLET IS INSTALLED ABOVE
ANTICIPATED SNOW LEVEL.
VENT PIPING TO BE
SLOPED (DOWN)
TOWARD HEATER
TO PREVENT
WATER FROM
COLLECTING
(MAY REQUIRE
A CONDENSATE
TEE).
Figure 36
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33
3” (76mm)
MIN. LENGTH
A VENT USED IN A
SPECIAL VENTING
SYSTEM WITH POSITIVE
VENT PRESSURE AND
PASSING THROUGH A
ROOF SHALL EXTEND
AT LEAST 18” (457mm)
ABOVE THE HIGHEST
POINT WHERE IT PASSES
THROUGH THE ROOF
SURFACE AND ANY
OTHER OBSTRUCTION
WITHIN A HORIZONTAL
DISTANCE OF 18”
(457mm). A VERTICAL
VENTING SYSTEM MUST
BE SUPPORTED EVERY 5
ft. (1.5m).
TERMINATION
MAY BE 90°
ELBOW
18” (457mm)
OR ABOVE
ANTICIPATED
SNOW LEVEL
RODENT
SCREEN
(INSTALL
INTO
ELBOW)
Different coupling installations according to vent
sizes
CONFIGURATION
FOR 40, 50 AND
60-GALLON (LOINPUT) HEATERS
CONNECTED TO
2" VENTING.
2” VENT
PIPE
2” RUBBER
COUPLING
(SUPPLIED)
ROOF
LINE
BLOWER
Figure 38
Figure 37
Vent pipe connection to blower
1. The plastic vent piping connects into the rubber
coupling located on the top of the blower assembly. This
coupling includes gear clamps to connect the venting to
the blower. These connections must be properly seated
and tightened to prevent the leakage of flue gases into
the area. See Figures 38-42.
2. The 40, 50 and 60-gallon heaters with rated inputs of
50k Btu/hr or less are designed and supplied with a 2”
(51mm) rubber coupling to accept the vent pipe.
3. The 50 and 75-gallon models with rated inputs of 60k
Btu/hr or more are supplied with a 3” (76mm) rubber
coupling to accept the vent pipe. Note: Polypropylene
vent systems require seperate adaptor.
4. Before installing clean and lightly sand the end of the
PVC/CPVC plastic vent piping that will connect into the
rubber coupling. For polypropylene vent systems follow
manufacturer’s instructions.
5. Loosen the upper clamp on the rubber coupling
and insert the sanded end of the vent piping a full
1-1/4” (32mm). Do not use glue or sealant in the
rubber coupling. Check that there is no stress on the
connection or the vent piping that may be caused by
twisting or bending.
6. Tighten the upper clamp so that the vent piping is firmly
secured in the coupling and is gas tight. Do not over
tighten or cause distortion of any of the parts. Ensure
the bottom of the rubber coupling is firmly seated on
the blower outlet and that the lower gear clamp is
also secure. Check to ensure there is no distortion
or movement of the clamped assembly once it is
completed.
CAUTION
Property Damage Hazard
• Do not overtighten the top and bottom gear clamps of the
rubber coupling.
CONFIGURATION
FOR 40, 50 AND
60-GALLON (LOINPUT) HEATERS
CONNECTED TO
3” VENTING.
3” VENT
PIPE
2” RUBBER
COUPLING
* FOR 3” DIRECT
(SUPPLIED)
CONNECTION TO
THE BLOWER,
ORDER
COUPLING Kit #
9008311005
(SEE ALSO
BLOWER
FIGURE 42).
Figure 39
CONFIGURATION
FOR LO-INPUT
3” RUBBER
HEATERS
COUPLING
CONNECTED TO
(ORDER COUPLING
4” VENTING.
Kit # 9008311005
TO REPLACE 2”
LOW-INPUT
RUBBER COUPLING
HEATERS ARE
SUPPLIED.)
SUPPLIED WITH
A 2” RUBBER
COUPLING.
4” VENT
PIPE
3”-4”
ADAPTER
(FIELD
SUPPLIED)
3” VENT PIPE,
75mm (3 in.)
MAX LENGTH
BLOWER
Figure 40
CONFIGURATION
FOR HI-INPUT
HEATERS
CONNECTED TO
TO 3” VENTING.
(OPTIONAL
CONFIGURATION
FOR LO-INPUT
HEATERS
CONNECTED TO
TO 3” VENTING.)
• Do not apply solvent cement or silicone to the rubber
coupling connection.
3” VENT
PIPE
3” RUBBER
COUPLING
(SUPPLIED)
BLOWER
Figure 41
34
2”-3”
ADAPTER*
(FIELD
SUPPLIED)
2” VENT PIPE,
75mm (3 in.)
MAX LENGTH
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CONFIGURATION
FOR HI-INPUT
HEATER
CONNECTED TO
4” VENTING.
4” VENT
PIPE
3”-4”
ADAPTER
(FIELD
SUPPLIED)
3” RUBBER
COUPLING
(SUPPLIED)
3” VENT PIPE,
75mm (3 in.)
MAX LENGTH
• Know your own qualifications or those of your
•
•
BLOWER
•
Figure 42
BLOWER EXHAUST DIRECTION
The blower assembly may be rotated 90 degree clockwise
or counterclockwise to allow horizontal venting in areas
having restricted space above the water heater. To rotate
the blower outlet, remove the four nuts (with 11/32” nut
driver) (see Figure 43), securing the flue collector to the
blower housing. Pull the blower assembly forward to free
it from the mounting studs. Rotate the blower housing
clockwise or counter-clockwise and align the four holes
and screws together. Reattach the blower housing to the
flue collector.
Note: Coupling to vent system
not shown for clarity.
11/32” nut
contractor. The solvent welding technique of joining
PVC and CPVC pipe is a specialized skill just as any
other pipe fitting technique.
Closely supervise the installation and inspect the
finished job before start-up.
Contact the manufacturer, supplier, or competent
consulting agency if you have any questions about
the application or installation of PVC and CPVC
pipe.
Take the time and effort to do a professional job.
Shortcuts will only cause you problems and delays
in start-up. By far, the majority of failures in PVC and
CPVC systems are the result of shortcuts and/or
improper joining techniques.
2. SELECTION OF MATERIALS (PCV and CPVC
VENTING)
• Cutting Device - Saw or Pipe Cutter
• Deburring Tool, Knife, File, or Beveling Machine (2”
and above)
• Brush - Pure Bristle
• Rag - Cotton (Not Synthetic)
• Primer and Cleaner
• Solvent Cement - PVC for PVC Components and
CPVC for CPVC Components only
• Containers - Metal or Glass to hold Primer and
Cement. Select the type of PVC or CPVC materials
to be used on the basis of their application with
respect to chemical resistance, pressure rating,
temperature characteristics, etc.
• Insertion Tool - Helpful for larger diameter pipe and
fittings 6” (152mm) and above.
WARNING
Fire or Explosion Hazard
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
Figure 43
VENT PIPE PREPARATION
1. INITIAL PREPARATION
• Make sure the solvent cement you are planning to
use is designed for the specific application you are
attempting.
• Know the physical and chemical characteristics and
limitations of the PVC and CPVC piping materials
that you are about to use.
• Know the reputation of your manufacturer and their
products.
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Read instruction manual before
installing, using or servicing
water heater.
Primer:
It is recommended that Tetrahydrofuran (THF) be
used to prepare the surfaces of pipe and fittings for
solvent welding. Do not use water, rags, gasoline
or any other substitutes for cleaning PVC or CPVC
surfaces. A chemical cleaner such as MEK may be
used.
35
Cement:
The cement should be a bodied cement of
approximately 500 to 1600 centipoise viscosity
containing 10-20% (by weight) virgin PVC material
solvated with Tetrahydrofuran (THF). Small
quantities of Dimethyl Formamide (DMF) may
be included to act as a retarding agent to extend
curing time. Select the proper cement; Schedule
40 cement should be used for Schedule 40 pipe.
Never use all-purpose cements, commercial glues
and adhesives or ABS cement to join PVC or CPVC
pipe and fittings.
WARNING
Fire Hazard
• Primers and cements are
extremely flammable, and must
not be stored or used near heat
or open flame.
• Also, use only in a well ventilated area.
Applicators:
Select a suitable pure bristle type paint brush. Use
a proper width brush or roller to apply the primer
and cement (see chart below). Speedy application
of cement is important due to its fast drying
characteristics. IMPORTANT NOTE: A dauber type
applicator should only be used on pipe sizes 2” and
below. For larger diameter pipe, a brush or roller
must be used.
Figure 44
B. Deburring
Use a knife, plastic pipe deburring tool, or file to
remove burrs from the end of small diameter pipe.
Be sure to remove all burrs from around the inside
as well as the outside of the pipe. A slight chamfer
(bevel) of about 10°-15° should be added to the end
to permit easier insertion of the pipe into the end of
the fitting. Failure to chamfer the edge of the pipe
may remove cement from the fitting socket, causing
the joint to leak.
RECOMMENDED BRUSH* SIZE FOR
PRIMER AND CEMENT APPLICATIONS
Nominal
Pipe (IPS)
Figure 45
Brush Size
2
1.5” (3.8cm)
3
1.5” - 2.5” (3.8cm - 6.4cm)
*USE ONLY NATURAL BRISTLE
Table 3
3. MAKING THE JOINT
A. Cutting
Pipe must be squarely cut to allow for the proper
interfacing of the pipe end and the fitting socket
bottom. This can be accomplished with a miter box
saw or wheel type cutter. Wheel type cutters are not
generally recommended for larger diameters since
they tend to flare the corner of the pipe end. If this
type of cutter is used, the flare on the end must be
completely removed.
Note: Power saws, if used, should be specifically
designed to cut plastic pipe.
36
C. Test dry fit of the joint
Tapered fitting sockets are designed so that
an interfaced fit should occur when the pipe is
inserted about 1/3 to 2/3 of the way into the socket.
Occasionally, when pipe fitting dimensions are at
the tolerance extremes, it will be possible to fully
insert dry pipe to the bottom of the fitting socket.
When this happens, a sufficient quantity of cement
must be applied to the joint to fill the gap between
the pipe and fitting. The gap must be filled to obtain
a strong, leak-free joint.
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D. Inspection, cleaning, priming
Visually inspect the inside of the pipe and fitting
sockets and remove all dirt, grease or moisture
with a clean dry rag. If wiping fails to clean the
surfaces, a chemical cleaner must be used. Check
for possible damage such as splits or cracks and
replace if necessary.
Depth-of-entry
Marking the depth of entry is a way to check if the
pipe has reached the bottom of the fitting socket
in Step F. Measure the fitting depth and mark this
distance on the pipe O.D. You may want to add
several inches to the distance and make a second
mark as the primer and cement will most likely
destroy your first one.
Apply primer to the surface of the pipe and fitting
socket with a natural bristle brush. This process
softens and prepares the PVC or CPVC for the
solvent cementing step. Move quickly and without
hesitation to the cementing procedure while the
surfaces are still wet with primer.
E. Application of solvent cement
• Apply solvent cement evenly and quickly around
•
•
outside of pipe at a width a little greater than the
depth of the fitting socket.
Apply a light coat of cement evenly around the inside
of the fitting socket. Avoid puddling.
Apply a second coat of cement to the pipe end.
A good joint will have sufficient cement to make a
bead all the way around the outside of the fitting hub.
The fitting will have a tendency to slide back while
the cement is still wet so hold the joint together for
about 15 seconds.
Figure 47
G. Cleanup and joint movement
Remove all excess cement from around the pipe
and fitting with a dry cotton rag. This must be done
while the cement is still soft.
The joint should not be disturbed immediately after
the cementing procedure, and sufficient time should
be allowed for proper curing of the joint. Exact drying
time is difficult to predict because it depends on
variables such as temperature, humidity and cement
integrity. For more specific information, you should
contact your solvent cement manufacturer.
WARNING
Fire Hazard
• Cans of cement and primer should
be closed at all times when not in
use to prevent evaporation of
chemicals and hardening of cement.
• They are also very flammable and
should be kept away from heat or
flame.
Figure 48
Figure 46
F. Joint assembly
Working quickly, insert the pipe into the fitting socket
bottom and give the pipe or fitting a 1/4 turn to evenly
distribute the cement. Do not continue to rotate the
pipe after it has hit the bottom of the fitting socket.
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37
INSTALLATION CHECKLIST
Note: Use and complete this checklist before lighting the
heater. Correct any conditions that do not meet these
instructions.
Check Here
Water Heater Location
1. Centrally located with the water piping system.
Located as close to gas piping and vent pipe
system as possible.
2. Located indoors and in a vertical position.
Protected from freezing temperatures.
3. Proper clearances from combustible surfaces
maintained and not installed directly on a
carpeted floor.
4. Provisions made to protect the area from water
damage. Metal drain pan installed and piped to
an adequate drain.
5. Installation area free of corrosive elements and
flammable material.
6. Sufficient room to service the water heater.
Gas Supply and Piping
1. Gas supply is the same type as listed on the
water heater data plate.
2. Gas line equipped with shut-off valve, union
and dirt leg
3. Approved pipe joint compound used.
4. Adequate pipe size and of approved material.
5. Chloride-free soap and water solution or other
approved means used to check all connections
and fittings for possible gas leaks.
Vent Pipe System
1. Vent pipe and fittings of approved material.
2. Acceptable size, length and number of elbows
on exhaust vent system.
3. Installed in accordance with prevailing provisions
of local codes, or in the absence of such, the
latest edition of “National Fuel Gas Code”
ANSI Z223.1 (NFPA 54).
4. Horizontal piping slopes at an upward pitch of
1/8 in. (3mm) rise per 4 ft. (1.2m) away from
the water heater.
5. Not obstructed in any way.
38
Check Here
Vent Termination
Horizontal
1. 12 in. (305mm) min. above grade/snow level.
2. Away from corners, other vents, windows etc.
Vertical
1. Exhaust vent termination 18 in. (450mm) min.
above roof/snow level.
Water System Piping
1. Temperature and Pressure relief valve properly
installed with a discharge line run to an open
drain and protected from freezing.
2. All piping properly installed and free of leaks.
3. Heater completely filled with water.
4. Closed system pressure build-up precautions
installed.
Electrical Connections
1. Unit connected to a dedicated 120V electrical
supply.
2. Proper polarity.
3. Water heater properly grounded.
4. Installed in accordance with prevailing provisions
of local codes, or in the absence of such, the
latest edition of “National Electrical Code”
(NFPA 70)”.
After all actions on checklist are checked/
completed, read the Lighting Instructions and
proceed with lighting the heater.
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LIGHTING INSTRUCTIONS
Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner
viewport is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater.
The gas control valve/thermostat has an “On/Off Switch” and must be turned on before the water heater is operational.
Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas. Do not start
this water heater with any gas other than the one listed on the label. If you have any questions or doubts, consult the
gas supplier or gas utility company. The following Lighting Instruction label appears on the front of the water heater.
This heater is equipped with a Honeywell gas control/thermostat and a hot-surface igniter. This control is a combination
gas valve, thermostat and ignition controller for use on this power vented water heater. The valve contains a microcontroller that supervises the ignition sequence and monitors the temperature settings and operation of the heater. The
controller also monitors the flammable vapor safety features of this heater.
This heater is equipped with a hot-surface ignition system that automatically ignites the burner. Do not attempt
to light this heater manually with a match or flame-producing device.
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire
or explosion may result causing property damage, personal
FLAMMABLE
injury or loss of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
• If you cannot reach your gas supplier, call the
A. This appliance does not have a pilot. It is
equipped with an ignition device which
fire department.
automatically lights the burner. Do NOT try
C. Use only your hand to turn the gas control
to light the burner by hand.
buttons. Never use tools. If the control
B. BEFORE OPERATING smell all around the
buttons will not turn, don't try to repair them,
appliance area for gas. Be sure to smell next
call a qualified service technician. Force or
to the floor because some gas is heavier
attempted repair may result in a fire or
than air and will settle on the floor.
explosion.
WHAT TO DO IF YOU SMELL GAS:
D. Do not use this appliance if any part has
been under water. Immediately contact a
• Do not try to light any appliance.
qualified installer or service agency to
• Do not touch any electric switch; Do not use
replace a flooded water heater. Do not
any phone in your building.
attempt to repair the unit. It must be
• Immediately call your gas supplier from a
replaced!
neighbor's phone. Follow the gas suppliers
instructions.
OPERATING INSTRUCTIONS
1.
2.
3.
4.
5.
6.
STOP! Read the safety
information above on this
label.
Turn off all electric power to the
appliance.
Turn the thermostat
counter-clockwise
to the
lowest setting.
Set the switch on the control to
the “OFF” position.
Do not attempt to light manually.
Wait five (5) minutes to clear out
any gas. If you then smell gas, STOP!
Follow “B” in the safety information above on
this label. If you don't smell gas, go the next
step.
7. Turn on all electric power to
the appliance.
8. Set the switch on the control
to the “ON” position.
9. Turn thermostat to desired
setting.
DANGER Hotter water
increases the risk of
scald injury. Consult the
instruction manual before
changing temperature.
10. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas
supplier.
TO TURN OFF GAS TO APPLIANCE
1. Turn the thermostat counter-clockwise
to the lowest setting.
2. Set the gas control switch to the “OFF” position.
3. Turn off electrical power to the appliance if service is to be performed.
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323546-000
39
OPERATING THE TEMPERATURE CONTROL SYSTEM
It is recommended that lower water temperatures be used
to avoid the risk of scalding. It is further recommended, in
all cases, that the water temperature be set for the lowest
temperature which satisfies your hot-water needs. This
will also provide the most energy efficient operation of
the water heater.
Short repeated heating cycles caused by small hot-water
uses can cause a temperature increase of the hot water
by 20F° (11C°) higher than the heater’s temperature
settings. If you experience this type of use you should
consider using lower temperature settings to reduce scald
hazards.
Should overheating occur or the gas supply fails to shut
off, turn off the main manual gas shut off valve to the
appliance (see Figure 1).
DANGER
HOT
BURN
Water temperature over
125°F (52°C) can cause
severe burns instantly
resulting in severe injury or
death.
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing valves must
be installed when required
by codes and to ensure safe
temperatures at fixtures.
Read instruction manual for
safe temperature setting.
area is not available, a cover should be installed over the
thermostat to prevent tampering.
This water heater is equipped with an adjustable
thermostat to control water temperature (see Figure 49).
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 time of the
exposure. The slower response time of children, aged or
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.
The hot setting shown on the dial is approximately
120°F (49°C). This is a good starting point to set the
temperature.
Setting the water heater temperature at 120°F (49°C) will
reduce the risk of scalds. Some states require settings at
specific lower temperatures.
The thermostat settings on the gas control valve are shown
in Figure 49.
The water temperature setting was factory set at the lowest
(VAC) temperature setting.
HOT WATER CAN SCALD:
Water heaters are intended to produce hot water. Water
heated to a temperature which will satisfy space heating,
clothes washing, dish washing, and other sanitizing needs
can scald and permanently injure you upon contact. Some
people are more likely to be permanently injured by hot
water than others. These include the elderly, children, the
infirm or physically/mentally handicapped. If anyone using
hot water from this heater fits into one of these groups
or if there is a local code or state law requiring certain
temperature water at the hot-water tap, then you must
take special precautions. In addition to using the lowest
possible temperature setting that satisfies your hot-water
needs, a means such as a mixing valve, should be used
at the hot-water taps used by these people or at the water
heater. Mixing valves are available at plumbing supply or
hardware stores (see Figure 8-10). Follow manufacturer’s
instructions for installation of the valves. Before changing
the factory setting on the thermostat, in this manual, see
Table 4.
The water heater should be located in an area where
the general public does not have access. If a suitable
40
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GAS CONTROL VALVE/THERMOSTAT
130°F 140°F 150°F 155°F
ON/OFF
SWITCH
TEMPERATURE
SETTING DIAL
120°F
110°F
70°F
Figure 49
Approximate
Temperature
Temperature
Dial Setting
°F (°C)
Time to induce a 2nd
and 3rd Degree burn
to adult skin
VERY HOT
155 (68)
Less than 1 second
C
150 (65)
About 1.5 seconds
B
140 (60)
Less than 5 seconds
A
130 (54)
More than 30 seconds
HOT
120 (49)
More than 5 minutes
LOW
110 (43)
Normal shower temp
VAC
70 (21)
N/A
Table 4
Note: The temperatures indicated are approximates. The
actual temperature of the heated water may vary.
The Vacation Setting (VAC) sets the controller at
approximately 70°F (21°C). This setting is recommended
when the water heater is not in use for a long period of time.
This effectively turns the controller temperature setting
down to a temperature that prevents the water in the water
heater from freezing while still conserving energy.
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41
FOR YOUR INFORMATION
START UP CONDITIONS
Condensate
Whenever the water heater is filled with cold water, some
condensate will form while the burner is ON. A water
heater may appear to be leaking when in fact the water is
condensate. This usually happens when:
a. A new water heater is filled with cold water for the first
time.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue
temperatures are lower.
c. Large amounts of hot water are used in a short time
and the refill water in the tank is very cold.
Moisture from the products of combustion condense on
the cooler tank surfaces and form drops of water which
may fall onto the burner or other hot surfaces to produce
a “sizzling” or “frying” noise.
Because of the suddenness and amount of water,
condensate water maybe diagnosed as a “tank leak”.
After the water in the tank warms up (about 1-2 hours),
the condition should disappear.
Do not assume the water heater is leaking until there has
been enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the
family’s demands for hot water including dishwashers,
washing machines and shower heads.
Excessive condensate maybe noticed during the winter and
early spring months when incoming water temperatures
are at their lowest.
Good venting is essential for a gas fired water heater
to operate properly as well as to carry away products
of combustion and water vapor (see also “Condensate”
section).
Thermal expansion
See “Thermal Expansion” section elswhere in this
manual.
CAUTION
Property Damage Hazard
• Avoid water heater damage.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold water inlet.
• Contact qualified installer or service agency.
A properly-sized thermal expansion tank should be
installed on all closed systems to control the harmful
effects of thermal expansion. Contact a plumbing
service agency or your retail supplier regarding the
installation of a thermal expansion tank.
42
Closed water systems
See “Closed Water Systems” section elswhere in this
manual.
Smoke/odor
It is not uncommon to experience a small amount of
smoke and odor during the initial start-up. This is due to
burning off of oil from metal parts, and will disappear in
a short while.
Strange sounds
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
necessarily represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the
burner area during heating and cooling periods and should
be considered normal. See “Condensate” section in this
manual.
OPERATIONAL CONDITIONS
Smelly water
Each water heater contains at least one anode rod for
corrosion protection of the tank. Certain water conditions
will cause a reaction between this rod and the water. The
most common complaint associated with the anode rod
is one of a “rotten egg smell” in the hot water. The smell
is a result of four factors which must all be present for the
odor to develop:
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused
by the corrosion protective action of the anode.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less
active material, and then chlorinating the water heater tank
and all water lines. Contact the local water heater supplier
or service agency for further information concerning an
Anode Replacement Kit and this chlorination treatment.
If the smelly water persists after the anode replacement
and chlorination treatment, we can only suggest that
chlorination or aeration of the water supply be considered
to eliminate the water problem.
Do not remove the anode leaving the tank unprotected.
By doing so, all warranty on the water heater tank is
voided.
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“AIR” IN HOT-WATER FAUCETS
WARNING
Explosion Hazard
• Flammable hydrogen gases may
be present.
• Keep all ignition sources away
from faucet when turning on hot
water.
HYDROGEN GAS: Hydrogen gas can be produced in
a hot-water system that has not been used for a long
period of time (generally two weeks or more). Hydrogen
gas is extremely flammable and explosive. To prevent
the possibility of injury under these conditions, it is
recommended that the hot-water faucet, located farthest
away, be opened for several minutes before any electrical
appliances which are connected to the hot-water system
are used (such as a dishwasher or washing machine). If
hydrogen gas is present, there will probably be an unusual
sound similar to air escaping through the pipe as the hotwater faucet is opened. There must be no smoking or open
flame near the faucet at the time it is open.
HIGH WATER TEMPERATURE SHUT-OFF SYSTEM
This water heater is equipped with a manual reset type
high limit (Thermal Cut Out (TCO)) sensor. The high limit
switch interrupts the main burner gas flow should the
water temperature reach 195°F (91°C). The high limit
can be reset when the water temperature drops below
140°F (60°C).
Note: See “TCO Resettable Lockout” for corrective action
and how to reset the control.
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43
PERIODIC MAINTENANCE
GENERAL UPKEEP
Make it a habit to look around the heater, the vent piping,
and the hot and cold water pipes. Do not allow any material
to be piled up against the heater. Do not place any object
on top of the vent pipes.
Every 3 – 6 months or as necessary:
• Clean lint from blower, top of heater.
Once per year:
• Inspect the Vent System.
• Burner Operation and Inspection.
• Combustion Chamber for scaling or sooting.
• Temperature-Pressure Relief Valve Test.
• Anode Rod Inspection.
• Flush a pail of water from the heater drain valve, once
per year.
If any deficiencies or abnormalities are encountered during
these inspections call a qualified service technician.
VENTING SYSTEM INSPECTION
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Flue gases may escape if vent pipe is not properly
connected.
• Be alert for obstructed, sooted or deteriorated vent
system to avoid serious injury or death.
• Do not store corrosive chemicals in vicinity of water
heater.
• Chemical corrosion of flue and vent system can
cause serious injury or death.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
At least once a year a visual inspection should be made
of the venting system. You should look for:
• Obstructions which could cause improper venting. The
combustion dilution and ventilation air flow must not
be obstructed.
• Damage or deterioration which could cause improper
venting or leakage of combustion products.
Be sure the vent piping is properly connected to prevent
escape of dangerous flue gasses which could cause
deadly asphyxiation.
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chemical
vapors. Spray can propellants, cleaning solvents,
refrigerator and air conditioner refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes, bleach
and process chemicals are typical compounds which are
potentially corrosive.
44
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility
to correct the problem and clean or replace the flue and
venting before resuming operation of the water heater.
BLOWER MAINTENANCE
Inspect the top of the heater and around the ventilation
openings of the blower motor and the rear blower dilution
air intakes for any lint and dust that may have accumulated.
Depending on the location of the heater, significant
quantities of lint may accumulate. The lint may obstruct
the free flow of air to the motor, and cause the motor and
blower to run hotter than normal (see Figure 50).
To clean any dust and lint, proceed as follows:
1. Unplug the water heater.
2. Using a nylon bristled paint or tooth brush, brush away
any lint. Pick up the lint with a cloth.
Better results can be achieved by using the small brush on
a vacuum cleaner to remove all lint and dust which have
accumulated on top of the heater, the the louvres of the
air intake snorkel, the motor ventilation openings and the
rear blower dilution air intakes.
Important: Do not insert any foreign object into the
ventilation openings of the motor.
CLEANING THE BLOWER.
In dusty and contaminated air conditions, the interior of
the blower and the blower wheel may require periodic
cleaning. This is often indicated by nuisance failures of the
air pressure switch or the high limit temperature control.
A collection of dust or debris on the rear blower dilution
air intakes can also indicate reduced blower capacity. To
clean the inside of the blower assembly and the blower
wheel requires the removal of the blower/motor from the
mounting plate located on the top of the heater. Tools
required include an 11/32” nut driver, small (1”) paint brush,
toothbrush and vacuum cleaner.
1. Turn the thermostat on the gas control to the lowest
setting. If the heater is running, wait for it to shut down
(see Figure 49).
2. Turn the gas control switch to the “OFF” position.
3. Disconnect the electrical power to the water heater
from the wall outlet.
4. Disconnect the vent piping from the top of the blower.
Loosen the lower gear clamp that holds the rubber
coupling to the blower (see Figure 50).
5. Remove and retain the (4) 11/32” nuts located on the
back of the blower with the nutdriver (see Figures 43
& 50).
6. Holding the blower motor and the blower housing,
pull the assembly forward to disengage it from the
mounting plate. The blower will still be connected to the
junction box so excercise care not to stress the wiring.
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7. Accessing the blower wheel through the outlet, use
the paint brush to brush off the outer edge of the
blower wheel to dislodge the dirt stuck on the blades
and the inside of the housing. Rotate the wheel until
all blades are clear. Note: The wheel is a balanced
component. Do not bend, dent or distort the blades as
this can upset the wheel balance and affect the blower
operation. Vacuum out the loosened dirt.
8. Accessing the inside of the blower wheel through the
rear of the housing, gently brush off the inside of the
blades using the toothbrush. Again, take care not to
distort the blades. Rotate the wheel until all blades are
cleaned and vacuum the debris. Do not remove any
of the balancing chips attached to the blades.
9. Inspect the flue collector hood (still attached to the
heater) and vacuum out the dust and debris that may
have accumulated.
10. With all parts cleaned and the blower wheel turning
freely, reinstall the blower to the mounting plate
aligning the (4) studs and pushing tight against the
mounting plate.
11. Reinstall the (4) 11/32” nuts and tighten securely. All
(4) nuts must be in place and secure to safely operate
the blower.
12. Reattach the vent piping and coupling to the top of the
blower, tighten the bottom gear clamp and ensure the
piping is secure.
13. With all components clean and secure, reconnect the
electrical power to the heater.
14. Reset the thermostat to the desired temperature
setting and turn the gas control switch back to the
“ON” position. Note: If the water in the heater is hot,
the unit will wait to operate until there is a need for
more hot water.
VENT
PIPE
COUPLING
GEAR
CLAMP
BURNER OPERATION AND INSPECTION
Flood damage to a water heater may not be readily visible
or immediately detectable. However, over a period of time
a flooded water heater will create dangerous conditions
which can cause death, serious bodily injury, or property
damage. Contact a qualified installer or service agency to
replace a flooded water heater. Do not attempt to repair
the unit! It must be replaced!
At least once a year a visual inspection should be made of
the main burner and the hot surface igniter assembly for
proper flame characteristics and ignition sequences. This
can be done by removing the outer door and viewing the
main burner operation through the viewport on the inner
door (see Figure 51). The main burner should provide
complete combustion of gas, ignite rapidly, give reasonably
quiet operation, and cause no excessive flame lifting from
the burner ports. If the proper flame characteristics are
not evident (see Figure 52), make sure that the flow of
combustion and ventilation air is not blocked.
You should also check for sooting. Soot is not normal and
will impair proper combustion. A visual inspection of the
main burner and hot surface igniter should also be done
at least once a year (see Figure 51).
Soot build-up indicates a problem that requires correction
before further use. Turn “OFF” gas to water heater by
unplugging the power cord and leave off until repairs are
made. Failure to correct the cause of the sooting can
result in a fire causing death, serious injury, or property
damage.
IGNITER
AND FLAME
ROD
MAIN
BURNER
11/32”
NUTS
IGNITER
AND
FLAME
ROD
MOTOR
FLUE
COLECTOR
HOOD
VIEWPORT
Figure 51
BLUE TIPS
LIGHT BLUE INNER
CONES ARE
SATISFACTORY
INCORRECT
FLAME LAZY
YELLOW
CORRECT FLAME
SOFT BLUE
BLOWER
MOUNTING
PLATE
BLOWER
DILUTION
AIR INTAKES
Figure 52
Figure 50
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45
COMBUSTION CHAMBER AND BURNER CLEANING
In the event your burner or burner air openings require
cleaning, Call your service agency to remove and clean
the burner and correct the problem that required the burner
to be cleaned.
The anode rod should be inspected after a maximum of
three years and annually thereafter until the condition of
the anode rod dictates its replacement. Note: Artificially
softened water requires the anode rod to be inspected
annually.
HOUSEKEEPING
The following are typical (but not all) signs of a depleted
anode rod:
• The majority of the anode rod’s diameter is less than
3/8”.
• Significant sections of the support wire (approx. 1/3
or more of the anode rod’s length) are visible (see
Figure 53).
DANGER
Fire and Explosion Hazard
• Do not obstruct combustion air
openings at the rear of the water
heater.
• Do not use or store flammable
vapor products such as gasoline, solvents or adhesives in the
same room or area near water
heater or other appliance.
• Can cause serious injury or
death.
INSTALLED IN SUITABLE AREA:
To ensure sufficient ventilation and combustion air
supply, proper clearances from the water heater must
be maintained. See “Locating the New Water Heater”
section. Combustible materials such as clothing, cleaning
materials, or flammable liquids, etc. must not be placed
against or adjacent to the water heater which can cause
a fire.
ANODE ROD INSPECTION
Each water heater contains at least one anode rod, which
will slowly deplete (due to electrolysis) prolonging the life
of the water heater by protecting the glass-lined tank from
corrosion. Adverse water quality, hotter water temperatures,
high hot water usage, hydronic heating devices and water
softening methods can increase the rate of anode rod
depletion. Once the anode rod is depleted, the tank will
start to corrode eventually developing a leak.
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water. Important: Do not remove this
anode rod permanently as it will void any warranties.
A special anode rod may be available if water odor or
discoloration occurs. Note: This anode rod may reduce
but not eliminate water odor problems. The water supply
system may require special filtration equipment from a
water conditioning company to successfully eliminate all
water odor problems.
Artificially softened water can be exceedingly corrosive
because the process substitutes sodium ions for
magnesium and calcium ions. The use of a excessively soft
water may decrease the life of the water heater tank.
46
If the anode rod show signs of either or both it should be
replaced. Note: Whether re-installing or replacing the
anode rod, check for any leaks and immediately correct
if found.
Figure 53
ANODE ROD
Important: Use only factory authorized replacement parts.
If you lack the necessary skills to properly perform the
installation, you should not proceed, but get help from a
qualified service technician.
• Tools required:
• Ratchet with 1-1/16” Socket
• Pliers
• Teflon® Tape or an approved pipe sealant
Removing Anode Rod:
1. Set the gas control valve/thermostat to its lowest
setting by turning the knob counter-clockwise to
the VAC point (see Figure 49). If the water heater is
running, wait for it to shut down.
2. Turn gas control switch to the “OFF” position.
3. Disconnect the electrical power to the water heater
from the wall outlet.
4. Shut off the incoming water supply to the water heater
and open a nearby hot-water faucet to depressurize
the water tank.
5. Connect a hose to the drain valve and terminate it to
adequate drain or to the exterior of the building. Open
the drain valve and allow at least 5 gallons of water to
drain from the tank. Close drain and remove hose.
6. Remove the anode cap on top of the heater and
remove just enough insulation so you can access to
the anode head (see Figure 54). Keep the anode cap
in a safe place for reinstallation later.
7. Remove the anode rod by using a ratchet and a 11/16” socket turning counter-clockwise (see Figure
54).
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Installing Anode Rod:
1. Use Teflon® tape or an approved pipe sealant on
threads of the new anode rod.
2. Place the anode rod in the spud (top of the tank) and
turn clockwise until the threads are hand tight. Using a
ratchet and 1-1/16” socket tighten down water tight.
3. Open a nearby hot-water faucet to purge air from the
water line. Open the incoming water supply and fill
water heater tank completely (Note: To assure the
water heater tank is full, keep the hot-water faucet
open for 3 minutes after a constant flow of water is
obtained).
4. Turning off the hot-water faucet, check for water
leaks around anode rod and immediately correct any
if found.
5. Reinstall the insulation and anode cap which were
removed in step 6 of removal instructions.
6. With all components clean and secure, reconnect the
electric power to the heater.
7. Reset the thermostat to the desired temperature
setting and turn the gas control switch back to the
“ON” position (see Figure 49).
TEMPERATURE-PRESSURE RELIEF VALVE TEST
DANGER
• Burn hazard.
• Hot water discharge.
• Keep clear of
temperature-pressure
relief valve discharge.
HOT
BURN
It is recommended that the temperature-pressure relief
valve be checked to ensure it is in operating condition at
least once a year.
When checking the temperature-pressure relief valve
operation, make sure that (1) no one is in front of or around
the outlet of the T&P valve discharge line, and (2) that
water discharge will not cause any property damage, as
water may be extremely hot. Use care when operating
valve as the valve may be hot.
To check the relief valve, lift lever at the end of valve
several times (see Figure 55). The valve should seat
properly and operate freely.
CAP
ANODE ROD *
If after manually operating the valve, it fails to completely
reset and continues to release water, immediately close
the cold-water inlet to the water heater and drain the water
heater, see “Draining and Flushing” section. Replace
the T&P valve with a properly rated/sized new one, see
“Temperature-Pressure Relief Valve” for instructions on
replacement.
* THE ANODE ROD IS COVERED
BY URETHANE FOAM LOCATED
UNDER THE CAP. CHIP AWAY
THE FOAM TO EXPOSE THE
TOP OF THE ANODE ROD
Figure 55
Figure 54
If the Temperature-Pressure Relief Valve on the water
heater weeps or discharges periodically, it may be due to
thermal expansion.
Note: Excessive water pressure is the most common
cause of temperature-pressure relief valve leakage.
Excessive water system pressure is most often caused
by “thermal expansion” in a “closed system.” See “Closed
Water Systems” and “Thermal Expansion” sections of this
manual. The T&P valve is not intended for the constant
relief of thermal expansion.
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47
Temperature-pressure relief valve leakage due to pressure
build up in a closed system that does not have a thermal
expansion tank installed is not covered under the Limited
Warranty. Thermal expansion tanks must be installed on
all closed water systems.
WARNING
Explosion Hazard
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperaturepressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
DRAINING AND FLUSHING
Periodic draining and cleaning of sediment from the tank
maybe necessary. It is recommended that the tank be
drained and flushed every 6 months to remove sediment
which may build up during operation. The water heater
should be drained if being shut down during freezing
temperatures. See “Typical Installation” section in this
manual for location of the water heater components
described below.
DANGER
• Burn hazard.
• Hot water discharge.
HOT
BURN
• Keep hands clear of drain
valve discharge.
To drain the water heater storage tank:
1. Turn “OFF” the electrical supply to the water heater.
2. Turn “OFF” the gas supply at the Main Gas shut-off
Valve if the water heater is going to be shut down for
an extended period.
3. CLOSE the cold-water inlet valve to the water
heater.
4. OPEN a nearby hot-water faucet and leave open to
allow for draining.
5. Connect a hose to the drain valve and terminate to
an adequate drain.
Note: If the water heater is going to be shut down
and drained for an extended period, the drain valve
should be left open with hose connected allowing
water to terminate to an adequate drain.
6. Close the water heater drain valve when all water in
the storage tank has drained.
7. Follow instructions in the “Filling the Water Heater”
section.
8. Turn “ON” the gas supply at the main gas shut-off
valve.
9. Follow the lighting instructions on the label or see
“Lighting Instruction” to restart the water heater.
To flush the water heater storage tank:
1. Turn “OFF” the electrical supply to the water heater.
2. Ensure the cold-water inlet valve is open.
3. Connect a hose to the drain valve and terminate it to
an adequate drain.
4. Ensure the drain hose is secured before and during the
entire flushing procedure. Flushing is performed with
system water pressure applied to the water heater.
5. Open the water heater drain valve to flush the storage
tank. Caution: Water will be hot.
6. Flush the water heater storage tank to remove
sediment and allow the water to flow until it runs
clean.
7. Close the water heater drain valve when flushing is
completed.
8. Remove the drain hose.
9. Ensure the heater is full of water.
10. Turn “ON” electrical supply to place water heater back
in operation and follow the lighting instructions.
11. Allow the water heater to complete several heating
cycles to ensure it is operating properly.
Caution: Do not turn on power to the water heater unless
the tank is full. Open a hot-water faucet and allow the
water to run until the air is purged and the water flows
uninterrupted from the faucet.
Important: When operating a cold tank, condensation can
occur and drip on the burner. This should not be confused
with a tank leak.
48
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LEAKAGE CHECKPOINTS
SERVICE
If a condition persists or you are uncertain about the
operation of the water heater contact a service agency.
Use this guide to check a “leaking” water heater. Many
suspected “leakers” are not leaking tanks. Often the source
of the water can be found and corrected.
If you are not thoroughly familiar with gas codes, your water
heater and safety practices, contact your gas supplier or
qualified installer to check the water heater.
Leakage from other appliances, water lines, or ground
seepage should also be checked.
* To check where threaded portion enters tank, insert
cotton swab between jacket opening and fitting. If cotton
is wet, follow “Draining” instructions in the “Periodic
Maintenance” section and then remove fitting. Put
pipe dope or Teflon tape on the threads and replace.
Then follow “Filling the Water Heater” instructions in
the “Installing the New Water Heater” section.
Ensure the venting is properly attached and secured.
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot-water
faucet before turning “ON” gas to the water heater.
A. Water at the blower assembly is water vapor which
has condensed out of the combustion products. This
is caused by a problem in the vent. A drainage port is
included at the vent pipe connection. Contact the gas
utility.
B. *Condensation may be seen on pipes in humid weather
or pipe connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure
relief valve may be due to thermal expansion or high
water pressure in your area.
E. *The temperature-pressure relief valve may be leaking
at the tank fitting.
F. Water from a drain valve may be due to the valve being
slightly opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets
form and drip onto the burner. This is common at the
time of start-up after installation and when incoming
water is cold.
I. Water in the water heater bottom may be from
condensation, loose connections, or the relief valve.
DO NOT replace the water heater until a full inspection
of all possible water sources is made and necessary
corrective steps taken.
B
C
A
E
G
H
F
I
D
Figure 56
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49
REFERENCE PARTS LISTING
Replacement parts may be ordered
through your plumber or the local
distributor. When ordering replacement
parts, always have the following
information ready:
1. M o d e l , S e r i a l a n d P r o d u c t
number
2. Type of gas
3. Item number
4. Parts description
1. Vent Termination Elbow with Rodent
Screen
2. **Vent Pipe
3. **Vent Pipe Coupling (if required)
4. **Vent Pipe Elbow (long radius)
5. Blower High Limit Switch (see
Figure 62)
6. T&P Valve
7. Cold-Water Inlet Nipple/Diptube
8. Baffle Assembly
9. ** Discharge Pipe
10. Gas Control Valve/Thermostat
(Honeywell)
2
1
3
4
11. Gas Valve Electronic Control Module
And Cover (Honeywell)
12. Drain Valve
13. Outer Gas Door
14. Manifold Door Assembly (behind
outer door) (see Figures 59 & 60)
15. **Floor Drain
16. **Metal Drain Pan
17. Flammable Vapor Sensor (under
cover) (see Figure 61)
18. Combo Heating System Return
Inlet (Optional)
19. Air Inlet Snorkel
20. Combo Heating System Supply
Outlet (Optional)
21. Blower with Power Cord (see also
Figure 62)
22. Air Switch (inside box) (see Figure
62)
23. Junction Box (see Figure 62)
24. Junction Box Cover (see Figure
62)
25. Air Tubing (see Figure 62)
27
26. Rubber Coupling (see also Figure
62)
27. Gear Clamp (see also Figure 62)
28. Flue Collector
29. Hot-Water Outlet Nipple
30. Anode (under cap)
32. Flexible Manifold Tube (see Figures
59 & 60)
33. Viewport (see Figures 59 & 60)
34. Flame Sensor Rod (see Figures 59
& 60)
35. Gas Orifice (see Figures 59 & 60)
36. Sheet Metal Burner (see Figures 59
& 60)
37. Gas Manifold (see Figures 59 &
60)
38. Hot-Surface Igniter (see Figures 59
& 60)
39. Manifold Door Gasket (see Figures
59 & 60)
40. Manifold Door (see Figures 59 &
60)
41. Two Piece Grommet With Clip (see
Figures 59 & 60)
** parts not supplied with the water
heater
27
26
6
21
7
21
29
28
20
30
7
Blower
Dilution Air
Inlets
9
10 11
8
Combustion
Air Inlets
18
19
12
13 14
17
16
50
15
Front View
Figure 57
Rear View
Figure 58
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Natural gas and Propane main
burner with igniter assembly for
40k to 50k Btu/hr models
34
22
25
26
23
*
35
32
27
24
Flare Nut**
36
37
21
38
33
5
Figure 62
39
41
Notes: * Natural gas models have Right-hand thread,
Propane models have Left-hand thread.
** For Natural gas models the Flare Nut has Righthand thread. For Propane models the Flare Nut
has Left-hand thread.
40
Figure 59
Natural gas and Propane
main burner with igniter
assembly for 60k to 75k
Btu/hr models
32
*
34 35
Flare
Nut**
36
37
38
33
39
41
40
Figure 60
17
Figure 61
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51
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent.
PROBLEM
BURNER FLAME
TOO HIGH
FLAME BURNS
AT ORIFICE
INSUFFICIENT
HOT WATER
WATER IS TOO HOT
SLOW HOT WATER
RECOVERY
DRIP FROM
RELIEF VALVE
POSSIBLE CAUSE(S)
1. Air inlets blocked
2. Insufficient secondary air
3. Orifice too large
1. Unblock inlet air openings
2. Provide ventilation to water heater
3. Replace with correct orifice
1. Low gas pressure
2. Defective gas control valve/thermostat
1. Check with gas utility company
2. Replace gas control valve/thermostat
1. Low gas pressure
2. Orifice too small
3. Thermostat set too low
4. Gas control error codes
5. Sediment or lime in tank
6. Water heater too small
7. Wrong piping connections
8. Leaking faucets
9. Wasted hot water
10.Long runs of exposed piping
11.Hot-water piping in outside wall
1. Check with gas utility company
2. Replace with correct orifice (see rating
plate)
3. Turn temperature knob to higher setting
4. Refer to gas control error codes
5. Drain/flush-provide water treatment if
needed
6. Install adequate heater
7. Correct piping: dip tube must be in cold
inlet
8. Repair faucets
9. Advise customer
10.Insulate piping
11.Insulate piping
1. Thermostat is too high
2. Defective gas control valve/thermostat
1. Turn temperature knob to lower setting
2. Replace the gas control valve/
thermostat
1.
2.
3.
4.
5.
6.
7.
8.
9.
Insufficient air/ flue blockage
Low gas pressure
Orifice too small
Thermostat set too low
Heater too small
Wrong piping connection
Wasted hot water
Flue clogged
Air inlets blocked
1. Provide ventilation to water heater.
Check flue way, flue baffle and burner
2. Check with gas utility company
3. Replace with correct orifice (see rating
plate)
4. Turn temperature knob to higher setting
5. Install adequate heater
6. Correct piping-dip tube must be in cold
inlet
7. Advise customer
8. Clean flue, locate source and correct
9. Unblock inlet air openings
1.
2.
3.
4.
Pressure build-up
Heater stacking
Closed water system
Improperly seated valve
1. Use a pressure-reducing valve and relief
valve
2. Lower the thermostat setting
3. See thermal expansion section
4. Check Relief valve for proper operation
(Do Not plug T&P valve)
GAS CONTROL VALVE/ 1. Defective gas control valve/thermostat
THERMOSTAT FAILS TO
SHUT OFF
SMELLY WATER
52
CORRECTIVE ACTION
1. Sulfides in water supply
2. Bacteria in water supply
3. 3.Incompatible anade
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1. Replace gas control valve/thermostat
1. Chlorination procedure
2. Chlorination procedure
3. Replace with anode appropriate for water
conditions
PROBLEM
CONDENSATION
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
1. Filling the new water heater for the first 1. Normal operation: the condensation
time
should disappear after heater warms up
2. M o i s t u r e f r o m t h e p r o d u c t s o f 2. Normal operation: the condensation
combustion
should disappear in time
3. Water dripping from blower assembly
3. Install condensate hose to drain port on
4. Undersized water heater
the rubber coupling
4. Install adequate heater
Air inlets blocked
Insufficient air
Flue clogged
Heater installed in a confined area
House too tight
1. Unblock inlet air openins
2. Provide fresh air ventilation to the water
heater
3. Clean, locate source and correct
4. Provide fresh air ventilation to the water
heater
5. Provide fresh air ventilation to the water
heater
1.
2.
3.
4.
SMOKING AND CARBON
5.
FORMATION
6.
7.
Air inlets blocked
Insufficient air
Low gas pressure
Orifice too large
Flue clogged
Defective gas control valve/thermostat
Heater installed in a confined area
1. Unblock inlet air openings
2. Provide ventilation to water heater.
Check flue way, flue baffle and burner
3. Check with gas utility company
4. Replace with correct orifice (see rating
plate)
5. Clean, locate source and correct
6. Replace gas control valve/thermostat
7. Provide fresh air ventilation
1.
2.
3.
4.
5.
Air in gas line
Pressure switch
Blocked exhaust
Wire connection
Defective gas control valve/thermostat
1. Purge the air from gas line
2. Check the pressure switch, make sure
the pressure switch hose is not kinked
3. Check vent pipe for blockage
4. Check wire connections
5. Replace the gas control valve/
thermostat
COMBUSTION ODORS
UNABLE TO LIGHT
THE BURNER
SIZZLING, RUMBLING
NOISE
WATER LEAKAGE
BLOWER WILL
NOT START
1.
2.
3.
4.
5.
1. Scale and sediment
2. Condensation dripping on burner
1. Drain/flush-provide water treatment if
needed
2. Refer to “Condensate” section
1. Condensation
1. Refer to “Condensate” section
2. Dripping Temperature & Pressure Relief 2. Refer to “Temperature & Pressure Relief
Valve
Valve” section
3. Drain valve dripping/leaking
3. Back flush to clean- out sediment, replace
4. Tank Leak
if necessary.
4. Check “Leakage Checkpoints”
1.
2.
3.
4.
5.
6.
No power to unit
Thermostat set too low
Defective air pressure switch
Defective blower
Disconnected or loose wire
Control locked out
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1. Plug in power cord, check fuses and/or
supply voltage
2. Turn temperature knob to higher setting
3. Replace air pressure switch
4. Replace blower
5. Repair and reconnect wires
6. Refer to “Resetting The Heater Control”
– determine cause of lockout
53
PROBLEM
BLOWER RUNS
CONTINUOUSLY
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
1. Air pressure switch not closing due to
insufficient draft – check for:
a. Vent piping blocked
b. Piping length too long
c. Clogged/dirty blower
2. Disconnected, torn or blocked pressure
switch hose from air pressure switch to
blower housing
3. Defective pressure switch
4. High limit switch open due to excessive
vent temperature or defective switch
1. Determine cause of insufficient
draft. Check draft with manometer at
pressure switch
a. Remove blockage
b. Reduce vent length/increase vent
size
c. Clean blower wheel
2. Reconnect or replace pressure switch
hose
3. Replace defective pressure switch
4. Determine cause of overheating check
for: overfiring, insufficient air supply,
high ambient air temperature
HOT SURFACE IGNITER 1. 120VAC polarity reversed at 120VAC 1. Reverse polarity at 120VAC outlet
receptacle
NOT GLOWING
outlet receptacle
2. Replace igniter
FOLLOWING WARM-UP 2. Defective hot surface igniter
3. Defective gas control valve/thermostat 3. Replace gas control valve/thermostat
PERIOD
VENT PIPE TOO HOT
1. Blower high limit switch fails to open switch defective
2. Not enough dilution air to mix with flue
gases
3. Air in room too hot for mixing with flue
gases
4. Wrong burner orifice
RESETTING THE HEATER CONTROL
• Soft lockouts as diagnosed by the system error codes
require the gas control to be reset.
• To reset the control, slide the “ON/OFF” switch to the
“OFF” position. Wait for 10 seconds and move the
switch back to the “ON” position.
• If the problem that caused the control to lock out has
not been corrected, the control will remain or again go
back into lockout.
LOCKOUTS
Soft Lockout
• occurs when a system safety device trips to break the
sequence of operation. The control will retry the system
in a timed basis but will not reinstate operation until the
failure is corrected.
Hard Lockout
• occurs when the main contrioller fails and must be
replaced.
TCO RESETTABLE LOCKOUT
Reseting a High Limit (Thermal Cutout) trip requires
manual intervention and cannot be reset by just cycling
power to the control.
To reset the control, first slide the “ON/OFF” switch to the
“OFF” position. Wait for 10 seconds and move the switch
back to the “ON” position.
A manual reset also requires turning the temperature
setting dial to the lowest (coldest) position for a minimum
of 10 seconds and then returning it to the desired setpoint.
A manual reset is allowed after each of the first two TCO
trips. After a third TCO trip, the control enters a hard lockout
state and must be replaced.
Note: A high limit cutout indicates an overheating situation
or very high water temperatures. Contact your local service
provider to determine the cause of the overheating or
another reason for the malfunction.
54
1. Replace blower high limit switch Replace
blower high limit switch
2. Proper air circulation must be provided for
combustion and dilution of flue temp
3. Increase ventilation to lower room
temperature
4. Install correct orifice.
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IGNITION STATE AND TIMING
IGNITION STATE
Pre-purge
SYSTEM STATUS AND ERROR CODES
The micro-controller inside the gas control monitors the
flammable vapor safety features, the ignition sequence,
temperature settings and overall operation of the heater.
If any of these parameters does not operate properly the
controller will shut down the water heater, diagnose the
failure and flash an error code. The table below lists the
System Status Codes for the Honeywell control. Refer to
it and to the “Trouble Shooting Guidelines” to diagnose
the problem before attempting corrective action. See
also “Flammable Vapor Sensor” and “TCO Resettable
Lockout”.
TIMING
5 seconds (NG models)
15 seconds (LP models)
Hot Surface Igniter
(HSI) Warmup
10 seconds
Ignition Activation
Period (IAP)
3.5 seconds maximum
Flame Recognition
Period (FRP)
0.5 second
Trial For Ignition
IAP + FRP
Flame Stabilization
Period
Not Applicable
Inter-purge
30 seconds
Flame Failure
Response Time
2 seconds max
(@ 1uA flame current)
Post-purge
Pressure Switch (PS)
Prove Period
LED Flash Sequence
Control Status
Short flash
once every four
seconds
IDLE (no call for heat,
no fault conditions)
30 seconds
“Heartbeat”,
alternates bright/dim
Call For Heat
(no fault conditions)
2 minutes
One Flash,
three second pause
Low Flame Signal
(control continues to operate)
Pressure Switch (PS)
Fault Delay (failed
open/closed)
2 minutes
Two Flash,
three second pause
Pressure Switch Failed
Closed
Soft Lockout
20 minutes
Three Flash,
three second pause
Pressure Switch Failed Open
Thermal Cut Out
(TCO) Limit Lockout
Indefinite (see “TCO Resttable
Lockout”)
Four Flash,
three second pause
Thermal Cut Out (TCO) Limit
Lockout
Flammable Vapor
(FV) Sensor Lockout
Indefinite (see “Resetting The
Heater Control”)
Five Flash,
three second pause
Flame Out Of Sequence
Six-One Flash,
three second pause
Soft Lockout
- Retry Limit
- Failed Trial For Ignition
Six-Two Flash,
three second pause
Soft Lockout
- Recycle Limit
- Pressure Switch/ High Limit
opened
Six-Three Flash,
three second pause
Soft Lockout
- Recycle Limit
- Flame Lost
Six-Four Flash, three
second pause
Soft Lockout
- Flame out of Sequence
Sensed
Seven Flash,
three second pause
Flammable Vapor Sensor
(FVS) Lockout
Eight-One Flash,
three second pause
Flammable Vapor Sensor
FVS Fault Detected
Eight-Two Flash,
three second pause
Temperature Sensor Fault
Detected
Eight-Three Flash,
three second pause
Electronics Fault Detected
Eight-Four Flash,
three second pause
Valve Fault Detected
Hardware Fault
Lockout
Indefinite
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57
LIMITED WARRANTY
RESIDENTIAL GAS LIMITED WARRANTY
THIS WARRANTY IS APPLICABLE TO THE ORIGINAL
OWNER ONLY, in accordance with the warranty terms and
conditions specified below.
A. O. Smith Water Heaters (the warrantor) will furnish the
ORIGINAL OWNER, 1) a replacement A. O. Smith water
heater of equivalent size and current model if the glass-lined
tank in this water heater leaks and, 2) a replacement part for
any component part which fails.
THE A. O. SMITH WATER HEATERS REPLACEMENT
MODEL OR PART WILL BE WARRANTED FOR ONLY THE
UNEXPIRED PORTION OF THE ORIGINAL WARRANTY.
The warranty period will be determined by the original date
of purchase of the water heater, or in the absence of a Bill
of Sale verifying said date, from the date of manufacture
indicated on rating plate affixed to this water heater. This
warranty is not transferrable and applies to models listed
below:
WARRANTY PERIOD
Product Line
TANK1
PARTS2
GPVL, GPVT, GPVX
6 YEARS
6 YEARS
When the water heater has been used for other than single
family residential application;
1. The tank warranty shall be reduced to 1 year for 6 year
models.
2. The parts warranty shall be reduced to 1 year for all
models.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is
installed and operated in accordance with 1) all local fire
codes and plumbing codes, ordinances and regulations,
2) the printed instructions provided with it, 3) good industry
practices, and 4) proper safety practices such as but not
limited to a properly sized drain pan if installed in an area
where leakage from the tank or its connections would result
in damage to the area adjacent to the heater. In addition, a
new temperature and pressure relief valve, certified by the
Canadian Gas Association must have been properly installed
and piped to the nearest drain.
This limited warranty shall apply only when the water heater
is:
• owned by the original purchaser;
• installed for indoor operation only;
• used at temperatures not exceeding the maximum
calibrated setting of its thermostat;
• used at water pressure not exceeding the working
pressure shown on the heater;
58
• filled with potable water, free to circulate at all times and
with the tank free of damaging water sediment or scale
deposits;
• used in a non-corrosive and non-contaminated
atmosphere;
• used with factory approved anode(s) installed;
• in its original installation location;
• in the United States, its territories or possessions, and
Canada;
• sized in accordance with proper sizing techniques for
residential water heaters;
• bearing a rating plate which has not been altered, defaced
or removed except as required by the warrantor;
• used in an open system or in a closed system with a
properly sized and installed thermal expansion tank;
• operated with properly installed sediment trap (dirt leg)
in the gas supply line;
• fired with the fuel for which it was factory built;
• fired at the factory rated input;
• operated with the inner and outer combustion chamber
doors in place and all factory seals to combustion chamber
intact.
• installed with no attempted, nor actual modification
or alteration of the water heater’s design in any way,
including but not limited to, the attachment of noncompany approved appliances or equipment, including
any additional aftermarket equipment introduced into the
sealed system.
Any accident to the water heater or any part thereof (including
freezing, fire, floods, or lightning), any misuse, abuse or
alteration of it, any operation of it in a modified form, any
operation of the water heater on desalinated (deionized)
water, or any damage caused by attempts to repair tank
leaks or parts, will void this warranty. This warranty does
not cover water heaters replaced for cosmetic reasons or for
reasons of noise, taste, odor, discolored and/or rusty water.
This warranty does not apply to water heaters used to heat
pools, whirlpools or hot tubs or used for space heating where
its sizing does not conform with specifications of the heating
component manufacturer.
This warranty gives you specific legal rights, and you may
have other rights which vary under the laws of each province.
If any provision of this warranty is prohibited or invalid under
applicable province law, that provision shall be ineffective to
the extent of the prohibition or invalidity without invalidating
the remainder of the affected provision or the other provisions
of this warranty.
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SERVICE AND LABOR RESPONSIBILITY
UNDER THIS LIMITED WARRANTY, THE WARRANTOR
WILL PROVIDE ONLY A REPLACEMENT WATER HEATER
OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR
ALL OTHER COSTS. Such costs may include but are not
limited to:
a. Labor charges for service, removal, or reinstallation of
the water heater or part thereof.
b. Shipping and delivery charges for forwarding the new
water heater or replacement part from the nearest
distributor and returning the claimed defective heater or
part to such distributor.
c. All cost necessary or incidental for handling and
administrative charges, and for any materials and/or
permits required for installation of the replacement heater
or part.
LIMITATION ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability
imposed on the sale of this heater under province law are
limited to one year duration for the heater or any of its parts.
Some provinces do not allow limitations on how long an
implied warranty lasts, so the above limitations may not
apply to you.
CLAIM PROCEDURE
Any claim under this warranty should be initiated with the
dealer who sold the heater, or with any other dealer handling
the warrantor’s products. If this is not practical, the owner
should contact: A. O. Smith Water Heaters, 500 Tennessee
Waltz Parkway, Ashland City, Tennessee 37015. Phone:
1.800.365.0024 or visit our website: www.hotwater.com.
Replacement Parts may be ordered through authorized
servicers or distributors. Refer to your local Yellow Pages
for where to call or contact A. O. Smith Water Heaters, 500
Tennessee Waltz Parkway, Ashland City, TN 37015, phone:
1.800.821.2017. The warrantor will only honor replacement
with identical or similar water heater or parts thereof which
are manufactured or distributed by the warrantor. Dealer
replacements are made subject to in-warranty validation by
warrantor.
PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION
DATE ARE REQUIRED TO SUPPORT WARRANTY
CLAIM FROM ORIGINAL OWNER. THIS FORM DOES
NOT CONSTITUTE PROOF-OF-PURCHASE OR PROOFOFINSTALLATION.
DISCLAIMERS
NO EXPRESSED WARRANTY HAS BEEN OR WILL BE
MADE IN BEHALF OF THE WARRANTOR WITH RESPECT
TO THE MERCHANTABILITY OF THE HEATER OR THE
INSTALLATION, OPERATION, REPAIR OR REPLACEMENT
OF THE HEATER OR PARTS. THE WARRANTOR SHALL
NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF
USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE
TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL
DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY
VIRTUE OF THIS WARRANTY OR OTHERWISE FOR
DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER
DIRECT OR INDIRECT, AND WHETHER ARISING IN
CONTRACT OR IN TORT.
Should governmental regulations or industry standards
prohibit the Manufacturer from furnishing a comparable
model replacement under this warranty, the Owner will be
furnished with the closest comparable water heater meeting
the then current governmental regulations and industry
standards. A supplementary fee may be assessed to cover
the additional cost associated with the changes made to
meet applicable regulations and standards.
IMPORTANT INFORMATION
Model Number
Serial Number
INSTALLATION INFORMATION
Date Installed
Company’s Name
Street or P.O. Box
City, Province, and Zip Code
Phone Number
Plumber’s Name
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Phone: 800-821-2017 • Fax: 800-644-9306
Website: www.hotwater.com
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59
500 Tennessee Waltz Parkway,
Ashland City, TN 37015
• Technical Support: 800-527-1953
• Parts: 800-433-2545
• Fax: 800-644-9306
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Copyright © 2012 A. O. Smith Corporation. All rights reserved.
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