Bradford White URG2PDV40S6N Ultra Low NOx Power Direct Vent Gas Installation And Operating Instruction Manual

POWER DIRECT VENT GAS WATER HEATER
A Spanish language version of these instructions is available by contacting the
company listed on the rating plate.
La version espanola de estas instrucciones se puede obtener al escribirle a la
fabrica cuyo nombre aparece en la placa de especificaciones.
INSTALLATION AND OPERATING INSTRUCTION MANUAL
WARNING: If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or death.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable, combustible,
or corrosive vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in
your building.
• Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be preformed by a qualified
technician.
For your family’s comfort, safety and convenience we recommend
this water heater be installed and serviced by a plumbing
professional.
238-51006-00D REV 5/18
CONGRATULATIONS!
You have just purchased one of the finest water heaters on the market
today!
This installation, operation and instruction manual will
explain in detail the installation and maintenance of your
new Power Direct Vent Gas Water Heater. We strongly
recommend that you contact a plumbing professional for
the installation of this water heater.
We require that you carefully read this manual, as well as
the enclosed warranty, and refer to it when questions arise.
If you have any specific questions concerning your
warranty, please consult the plumbing professional from
whom your water heater was purchased. For your records
we recommend that you write the model, serial number and
installation date of your water heater in the maintenance
section in the back of this manual.
This manual should be kept with the water heater.
Special Flammable Vapor Ignition Resistant System:
This water heater is equipped with a Flammable Vapor Ignition Resistant System. In
the event of improper usage or storage of gasoline or other flammable materials in
the location where the water heater is installed, the technology will resist ignition of
the flammable vapors outside the confines of the water heater.
The Flammable Vapor Ignition Resistant System features:
• Flammable Vapor Sensor.
• Automatic Ignition Device.
• Sight Window to observe operation of pilot and burner.
FOR YOUR SAFETY: Activation of the Flammable Vapor Ignition Resistant System
occurs when flammable vapors are present in the room where the water heater is
installed. If flammable vapors are detected and/or sensed:
• Do not try to light any appliance.
• Do not touch any electrical switch; Do not use any phone in your building.
• Leave the premises and immediately call the fire department from a
neighbor’s phone. Follow the fire department’s instructions.
Once the flammable vapor has been evacuated, contact your plumbing professional
or the manufacturer for further instructions. Replacement of a Flammable Vapor
Ignition Resistant System equipped water heater due to a flammable vapor
shutdown is not covered under the terms of the limited warranty.
2
TABLE OF CONTENTS
GENERAL INFORMATION .................................................................
INSTALLATION. ..................................................................................
Locating The Water Heater .........................................................
Minimum Clearances ...................................................................
Venting ..........................................................................................
Specifications for
48 Gal. (181.6 L) ......................................................................
Specifications for
40 Gal. (151.4 L)
50 Gal. (189.2 L) ......................................................................
Vent pipe preparation and joining ....................................................
Water Connections ......................................................................
Gas Connections..........................................................................
Electrical Connections ................................................................
Wiring Diagram ......................................................................
page
4
5
5
8
8
12
24
35
36
39
40
41
GENERAL OPERATION .....................................................................
Lighting and Shutdown Instructions .........................................
Thermostat Adjustment ...............................................................
Burner Flame Check ....................................................................
42
43
44
45
MAINTENANCE ...................................................................................
46
TROUBLESHOOTING .........................................................................
50
PARTS LIST AND PARTS LIST DRAWING.......................................
53
INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND
SPACE HEATING ................................................................................
NOTES .................................................................................................
54
55
3
GENERAL INFORMATION
This gas-fired water heater’s design is certified by CSA International under the
American National Standard Z21.10.1 and CSA 4.1-M, most current editions at
the time of manufacture. This is a category III water heater.
This water heater must be installed in accordance with local codes or, in the
absence of local codes, the National Fuel Gas Code, ANSI Z223.1-Latest
Edition) and/or in Canada CAN/CGA B149 Installation Codes (Latest Editions).
The warranty for this water heater is in effect only when the water heater is
installed, adjusted, and operated in accordance with these Installation and
Operating Instructions. The manufacturer will not be held liable for any damage
resulting from alteration and/or failure to comply with these instructions.
This water heater is not design certified for installation in a mobile home. Such
an installation may create a hazardous condition and will nullify the warranty.
CAUTION
Incorrect operation of this appliance may create a hazard to life
and property and will nullify the warranty.
WARNING
Prior to connecting the gas supply line to a gas fired water heater,
ensure that the gas supply line does not have moisture/water or
dirt/scale inside the gas line. Commonly this check is done at the
lowest point in the gas distribution system prior to gas burning
appliances.
Do not use this appliance if any external part to the tank has been submerged in
water. You should contact a qualified service technician to inspect the appliance
and to replace any part of the control system including the combination gas
control which has been submerged in water. See the Gas Connections section
of this manual before servicing or replacing a water heater that has had any
external part to the tank submerged in water.
DANGER
Do not store or use gasoline or other flammable, combustible, or
corrosive vapors and liquids in the vicinity of this or any other
appliance.
IMPORTANT
Before proceeding, please inspect the water heater and its components for
possible damage. DO NOT install any water heater with damaged
components. If damage is evident then please contact the supplier where the
water heater was purchased or the manufacturer listed on the rating plate for
replacement parts.
4
General Information continued-
Make sure that you check the rating plate and combination gas control on the
water heater to be certain that the type of gas being supplied corresponds with
the marking on the rating plate and combination gas control.
A sacrificial anode(s) is used to extend tank life. Removal of any anode, except
for inspection and/or replacement, will nullify the warranty. In areas where water
is unusually active, an odor may occur at the hot water faucet due to a reaction
between the sacrificial anode and impurities in the water. If this should happen,
an alternative anode(s) may be purchased from the supplier that installed this
water heater. This will minimize the odor while protecting the tank. Additionally,
the water heater should be flushed with appropriate dissolvers to eliminate any
bacteria.
INSTALLATION
Locating The Water Heater
WARNING
Water heaters are heat producing appliances. To avoid damage or
injury, do not store materials against the water heater or vent-air intake
system. Use proper care to avoid unnecessary contact (especially by
children) with the water heater and vent-air intake components. UNDER
NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS
GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY
OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY
LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER
OR VENT-AIR INTAKE SYSTEM.
DO NOT install the water heater in any location where gasoline or
flammable vapors are likely to be present.
Water heaters in residential garages must be installed and located, or
protected, to avoid physical damage. For other installations refer to local
codes. In the absence of local codes, the water heater must be installed in
compliance with the National Fuel Gas Code, (ANSI Z223.1- Latest
Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code
(Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest
Edition).
The location of this water heater is of the utmost importance. Before installing
this water heater, read the installation section of these instructions. After
reading these installation and operating instructions, select a location for the
water heater where the floor is level and is easily accessible to gas and water
supply lines. DO NOT locate the water heater where water lines could be
subjected to freezing temperatures. Make sure the cold water pipes are
not located directly above the gas control so that condensate during
humid weather does not drip on the controls.
5
Installation (Locating The Water Heater) continued-
Water heater corrosion and component failure can be caused by the heating
and breakdown of airborne chemical vapors. Examples of some typical
compounds that are potentially corrosive are: spray can propellants, cleaning
solvents, refrigerator and air conditioning refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes and process chemicals. These
materials are corrosive at very low concentration levels with little or no odor to
reveal their presence. NOTE: DAMAGE TO THE WATER HEATER CAUSED
BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY THE
WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE HAS
OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY CORROSIVE
COMPOUNDS IN THE VICINITY OF THE WATER HEATER.
To comply with NSF requirements this water heater is to be:
a) Sealed to the floor with
sealant, in a smooth
and easily cleanable
way, or
b) Installed with an
optional leg kit that
includes legs and/or
extensions that provide
a minimum clearance
of 6” beneath the water
heater.
WARNING
Liquefied petroleum gases/propane gas are heavier than air and
will remain at floor level if there is a leak. Basements, crawl spaces,
closets, and areas below ground level will serve as pockets for
accumulation of leaking gas. Before lighting, smell all around the
appliance area for gas. Be sure to smell next to the floor.
IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any telephone in
your building.
• Immediately call your gas supplier from a neighbor’s
telephone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
DO NOT OPERATE APPLIANCE UNTIL THE LEAKAGE IS
CORRECTED!
6
Installation (Locating The Water Heater) continued-
WARNING
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE
NOT CERTAIN OF THE FOLLOWING:
• Liquefied petroleum gases/propane gas and natural gas have
an odorant added by the gas supplier that aids in the detection
of the gas.
• Most people recognize this odor as a “sulfur” or “rotten egg”
smell.
• Other conditions, such as “odorant fade” can cause the
odorant to diminish in intensity, or “fade”, and not be as
readily detectable.
• If you have a diminished sense of smell, or are in any way
unsure of the presence of gas, immediately contact your gas
supplier from a neighbor’s telephone.
Gas detectors are available. Contact your gas supplier, or
plumbing professional, for more information.
The water heater must be located close enough to the outside wall to keep the
venting distance within the maximum distance described in the installation
instructions. Locate the water heater as close as possible to the vent opening.
Read the venting section in this installation instruction manual before locating
the water heater.
This water heater must be located in an area where leakage of the tank or water
line connections and the combination temperature and pressure relief valve will
not result in damage to the area adjacent to the water heater or to lower floors
of the structure. When such locations cannot be avoided, a suitable drain pan
adequately piped for proper drainage must be installed under the water heater.
The drain pan, as described above, can be purchased from your plumbing
professional. The drain pan must be piped to an adequate drain. The piping
must be at least 3/4 inch (1.9 cm) in diameter and pitched for proper drainage.
It is recommended that a minimum clearance of four (4) inches (10.2 cm) be
provided on the side of the water heater for servicing and maintenance of the
combination temperature and pressure relief valve.
This water heater MUST be installed indoors out of the wind and weather.
Note: For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during an earthquake.
See instructions for correct installation procedures. Instructions may be
obtained from DSA Headquarters Office, 1102 Q Street, Suite 5100,
Sacramento, CA 95811.
7
Minimum Clearances
WARNING
Failure to adhere to these installation and operating instructions
may create a hazard to life and property and will nullify the
warranty.
This installation must allow access to the front of the water heater and adequate
clearance must be provided for servicing and operating this water heater. The
water heater may be installed on either a combustible or non-combustible floor.
If the water heater is to be installed directly on carpeting, it must be installed on
top of a metal or wood panel extending beyond the full width and depth of the
appliance by at least three (3) inches (7.6 cm) in any direction or, if the
appliance is to be installed in an alcove or closet, the entire floor must be
covered by the panel. The minimum clearances to combustibles for this water
heater are: zero (0) inch (0 cm) from the sides and rear, five (5) inches (12.7
cm) from the front of the jacket, zero (0) inch (0 cm) from the vent connector
and fifteen (15) inches (38.1 cm) from the jacket top. Increase distances to
provide clearance for servicing.
Venting
Figure 1 – Direct Vent Terminal Clearances
8
Venting continuedCanadian
Installations1
US
Installations2
12 inches
(30 cm)
12 inches
(30 cm)
12 inches
(30 cm)
12 inches
(30 cm)
*b
*b
A=
Clearance above grade, veranda, porch, deck or balcony
B=
Clearance to window or door that may be opened
C=
Clearance to permanently closed window
D=
Vertical clearance to ventilated soffit located above the terminal within a
horizontal distance of 2 feet (61 cm) from the center line of the terminal
*b
*b
E=
Clearance to unventilated soffit
*b
*b
F=
Clearance to outside corner
*b
*b
G=
Clearance to inside corner
*b
*b
H=
Clearance to each side of center line extended above meter/regulator
assembly
I=
Clearance to service regulator vent outlet or oil tank vent
J=
Clearance to non-mechanical air supply inlet to building or the
combustion air inlet to any other appliance
K=
Clearance to a mechanical air supply inlet
L=
Clearance above paved sidewalk or paved driveway located on public
property
M=
3 feet (91 cm)
within a height 15
feet (4.6 m) above
the
meter/regulator
assembly
36 inches
(91 cm)
12 inches
(30 cm)
6 feet
(1.83 m)
Clearance under a veranda, porch, deck, or balcony
7 feet
(2.13 m)†
12 inches
(30 cm) ‡
*b
*b
12 inches
(30 cm)
3 feet
(91 cm)
above if
within 10
feet
horizontally
7 feet
(2.13 m)†
12 inches
(30 cm) ‡
1
In accordance with the current CAN/CGA-B149 Installation Codes.
2
In accordance with the current ANSI Z223.1-(Latest edition)/NFPA 54 National Fuel Gas Code.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two singlefamily dwellings and serves both dwellings.
‡ Permitted only if a veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the
floor.
*a) A minimum clearance value determined by testing in accordance with section 5.21.1 of ANSI Z21.10.1,
latest edition.
*b) “Clearance in accordance with local installation codes and the requirements of the gas supplier”.
The vent system must terminate so that proper clearances are maintained as cited
in local codes or the latest edition of the National Fuel Gas Code, ANSI
Z223.1.73.4e and 7.8a, b as follows:
1.
2.
3.
4.
Do not terminate near soffit vents or crawl space or other area where condensate
or vapor could create a nuisance or hazard or cause property damage.
Do not terminate the exhaust vent terminal where condensate or vapor could cause
damage or could be detrimental to the operation of regulators, relief valves, or
other equipment.
Do not terminate the exhaust vent terminal over public area or walkways where
condensate or vapor can cause nuisance or hazard.
The vent shall terminate a minimum of 12” (25.4 cm) above expected snowfall level
to prevent blockage of vent termination.
9
Venting continued-
NOTICE
In locations where sustained outside air temperatures are below freezing, it
is possible for the vent terminations to accumulate ice build-up due to
adverse local climate conditions (prevailing wind direction, wind speed,
termination orientation, etc.). The optional concentric vent terminal is more
resistant to this ice build-up. In more severe temperature conditions, an
optional manufacturer approved air intake relief device is available and may
be installed, per the instructions, to prevent nuisance shut down of the
water heater. The air intake relief device may be installed with the
concentric vent termination or the standard separate vent terminations.
Consult the concentric vent and/or the air intake relief device instructions for
installation requirements.
Vent pipes serving power vented appliances are classified by building codes as
“vent connectors”. Required clearances from combustible materials must be
provided in accordance with information in this manual under LOCATION OF
WATER HEATER and CLEARANCES, and with National Fuel Gas Code and
local codes.
Clearance to combustibles for all venting pipes
and terminals
For installations in Canada
Refer to vent pipe and terminal
manufacturer’s installation instructions
for clearances to combustibles
For installations in the US
0” minimum
DO NOT place of insulation or other materials in the required clearance spaces
between the venting to combustible material unless otherwise specified.
WARNING
Risk of carbon monoxide poisoning or fire due to joint separation
or pipe breakage.
This water heater must be properly vented and connected to an
approved vent system in good condition. DO NOT operate water heater
with the absence of an approved vent system. A clean and unobstructed
vent system is necessary to allow noxious fumes that could cause injury
or loss of life to vent safely and will contribute toward maintaining the
water heater’s efficiency. The acceptance of the venting system is
dependent upon full compliance with these installation instructions.
Venting system must not pass through rated fire separations.
The venting system must be free to expand and contract. This venting
system must be supported in accordance with these instructions.
10
Venting continued-
NOTICE
For installations in Canada, field supplied vent piping must comply with
CAN/CGA B149.1 (latest edition) and be certified to the Standard For Type
BH, Class II, 65°C, Gas Venting Systems, ULC S636. Components of this
listed system shall not be interchanged with other vent systems or unlisted
pipe/fittings. All components and specified primers and cements of the
certified vent system must be from a single system manufacturer and not
intermixed with other system manufacturer’s vent system parts. The supplied
vent connector and vent termination are certified under ULC S636 and are
also certified as part of the water heater. Refer to the following tables for
approved venting materials, primers, and cements. All approved primers and
cements are to be used within their marked time limitations.
Approved Venting Materials
For installations in the US only
• PVC DWV (ASTM D-2665)
• PVC Sch. 40, 80, 120 (ASTMD1785)
• CPVC Sch. 40, 80 (ASTMF441)
• CPVC (ASTM D2846)
• ABS Sch. 40 DWV (ASTM
D2661)
For installations in CANADA
• ULC S636 approved PVC for
flue gas venting rated Class II,
65°C
• ULC S636 approved CPVC for
flue gas venting rated Class II,
65°C
Approved Primers and Cements
For installations in the US only
• PVC and CPVC Primer
(ASTM-F656)
• PVC Cement (ASTM D-2564)
• CPVC Cement (ASTM F493)
• ABS Primer and Cement
(ASTM D-2235)
For installations in CANADA
• ULC S636 approved Primer and
Cement for flue gas venting
rated Class II, 65°C
NOTICE
Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel®
(polyphenosulfone) in non-metallic11venting systems is prohibited, and
covering non-metallic venting with thermal insulation is prohibited.
Venting System Condensation
Condensate formation does not occur in all installations of power direct vented
water heaters, but should be protected against on installations where
condensation can form in the venting system.
Formation of 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 distance and slope;
and product usage.
In order to effectively control condensate from adversely affecting the
mechanical components of the water heater several methods may be
employed:
1. For horizontal installations the vent pipe can be installed with a
downward slope (not less than 1/8" (3 mm)) and away from the blower.
2. In order to prevent condensate from draining back into the blower
(vertical or horizontal runs), an optional condensate kit is available as a
service part (Condensate kit, p/n 239-45875-00). A factory supplied
exhaust adapter with drain outlet mounts directly to the blower outlet
and is secured with two hose clamps, one to the blower and the other to
the vent pipe. Tubing is provided to drain any accumulated condensate
away from the water heater and to a suitable drain. The kit comes
complete with instructions for proper installation.
PART I - Venting Specifications for:
48 Gallon (181.6L)
This water heater is a power vented appliance and is designed to intake and
exhaust the products of combustion through 3” (7.6 cm) or 4” (10.2 cm)
diameter vent pipe to the outdoors. This water heater may be either vented
horizontally through the wall or vertically through the roof. Use a 3” (7.6 cm) to
4” (10.2 cm) reducer to connect to the intake and outlet when using 4” (10.2 cm)
vent pipe. Apply the proper cement at the joint locations. Table 1 lists the
maximum vent lengths for this water heater using 3” (7.6 cm) intake and
exhaust pipe. If possible, locate the water heater so that the venting length and
number of elbows are kept to the minimum distance necessary to reach the
outside. If the installation requires venting lengths that exceed the lengths listed
for 3” (7.6 cm) vent pipe in Table 1, then use 4” (10.2 cm) vent pipe for the vent
connector.
12
Venting continued-
Table 2 lists the venting distances allowed with 4” (10.2 cm) diameter vent pipe.
When venting with 4” (10.2 cm) vent pipe, use a 4” (10.2 cm) to 3” (7.6 cm)
reducer to exit through the building wall with 3” (7.6 cm) vent pipe. Use the 3”
(7.6 cm) vent terminal supplied with the water heater to terminate on the outside
of the building. If the length of 3” (7.6 cm) vent pipe needed to go through the
wall is greater than 14” (35.5 cm), use 4” (10.2 cm) to go through the wall and
reduce to 3” (7.6 cm) vent pipe immediately after exiting the outside wall. Refer
to the venting illustrations on the following pages. Make sure the vent pipe
terminal elbow fitting is at least 1” (2.5 cm) away from the edge of the wall.
IMPORTANT
The minimum equivalent length for the exhaust portion of the vent is 7
feet. The maximum equivalent vent length for the exhaust is 60 feet for
3” diameter pipe and 100 feet for 4” diameter pipe. The intake portion of
the vent must be equal to or less than the vent length of the exhaust.
The tables below are provided for your quick reference, some
installations may require a greater number of elbows. When calculating
equivalent vent length, one 90º elbow is equivalent to 5 feet.
TABLE 1 - VENT CONNECTOR LENGTHS
FOR 3” (7.6 cm) DIAMETER VENT PIPE
Maximum straight
# of Elbows
Length ft (m)
(excl. vent
Terminating
48 gal.
term.)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
Through the Roof
Through the Roof
Through the Roof
Through the Roof
1
2
3
4
0
1
2
3
55 (16.8)
50 (15.2)
45 (13.7)
40 (12.2)
60 (18.3)
55 (16.8)
50 (15.2)
45 (13.7)
13
Minimum
straight
Length
ft (m)
2 (.6)
2 (.6)
2 (.6)
2 (.6)
7 (2.1)
7 (2.1)
7 (2.1)
7 (2.1)
Venting continued-
TABLE 2 -VENT CONNECTOR LENGTHS
FOR 4” (10.2 cm) DIAMETER VENT PIPE
Maximum straight
# of 90°
Length ft (m)
Terminating
Elbows (excl.
48 gal.
vent term.)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
Through the Wall
Through the Roof
Through the Roof
Through the Roof
Through the Roof
Through the Roof
1
2
3
4
5
0
1
2
3
4
95 (29.0)
90 (27.4)
85 (25.9)
80 (24.4)
75 (22.9)
100 (30.5)
95 (29.0)
90 (27.4)
85 (25.9)
80 (24.4)
Min
straight
Length
ft (m)
10 (3.1)
10 (3.1)
10 (3.1)
10 (3.1)
10 (3.1)
15 (4.6)
15 (4.6)
15 (4.6)
15 (4.6)
15 (4.6)
NOTE: When using 4” (10.2 cm) vent pipe, use two 4” (10.1 cm) to 3” (7.6
cm) reducers for each portion of the vent. One reducer is installed just
after the blower and the other reducer is used just prior to exiting the
building. Exit the building wall with 3” (7.6 cm) vent pipe using the 3”
(7.6 cm) 90° vent terminal supplied. Two 45° elbows are equivalent to one
90° elbow.
Figure 2
IMPORTANT
All of the Venting connections must be leak checked with a soap and
water solution upon initial start up of the water heater. Any leaks must
be repaired before continuing operation of the water heater.
14
Venting continued-
THROUGH THE WALL VENTING: (HORIZONTAL VENTING WITH
STANDARD VENT TERMINALS).
Cut two 3 1/2 in. (8.9 cm) diameter holes in the wall at the point where the vent
connector is going to pass through the wall. Use the proper cement to secure
the 90° vent terminal provided with the water heater to the vent connector. The
distance between the edge of the 90° vent terminal and the exterior wall (see
Figure 3) must be 1 in. (2.5 cm). The exhaust and intake must not be less than
16 in. (40.6 cm) apart (see figure 4a) and the exhaust terminal must be a
minimum of 3 in. (7.6cm) higher than the intake terminal. Use the proper
cement and assembly procedures to secure the vent connector joints between
the terminal and the blower outlet. Provide support brackets for every 5 feet
(1.5m) of horizontal vent.
3” VENT INSTALLATION
4” VENT INSTALLATION
Figure 3
15
Venting continuedVent terminal configurations for through the wall venting.
When venting through the wall, the exhaust terminal must exit the structure at a
minimum distance of 16” (40.6 cm) from the intake terminal. The exhaust terminal must
exit the structure at a minimum of 3 in. (7.6 mm) higher than the intake terminal. The
exhaust terminal must not be located below the intake terminal for any reason (see
figure 4a below for examples of acceptable vent terminal configurations).
Figure 4a
CAUTION
NEVER INSTALL AIR INTAKE ABOVE EXHAUST
When local conditions present a risk of ice accumulation on the vent terminals, the
configurations in 4b and 4c or the concentric termination are preferred.
The air intake screen can be removed for cold installations but this may make the air
intake susceptible to debris buildup from birds or other animals. If the air intake
screen is removed to prevent freezing, it is recommended that the air inlet screen be
installed during the spring.
Figure 4b
16
Venting continued-
Figure 4c
IMPORTANT
When using the vent terminal configuration shown in 4c the extra
elbows must be accounted for in the total vent length see Table 3 or
Table 4.
17
Venting continued-
THROUGH THE WALL VENTING: (HORIZONTAL VENTING WITH
CONCENTRIC VENT).
Cut one 4 5/8 in. (11.7 cm) diameter hole in the wall at the point where the vent
connector is going to pass through the wall. Use the proper cement to secure
the vent terminal to the vent connector. Use the proper cement and assembly
procedures to secure the vent connector joints between the terminal and the
blower outlet. Provide support brackets for every 5 feet (1.5 m) of horizontal
vent.
IMPORTANT
When using the concentric vent terminal the maximum vent length is
reduced by 10 feet.
Figure 5a
THROUGH THE ROOF VENTING: (VERTICAL VENTING STANDARD
TERMINALS).
Cut the necessary holes through the roof and ceiling and install the vent
connector as shown in Figure 6. Make sure that the installation meets the local
codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or
CGA/CAN B149 Installation Code (latest edition).
18
Venting continued-
It is acceptable to install a 90 degree elbow on IPEX concentric vent
terminations use with this power direct vent water heater (see Figure 5a). A
short length of appropriate diameter vent pipe should be used to transition from
the vent terminal to the 90 degree elbow. Approved venting materials along with
primers and cements are listed at the beginning of this venting section. When
the 90 degree elbow is used the equivalent length of the elbow and short length
of vent pipe must be factored into the total vent/air intake pipe determinations
(see Tables 1 and 2 for appropriate vent connector lengths).
(B) DIMENSION
MIN
12” (30.5 CM)
MAX
44” (111.8 CM)
Figure 5b
THROUGH THE ROOF VENTING: (VERTICAL VENTING STANDARD
TERMINALS).
Cut the necessary holes through the roof and ceiling and install the vent
connector as shown in Figure 6. Make sure that the installation meets the local
codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or
CGA/CAN B149 Installation Code (latest edition).
19
Venting continued-
3” VENT INSTALLATION
4” VENT INSTALLATION
Figure 6
NOTE: For installations requiring both horizontal and vertical runs, the
following rule must be followed: Total length of straight pipe (both
horizontally and vertically) must not exceed the maximum equivalent
length listed in these instructions.
20
Venting continued-
THROUGH THE ROOF VENTING: (VERTICAL VENTING CONCENTRIC
VENT TERMINAL):
Cut the necessary holes through the roof and ceiling and install the vent
connector as shown in Figure 7. Make sure that the installation meets the local
codes and/or the National Fuel Gas Code ANSI Z223.1 (Latest Edition) or
CAN/CGA B149 installation code (latest edition). A condensate kit must be
installed when venting through the roof.
Figure 7
NOTE: For installations requiring both horizontal and vertical runs,
the following rule must be followed. Total length of straight pipe
(both horizontally and vertically) must not exceed the equivalent
length listed in these instructions. For the concentric vent terminal
the maximum vent length is reduced by 10 feet.
CAUTION
FOR VERTICAL INSTALLATIONS WITH CONCENTRIC VENT
TERMINAL, CONDENSATE KIT, P/N 239-45875-00, MUST BE USED.
21
Venting continued-
THROUGH THE WALL VENTING WITH LOW GROUND CLEARANCE:
When venting cannot exit through the wall at a height greater than or equal to
12” (30.5 cm) above the ground, or anticipated snow level, the installation must
be modified as shown below (see Figure 8). Refer to Table 3 for maximum
venting lengths using 3” (7.6 cm) vent pipe or Table 4 for maximum lengths
using 4” (10.2 cm) vent pipe. The exhaust and intake terminals must not be less
than 16 in. (40.6 cm) apart (see figure 4a).
3” VENT
INSTALLATION
4” VENT
INSTALLATION
Figure 8
22
Venting continued-
TABLE 3
3” (7.6 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR
LOW GROUND CLEARANCE INSTALLATIONS
Max Straight
Min
# of Elbows
Length ft (m)
straight
Terminating
(excl. vent term.)
Length
48 gal.
ft (m)
(2) 90° Elbows with (1)
40 (12.2)
1
5 (1.5)
90° Elbow
(2) 90° Elbows with (1)
35 (10.7)
2
5 (1.5)
90° Elbow
(2) 90° Elbows with (1)
30 (9.1)
3
5 (1.5)
90° Elbow
(2) 90° Elbows with (1)
25 (7.6)
4
5 (1.5)
90° Elbow
TABLE 4
4” (10.2 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR
LOW GROUND CLEARANCE INSTALLATIONS
Terminating (Reduce 4”
# of Elbows
Max straight
Min
to 3”) (Reduce 10.1 cm
Length ft (m)
straight
(excl. vent
to 7.6 cm)
Length
term.)
48 gal.
ft (m)
(2) 90° Elbows with (1) 90°
85 (25.9)
1
10 (3.1)
Elbow
(2) 90° Elbows with (1) 90°
80 (24.4)
2
10 (3.1)
Elbow
(2) 90° Elbows with (1) 90°
75 (22.9)
3
10 (3.1)
Elbow
(2) 90° Elbows with (1) 90°
70 (21.3)
4
10 (3.1)
Elbow
(2) 90° Elbows with (1) 90°
65 (19.8)
5
10 (3.1)
Elbow
HIGH ALTITUDE INSTALLATIONS FOR ELEVATIONS OVER 2,500
FEET (762 m) ABOVE SEA LEVEL
The capacity of the induced draft blower declines with increasing altitude due to
a reduction in the air density. In order to assure safe and reliable performance
of the water heater, contact the supplier for high altitude kit.
23
Venting continued-
PART II - Venting Specifications for:
40 Gallon (151.4L)
50 Gallon (189.2L)
IMPORTANT
The minimum equivalent length for the exhaust portion of the vent is 7
feet. The maximum equivalent vent length for the exhaust is 35 feet for
2” diameter pipe and 85 feet for 3” diameter pipe. The intake portion of
the vent must be equal to or less than the vent length of the exhaust.
The tables below are provided for your quick reference, some
installations may require a greater number of elbows. When calculating
equivalent vent length, one 90º elbow is equivalent to 5 feet.
TABLE 5 - VENT CONNECTOR LENGTHS
FOR 2” (5.1 cm) DIAMETER VENT PIPE
# of Elbows
Terminating
(excl. vent
term.)
Maximum
straight
Length ft (m)
Through the Wall
Through the Wall
Through the Wall
Through the Wall
Through the Roof
Through the Roof
Through the Roof
Through the Roof
1
2
3
4
0
1
2
3
30 (9.1)
25 (7.6)
20 (6.1)
15 (4.6)
35 (9.1)
30 (9.1)
25 (7.6)
20 (6.1)
Minimum
straight
Length
ft (m)
2 (.6)
2 (.6)
2 (.6)
2 (.6)
7 (2.1)
7 (2.1)
7 (2.1)
7 (2.1)
TABLE 6 -VENT CONNECTOR LENGTHS
FOR 3” (7.6 cm) DIAMETER VENT PIPE
# of 90°
Maximum
Min straight
Elbows
Terminating
straight
Length
(excl. vent
ft (m)
Length ft (m)
term.)
1
Through the Wall
80 (24.4)
10 (3.1)
2
Through the Wall
75 (22.9)
10 (3.1)
3
Through the Wall
70 (21.3)
10 (3.1)
4
Through the Wall
65 (19.8)
10 (3.1)
5
Through the Wall
60 (18.3)
10 (3.1)
0
85 (25.9)
Through the Roof
15 (4.6)
1
Through the Roof
80 (24.4)
15 (4.6)
2
Through the Roof
75 (22.9)
15 (4.6)
3
Through the Roof
70 (21.3)
15 (4.6)
4
Through the Roof
65 (19.8)
15 (4.6)
24
Venting continued-
NOTE: When using 3” (7.6 cm) vent pipe, use two 3” (7.6 cm) to 2” (5.1
cm) reducers for each portion of the vent. One reducer is installed just
after the blower and the other reducer is used just prior to exiting the
building. Exit the building wall with 2” (5.1 cm) vent pipe using the 2” (5.1
cm) 45° vent terminals supplied. Two 45° elbows are equivalent to one 90°
elbow.
Figure 9
IMPORTANT
All of the Venting connections must be leak checked with a soap and
water solution upon initial start up of the water heater. Any leaks must
be repaired before continuing operation of the water heater.
25
Venting continued-
THROUGH THE WALL VENTING: (HORIZONTAL VENTING WITH
STANDARD VENT TERMINALS).
Cut two 2 1/2 in. (6.4 cm) diameter holes in the wall at the point where the vent
connector is going to pass through the wall. Use the proper cement to secure
the 45° vent terminal provided with the water heater to the vent connector. The
distance between the edges of the 45° vent terminal and the exterior wall (see
Figure 10) must be 1 in. (2.5 cm). The exhaust and intake must not be less than
16” (40.6 cm) apart, and the exhaust terminal must be a minimum of 2 in. (5.1
cm) higher than the intake terminal (see figure 11a). Use the proper cement and
assembly procedures to secure the vent connector joints between the terminal
and the blower outlet. Provide support brackets for every 5 feet (1.5m) of
horizontal vent.
2” VENT INSTALLATION
3” VENT INSTALLATION
Figure 10
26
Venting continuedVent terminal configurations for through the wall venting.
When venting through the wall, the exhaust terminal must exit the structure at a
minimum distance of 16” (40.6 cm) from the intake terminal. The exhaust terminal must
not be located below the intake terminal for any reason (see figure 11a below for
examples of acceptable vent terminal configurations).
Figure 11a
CAUTION
NEVER INSTALL AIR INTAKE ABOVE EXHAUST
When local conditions present a risk of ice accumulation on the vent terminals, the
configurations in 11b and 11c or the concentric termination are preferred.
The air intake screen can be removed for cold installations but this may make the air
intake susceptible to debris buildup from birds or other animals. If the air intake
screen is removed to prevent freezing, it is recommended that the air inlet screen be
installed during the spring.
Figure 11b
27
Venting continued-
Figure 11c
IMPORTANT
When using the vent terminal configuration shown in 11c the extra
elbows must be accounted for in the total vent length see Table 7 or
Table 8.
28
Venting continued-
THROUGH THE WALL VENTING: (HORIZONTAL VENTING WITH
CONCENTRIC VENT).
Cut one 3 5/8 in. (11.7 cm) diameter hole in the wall at the point where the vent
connector is going to pass through the wall. Use the proper cement to secure
the vent terminal to the vent connector. Use the proper cement and assembly
procedures to secure the vent connector joints between the terminal and the
blower outlet. Provide support brackets for every 5 feet (1.5 m) of horizontal
vent.
IMPORTANT
When using the concentric vent terminal the maximum vent length is
reduced by 10 feet.
Figure 12a
29
Venting continued-
It is acceptable to install a 90 degree elbow on IPEX concentric vent
terminations use with this power direct vent water heater (see Figure 12b). A
short length of appropriate diameter vent pipe should be used to transition from
the vent terminal to the 90 degree elbow. Approved venting materials along with
primers and cements are listed at the beginning of this venting section. When
the 90 degree elbow is used the equivalent length of the elbow and short length
of vent pipe must be factored into the total vent/air intake pipe determinations
(see Tables 5 and 6 for appropriate vent connector lengths).
Figure 12b
(B) DIMENSION
MIN
12” (30.5 CM)
MAX
44” (111.8 CM)
THROUGH THE ROOF VENTING: (VERTICAL VENTING STANDARD
TERMINALS).
Cut the necessary holes through the roof and ceiling and install the vent
connector as shown in Figure 13. Make sure that the installation meets the local
codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or
CGA/CAN B149 Installation Code (latest edition).
30
Venting continued-
2” VENT INSTALLATION
3” VENT INSTALLATION
Figure 13
NOTE: For installations requiring both horizontal and vertical runs, the
following rule must be followed: Total length of straight pipe (both
horizontally and vertically) must not exceed the maximum equivalent
length listed in these instructions.
31
Venting continued-
THROUGH THE ROOF VENTING: (VERTICAL VENTING CONCENTRIC
VENT TERMINAL):
Cut the necessary holes through the roof and ceiling and install the vent
connector as shown in Figure 14. Make sure that the installation meets the local
codes and/or the National Fuel Gas Code ANSI Z223.1 (Latest Edition) or
CAN/CGA B149 installation code (latest edition). A condensate kit must be
installed when venting through the roof.
Figure 14
NOTE: For installations requiring both horizontal and vertical runs,
the following rule must be followed. Total length of straight pipe
(both horizontally and vertically) must not exceed the equivalent
length listed in these instructions. For the concentric vent terminal
the maximum vent length is reduced by 10 feet.
CAUTION
FOR VERTICAL INSTALLATIONS WITH CONCENTRIC VENT
TERMINAL, CONDENSATE KIT, P/N 239-45875-00, MUST BE USED.
32
Venting continued-
THROUGH THE WALL VENTING WITH LOW GROUND CLEARANCE:
When venting cannot exit through the wall at a height greater than or equal to
12” (30.5 cm) above the ground, or anticipated snow level, the installation must
be modified as shown below (see Figure 15). Refer to Table 3 for maximum
venting lengths using 2” (5.1 cm) vent pipe or Table 4 for maximum lengths
using 3” (7.6 cm) vent pipe. The exhaust and intake terminals must not be less
than 16 in. (40.6 cm) apart (see figure 11a).
Figure 15
33
Venting continued-
TABLE 7
2” (5.1 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR
LOW GROUND CLEARANCE INSTALLATIONS
# of Elbows
Min straight
Max Straight
(excl. vent
Terminating
Length
Length ft (m)
ft (m)
term.)
(2) 90° Elbows with (1) 90°
1
5 (1.5)
20 (6.1)
Elbow
(2) 90° Elbows with (1) 90°
2
5 (1.5)
15 (4.6)
Elbow
(2) 90° Elbows with (1) 90°
3
5 (1.5)
10 (3.0)
Elbow
TABLE 8
3” (7.6 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR
LOW GROUND CLEARANCE INSTALLATIONS
Terminating (Reduce 4”
# of Elbows
Max straight
Min straight
to 3”) (Reduce 10.1 cm to
Length ft (m)
Length
(excl. vent
ft (m)
7.6 cm)
term.)
(2) 90° Elbows with (1) 90°
Elbow
(2) 90° Elbows with (1) 90°
Elbow
(2) 90° Elbows with (1) 90°
Elbow
(2) 90° Elbows with (1) 90°
Elbow
(2) 90° Elbows with (1) 90°
Elbow
1
40 (12.2)
10 (3.1)
2
35 (10.7)
10 (3.1)
3
30 (9.1)
10 (3.1)
4
25 (7.6)
10 (3.1)
5
20 (6.1)
10 (3.1)
HIGH ALTITUDE INSTALLATIONS FOR ELEVATIONS OVER 2,500
FEET (762 m) ABOVE SEA LEVEL
The capacity of the induced draft blower declines with increasing altitude due to
a reduction in the air density. In order to assure safe and reliable performance
of the water heater, contact the supplier for high altitude kit.
34
VENT PIPE PREPARATION AND JOINING
Most failures in vent systems result from improper preparation and joining of pipe and
fittings. The guidelines below must be followed when installing the venting system. If
you have any question about the application or installation of the venting system,
contact the vent pipe manufacturer, supplier, or your plumbing professional.
1) Specific cleaners, solvents, primers and cements are available for PVC, CPVC, and
ABS pipe. Be sure these materials match the type of pipe to be installed. The vent
pipe manufacturers joining instructions must be followed in all cases. Never use allpurpose cements, commercial glues and adhesives or ABS cement to join PVC or
CPVC pipe and fittings. Refer to the table at the beginning of the “VENTING”
section for approved primers and cements.
a) CLEANERS, SOLVENTS, PRIMERS AND CEMENTS ARE FLAMMABLE. Do
not store or use these materials near heat or open flame, or in the vicinity
of other appliances.
2) Use proper cutting, deburring and applicator tools to ensure proper preparation and
joining of pipe and fittings.
a) Cutting Tools
i) A square cut must be achieved with a miter box saw or pipe cutter to
ensure a proper mating with the female. If a pipe cutter is used, the burr
created at the outer edge of the pipe must be removed.
b) Deburring Tools
i) A file, knife or plastic deburring tool can be used to remove burrs. Burrs
must be removed from the inside and outside edges of the pipe to ensure
a proper seal.
c) Applicator Tools
i) A natural bristle paintbrush or roller may be used to apply cement. Prompt
application of the cement is important due its fast drying properties.
3) Inspection, Cleaning, Priming and Cementing
a) Inspect the pipe inside and out for dirt, dust, moisture or grease etc. Check
pipe and fittings for splits or cracks and replace if found.
b) Clean pipe and fittings are imperative for proper joining. Following cutting and
deburring, wipe away any foreign material with a clean dry rag. If wiping fails to
thoroughly clean surfaces, chemical cleaning is necessary.
c) Primer must be applied to the pipe surface and fitting socket with a natural
bristle brush. This serves to soften and prepare the pipe for cementing.
d) Cementing must be done quickly to avoid over-drying before joining.
i) Apply one coat to the outside end of the pipe at a width slightly greater
than the depth of the socket.
ii) Apply a coat around the inside of the fitting socket.
iii) Apply a second coat around the end of the pipe.
4) Joining
a) Joints should be made immediately after cement is applied.
b) After fully inserting pipe into fitting socket, hold joint together for about 15 to 20
seconds.
c) Remove excess cement from around pipe and fitting with a clean rag.
d) Cement drying times may vary. Be sure to allow for the recommended drying
time before disturbing joints.
For more specific and detailed information about the above, contact the vent pipe
manufacturer, supplier, or competent professional.
35
Water Connections
Note: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN
WATER SUPPLY VALVE.
After shutting off the main water supply, open a faucet to relieve the water line
pressure to prevent any water from leaking out of the pipes while making the
water connections to the water heater. After the pressure has been relieved,
close the faucet. The COLD water inlet and HOT water outlet are identified on
the top of the water heater. The fittings at the cold water inlet and hot water
outlet are dielectric waterway fittings with 3/4” NPT male thread. Make the
proper plumbing connections between the water heater and the plumbing
system to the house. Install a shut-off valve in the cold water supply line.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to the nipples on top
of the water heater. Sweat the tubing to the adapter before fitting the
adapter to the water connections. It is imperative that heat is not applied
to the nipples containing a plastic liner.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4”
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE
THE MANUFACTURER FROM ANY CLAIM THAT MIGHT RESULT
FROM EXCESSIVE TEMPERATURE AND PRESSURES.
If this water heater is installed in a closed water supply system, such as one
having a back-flow preventer in the cold water supply, provisions must be made
to control thermal expansion. DO NOT operate this water heater in a closed
system without provisions for controlling thermal expansion. Your water supplier
or local plumbing inspector should be contacted on how to control this situation.
After installation of the water lines, open the main water supply valve and fill the
water heater. While the water heater is filling, open several hot water faucets to
allow air to escape from the water system. When a steady stream of water flows
through the faucets, close them and check all water connections for possible
leaks. NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING
CERTAIN IT IS FILLED WITH WATER.
36
Water Connections continued-
WARNING
For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local codes,
but not less than a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment or materials as
meeting the requirements of the Standard for Relief Valves and
Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANS
Z21.22 or the Standard CAN1-4.4. Temperature and Pressure and the
Standard CAN1-4.4, Temperature, Pressure, Temperature and Pressure
Relief Valves and Vacuum Relief Valves. The combination temperature
and pressure relief valve must be marked with a maximum set pressure
not to exceed the maximum working pressure of the water heater. The
combination temperature and pressure relief valve must also have an
hourly rated temperature steam BTU discharge capacity not less than
the hourly rating of the water heater.
Install the combination temperature and pressure relief valve into the
opening provided and marked for this purpose on the water heater.
Note: Some models may already be equipped or supplied with a
combination temperature and pressure relief valve. Verify that the
combination temperature and pressure relief valve complies with local
codes. If the combination temperature and pressure relief valve does not
comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination
temperature and pressure relief valve will exit within six (6) inches (15.2
cm) above, or any distance below the structural floor and cannot contact
any live electrical part. The discharge line is to be installed to allow for
complete drainage of both the combination temperature and pressure
relief valve and the discharge line. The discharge opening must not be
subjected to blockage or freezing. DO NOT thread, plug or cap the
discharge line. It is recommended that a minimum clearance of four (4)
inches (10.2 cm) be provided on the side of the water heater for
servicing and maintenance of the combination temperature and
pressure relief valve.
Do not place a valve between the combination temperature and
pressure relief valve and the tank.
37
Water Connections continued-
WARNING
Hydrogen gas can be produced in an operating water heater that
has not had water drawn from the tank for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable. To prevent the possibility of injury under these
conditions, we recommend the hot water faucet to be open for
several minutes at the kitchen sink before you use any electrical
appliance which is connected to the hot water system. If hydrogen
is present, there will be an unusual sound such as air escaping
through the pipes as hot water begins to flow. Do not smoke or
have open flame near the faucet at the time it is open.
This water heater can deliver scalding temperature water at any faucet in the
system. Be careful whenever using hot water to avoid scalding injury. Certain
appliances such as dishwashers and automatic clothes washers may require
increased temperature water. By setting the thermostat on this water heater to
obtain the increased temperature water required by these appliances, you may
create the potential for scald injury. To protect against injury, you should install
an ASSE approved mixing valve in the water system. This valve will reduce
point of discharge temperature by mixing cold and hot water in branch supply
lines. Such valves are available from the manufacturer of this water heater or a
local plumbing supplier. Please consult with a plumbing professional.
APPROXIMATE TIME/TEMPERATURE RELATIONSHIPS IN SCALDS
120°F (49°C)
More than 5 minutes
125°F (52°C)
1½ to 2 minutes
130°F (54°C)
About 30 seconds
135°F (57°C)
About 10 seconds
140°F (60°C)
Less than 5 seconds
145°F (63°C)
Less than 3 seconds
150°F (66°C)
About 1½ seconds
155°F (68°C)
About 1 second
38
Gas Connections
WARNING
Prior to connecting the gas supply line to a gas fired water heater, ensure that
the gas supply line does not have moisture/water or dirt/scale inside the gas
line. Commonly this check is done at the lowest point in the gas distribution
system prior to gas burning appliances.
The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI
Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code
(Latest Edition) or CAN/CGA B149.2 Propane Installation Code (Latest Edition).
The minimum permissible gas supply pressure for the purpose of input adjustment is
one (1.0) inch (0.25 kPa) water column above the operating manifold pressure. See the
rating plate and gas valve for the manifold pressure and gas type. The maximum
permissible gas supply pressure is fourteen (14.0) inches (3.5 kPa) water column for
natural gas and liquefied petroleum gases/propane gas.
1.
Connect this water heater only to the type of gas (Natural or Propane gas) as
shown on the rating plate. Use clean black iron pipe or equivalent material
approved by local codes and ordinances. (Dirt and scale from the pipe can enter
the gas valve and cause it to malfunction). The inlet gas line must have a minimum
length of three (3) inches (7.6 cm) drip leg (sediment trap) installed as close to the
water heater’s gas valve as possible. A ground joint union must be installed as
close to the water heater as possible in the gas supply line feeding the water
heater to permit servicing of the water heater. Compounds used on the threaded
joints of the gas piping must be resistant to the action of liquefied petroleum
gases/propane gas. DO NOT apply pipe dope to the gas valve inlet and make
certain that no pipe dope has become lodged in the inlet screen of the gas valve.
Extreme care must be taken to ensure no pipe dope enters the gas valve. Avoid
excessive torque when tightening the gas supply line to the gas valve. Excessive
torque may result in cracking of the gas valve housing and could create a gas leak.
The suggested maximum torque is 31.5 ft. lbs. (4.4 kg-m).
WARNING
The manufacturer of this water heater will not be liable for any damage or injury
caused as a result of a cracked gas inlet as a result of excessive torque.
2.
This water heater and its gas connection must be leak tested before placing the
water heater in operation. Check for gas leaks with a soap and water solution and a
brush or a commercial leak detector fluid. NEVER USE A MATCH OR OPEN
FLAME FOR TESTING!
39
Gas Connections continued-
CAUTION
The water heater and individual shutoff valve must be disconnected from the
gas supply piping system during any pressure testing of the system at test
pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated
from the gas supply piping system by closing its manual shutoff valve during
any pressure testing of the gas supply system at test pressures equal to or less
than 1/2 psi (3.5 kPa). The supply line must be capped when not connected to
the water heater.
3.
While checking for leaks care must be taken to prevent solution from contacting the
electrical connections at the control. If electrical connections at the control become
wet, they must be thoroughly dried before attempting to operate the water heater.
Electrical Connections
All electrical wiring and connections must be in accordance with the National
Electric Code ANSI/NFPA No. 70 (latest edition), or the Canadian Electrical
Code C22.1 (latest edition) and any local codes which may apply. The water
heater must be electrically grounded.
If a flexible line cord and plug is permitted by local code, then provide a (3) three
wire grounding type receptacle within 6 feet (1.9 m) of the water heater and use
the flexible cord provided. Do not plug the line cord into a receptacle that can
have its power supply interrupted by a switch that is used to turn on and off
lights.
If wiring in conduit is required, cut the flexible line cord flush with the bushing.
Remove the junction box cover and pull the pressure switch outside of the
junction box. Cut the three wires from the line cord at the bushing inside of the
junction box. Drill a hole to receive the 1/2” electrical conduit connector on the
backside of the blower. Wire the power supply into the circuit at the appropriate
locations. Replace the pressure switch and junction box cover.
CAUTION
Turn off or disconnect the electrical power supply to the water heater
before servicing. Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
40
Wiring Diagram
Figure 16
41
GENERAL OPERATION
WARNING
Water heaters are heat producing appliances. To avoid damage or injury
there must be no materials stored against the water heater or vent-air
intake system, and proper care must be taken to avoid unnecessary
contact (especially by children) with the water heater and vent-air intake
system. UNDER NO CIRCUMSTANCES MUST FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED
OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR
INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES
COULD REACH THE WATER HEATER OR VENT-AIR INTAKE
SYSTEM.
TO FILL THE WATER HEATER
1. Close the water heater drain valve by turning the stem clockwise.
2. Open the cold water supply shut-off valve.
3. Open several hot water faucets to allow air to escape from the system.
4. When a steady stream of water flows from the faucets, the water heater is
filled. Close the faucets and check for water leaks at the water heater drain
valve, combination temperature and pressure relief valve and the hot and
cold water connections.
TO DRAIN THE WATER HEATER
Should it become necessary to completely drain the water heater, make sure
you follow the steps below:
1. Shut off the gas supply to the water heater.
2. Turn off/disconnect all electric power to the water heater.
3. Close the cold water supply shut-off valve.
4. Open the drain valve on the water heater by turning the stem counterclockwise. The drain valve has threads on the end that will allow the
connection of a standard hose coupling.
5. Open a hot water faucet to allow air to enter the system.
To refill the water heater, refer to “To Fill the Water Heater.”
42
Lighting and Shutdown instructions
43
Thermostat Adjustment
The thermostat dial is adjusted to its lowest setting when shipped from the
factory. When adjusting the thermostat, it should be remembered that lower
temperature settings are more energy efficient. To adjust the thermostat turn
the dial clockwise until the minimum acceptable temperature is set. It is
suggested that the starting point setting not exceed the 120°F (49°C) or “HOT”
setting on the thermostat.
Note: Taupe/Silver faceplate is approximately160º F maximum set point, Dark
(battleship) grey is approximately 180º F, maximum set point.
Figure 17
DANGER
Hotter water increases the risk of scald injury. Scalding may occur within
five (5) seconds at a temperature setting of 140°F (60°C). To protect
against hot water injury, install an ASSE approved mixing valve in the
water system. This valve will reduce point of discharge water
temperatures by mixing cold and hot water in branch water lines. A
licensed plumbing professional or local plumbing authority should be
consulted.
Note: This water heater is equipped with an energy cut out device to
prevent overheating. Should overheating occur, turn off the electrical
supply to the water heater and contact a qualified service technician.
44
Burner Flame Check
Steel Burner: These models are equipped with self-adjusting air mixture and
do not have an adjustable air shutter (See Figure 18). At periodic intervals a
visual check of the main burner and pilot flames should be made to determine if
they are burning properly. The main burner flame should light smoothly from the
pilot.
Figure 18
WARNING
Do not run out of propane gas. Damage to the water heater may occur.
45
MAINTENANCE
WARNING
Water heaters are heat producing appliances. To avoid damage or injury
there must be no materials stored against the water heater or vent-air
intake system, and proper care must be taken to avoid unnecessary
contact (especially by children) with the water heater and vent-air intake
system. UNDER NO CIRCUMSTANCES MUST FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED
OR STORED IN THE VICINITY OF THIS WATER HEATER, VENT-AIR
INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH FUMES
COULD REACH THE WATER HEATER OR VENT-AIR INTAKE
SYSTEM.
IMPORTANT
The water heater should be inspected at a minimum annually by a
qualified service technician for damaged components and/or joints not
sealed. DO NOT operate this water heater if any part is found damaged
or if any joint is found not sealed.
The following maintenance should be performed by a qualified service
technician at the minimum periodic intervals suggested below. In some
installations, the maintenance interval may be more frequent depending on the
amount of use and the operating conditions of the water heater. Regular
inspection and maintenance of the water heater and vent-air intake system will
help to insure safe and reliable operation.
1. Annually check the operation of the thermostat.
2. The flow of combustion and ventilation air MUST NOT be restricted. Clear
the combustion air openings of any dirt, dust, or other restrictions.
WARNING! The ventilation air system may be HOT.
3. At all times keep the water heater area clear and free from combustible
materials, gasoline and other flammable vapors and liquids.
4. Bi-annually conduct a visual check of the main and pilot burner flames to
determine that they are burning properly. See Burner Flame Check section.
If sooting or other burner anomalies are evident, shut down the water heater
by turning off the gas per the instructions listed in this manual or as listed on
the water heater.
46
Maintenance continued-
5. Annually remove the inner door and main burner assembly to clean orifices
and related parts of any dirt or other foreign material. Inspect the burner
ports for obstructions or debris and clean with a wire brush as needed. Wire
brush and/or vacuum clean the combustion chamber as needed to remove
scale deposits and debris. NOTE: It is imperative for proper operation of the
water heater that the inner door be replaced in the original location.
Do not operate water heater with jumpered, altered,
loosely tightened or absent controls and/or components.
Do not operate water heater with replacement controls
and/or components which are not exact duplicates of
original equipment.
Thoroughly inspect and replace, (as needed) burner inner
door gasket and/or sight window gasket any time burner
inner door is removed or disturbed.
Replace water heater if involved in flammable vapor
incident.
This water heater is equipped with a flammable vapor
sensor. If the sensor is exposed to flammable vapor, the
water heater control will shut down the water heater and
display a code of 7 flashes and then a 3 second pause.
If a 7 flash error code is present, check to see if flammable
vapor is present in the area. If flammable vapor is
present or suspected in the area, immediately leave the
area and contact a service professional.
Do not try to light any appliance.
Do not touch any electric switch; do not use any
phone in your building.
If you are certain there is no flammable vapor present,
check the flammable vapor sensor to make certain
it has not become disconnected from the control.
Review this instruction manual for troubleshooting.
47
Maintenance continued-
WARNING
When lifting lever of the combination temperature and pressure
relief valve, hot water will be released under pressure. Be careful
that any released water does not result in bodily injury or property
damage.
WARNING
Do not run out of propane gas. Damage to the water heater may occur.
6. At least once a year, check the combination temperature and pressure relief
valve to insure that the valve has not become encrusted with lime. Lift the
lever at the top of the valve several times until the valve seats properly
without leaking and operates freely.
7. Monthly drain off a gallon of water to remove silt and sediment.
WARNING
THIS WATER MAY BE HOT.
8. If the combination temperature and pressure relief valve on the appliance
discharges periodically, this may be due to thermal expansion in a closed
water supply system. Contact the water supplier or local plumbing inspector
on how to correct this situation. Do not plug the combination
temperature and pressure relief valve outlet.
9. A combination sacrificial anode rod/hot water outlet nipple has been
installed to extend tank life. The anode rod should be inspected periodically
(every 2 years) and replaced when necessary to prolong tank life. Water
conditions in your area will influence the time interval for inspection and
replacement of the anode rod. Contact the plumbing professional who
installed the water heater or the manufacturer listed on the rating plate for
anode replacement information. The use of a water softener may increase
the speed of anode consumption. More frequent inspection of the anode is
needed when using softened (or phosphate treated) water.
10. The blower has sealed motor bearings and does not require adding oil.
48
Maintenance continued-
CAUTION
FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION
GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A
QUALIFIED SERVICE TECHNICIAN.
Contact your supplier or plumbing professional for replacement parts or contact
the company at the address given on the rating plate of the water heater.
Provide the part name, model and serial numbers of the water heater when
ordering parts.
READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF
TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.
Manufactured under one or more of the following U.S. Patents: RE.34,534;
B1 5,341,770; 4,416,222; 4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983;
4,861,968; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519;
5,115,767; 5,199,385; 5,277,171; 5,372,185; 5,485,879; 5,574,822; 5,596,952;
5,660,165; 5,682,666; 5,761,379; 5,943,984; 5,954,492; 5,988,117; 6,142,216;
6,684,821; 7,063,132; 6,395,280; 7,007,748.
Other U.S. and Foreign patent applications pending. Current Canadian Patents:
1,272,914; 1,280,043; 1,289,832; 2,045,862; 2,092,105; 2,107,012; 2,108,186;
2,112,515
Complete the following information and retain for future reference:
Model No:
Serial No:
Service Phone
Days: Nights:
Address:
Supplier:
Supplier Phone No:
49
TROUBLESHOOTING
LED Status
Control Status
Probable Cause
None (LED not on
or flashing)
Electrical power not
present.
Control power switch in “OFF” position.Supply
voltage interuppted.
One short flash
every four seconds
Stand-by mode,
Thermostat is
satisfied (no faults).
Temperature demand is satisfied (no call for
heat).
Alternates bright
and dim
(Heartbeat)
Thermostat calling
for heat (no fault).
Tank temperature below set point of
thermostat.
1. Unstable pilot.
2. Pilot tube block or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection
at gas valve.
Short flash once
every second
Weak pilot signal on
last call for heat.
Short flash once
every two seconds
Idle remote
command off
1. Control put in idle or Sabbath mode from
accessory module
Two flashes, three
second pause
Pressure switch not
working-closed
position.
1. Pressure switch tubing kinked or blocked.
2. Blocked pressure tap on switch.
3. Faulty pressure switch.
Three flashes,
three second
pause
Pressure switch or
blower temperature
switch not working open position.
1. Vent blockage or improper vent
configuration.
2. Pressure switch tubing kinked or blocked.
3. Blower not spinning up to speed.
4. Vent temperature too high
5. Faulty pressure switch or vent limit switch.
Four flashes, three
second pause
Excessive tank
temperature.
System must be
reset.
1. Excessive sediment
2. Hot water entering the tank from another
source in the potable loop.
3. Faulty gas valve.
Five flashes, three
second pause
False pilot flame
present.
1. Pilot valve stuck in open position.
Six flashes-one
flash, three
second pause
(Soft lockout)
Failed to light pilot.
System auto resets
after 5 minutes.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
50
Troubleshooting continued-
LED Status
Control Status
Probable Cause
Six flashes-two
flashes, three
second pause
(Soft lockout)
Pressure switch or
blower temperature
switch opened during
burner operation.
System auto resets
after 5 minutes.
1. Pressure switch tubing kinked or blocked.
2. Vent blockage or improper vent
configuration.
3. Vent termination being affected by windy
conditions.
4. Blower not spinning up to speed.
5. Vent temperature too high.
6. Faulty pressure switch or blower temp.
switch.
Six flashes-three
flashes, three
second pause
(Soft lockout)
Pilot flame
extinguished.
System resets after 5
minutes.
1. Unstable pilot.
2. Pilot tube blocked or restricted.
3. Oxidation build up on pilot electrode.
4. Wire damage to pilot assembly or bad
connection at gas valve.
5. Insufficient combustion air.
Six flashes-four
flashes, three
second pause
(Soft lockout)
Undesired-false pilot
flame sensed.
System auto resets.
Pilot valve stuck in open position.
Seven flashes,
three second
pause
Flammable vapor
sensor fault
detected, see
warning label
1. Flammable vapor present
2. Flammable vapor sensor exposed to
excessive
moisture
3. Flammable vapor sensor exposed to extreme
ambient temp
Eight flashes-one
flash, three
second pause
Flammable vapor
sensor out of
specification.
Possible short.
1. Flammable vapor sensor out of specification
2. Possible short.
Eight flashes, two
flashes, three
second pause
Temperature sensor
fault
1. Damage to sensor or wire in control’s well.
2. Control’s sensor resistance out of range.
3. Replace control.
Eight flashes-three
flashes, three
second pause
Electronics fault
detected
1. Verify control is not wet or physically
damaged
2. Reset control on/off switch.
3. Replace electronic module if 8-3 error
persists
Eight flashes-four
flashes, three
second pause
Gas valve fault
detected.
1. Verify control is not wet or physically
damaged.
2. Reset control on/off switch.
3. Replace gas control if 8-4 error persists
51
Control Sequence of Operation
Start up Sequence
Upon powering up, the control checks for the presence of the vapor sensor, if the
resistance is in the expected range the control will begin normal operation after 5 to 8
seconds.
Normal Heating Sequence
1. The thermostat senses a need for heat.
2. The control checks the pressure switch condition.
3. If the pressure switch is open, the control sends power to the blower motor.
4. The blower starts moving combustion air through the combustion system.
5. The pressure switch closes.
6. The control senses the closed pressure switch and starts the ignition process by
providing a spark at the pilot electrode and allowing gas to flow to the pilot.
7. When the pilot is lit the gas control senses the pilot flame and opens the main gas
valve.
8. The main burner is lit.
9. The main burner and blower continue to operate until the thermostat is satisfied.
10. When the thermostat is satisfied the main and pilot gas valves close.
11. The blower operates for a short post purge period before shutting down.
12. The water heater remains in the stand-by mode until the next call for heat.
52
PARTS LIST DRAWING
PARTS LIST
PART NAME AND DESCRIPTION
1. Blower Assembly
13. T&P Relief Valve
2. Temp. Switch
14 Pilot Assembly
3. Pressure Switch N.O.
15. Main Burner Orifice
4. Flue Baffle
16. Gas Feedline
5. Honeywell Gas Control Valve
17. Flammable Vapors Sensor
6. Drain Valve
18. Sensor Harness
7. Fiberglass Insulation (not shown)
19. Inner Door Assembly
8. Foam Insulation (not shown)
20. Blower Harness
9. Outer Door
21. Air intake boot
10. Steel Burner
22. Tee and vent pipe assembly
11. Diptube–Nipple
23. Vapor switch mounting bracket
12. Anode–Nipple
53
THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:
GAS WATER HEATERS SUITABLE FOR WATER (POTABLE)
HEATING AND SPACE HEATING
1. All piping components connected to this water heater for space heating
applications must be suitable for use with potable water. In Massachusetts,
space heating piping length must not exceed 50 feet.
2. Toxic chemicals, such as those used for boiler treatment, must not be
introduced into potable water used for space heating.
3. This water heater must not be connected to an existing heating system or
component(s) previously used with a non-potable water heating appliance.
4. When the system requires water for space heating at temperatures higher
than required for other uses, a means such as an ASSE approved mixing
valve shall be installed to temper the water for those uses in order to reduce
scald hazard potential.
Please refer to the illustrations below for the suggested piping arrangement.
54
NOTES
55
NOTES
56