1
Instruction Manual
PRINTED 0417 100282882 (Rev. B) 2000542152
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
RESIDENTIAL GAS WATER HEATERS
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
POWER VENTED GAS MODELS W/HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
LOW LEAD
CONTENT
2
SAFE INSTALLATION, USE AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
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.
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
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.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
WARNING
CAUTION
CAUTION
DANGER
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.
IMPORTANT DEFINITIONS
• 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.
APPROVALS
LOW LEAD
CONTENT
3
GENERAL SAFETY INFORMATION
Fire Hazard
For continued protection against risk
of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if any
part has been exposed to flooding
or water damage.
4
GENERAL SAFETY INFORMATION
at least 18" (45.7 cm) above the floor. This
will reduce, but not eliminate, the risk
Improper installation, use and service may result
in property damage.
•
Do not operate water heater if any part has been exposed
to flooding or water damage.
•
Inspect anode rods regularly, replace if damaged.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
CAUTION
Breathing Hazard - Carbon Monoxide Gas
•
Install vent system in accordance with codes.
•
Do not operate water heater if any part has been
exposed to flooding or water damage.
•
High altitude models should be installed at
elevations
above
5,300
feet
(
1,615 m
).
For operation above
10,100
feet (3,079 m), a high altitude orifice must be installed.
•
Do not operate if soot buildup is present.
•
Do NOT elevate any portion of the field supplied
drain line beyond the 1/2” adaptor above the
adaptor. This must be true for the entire length
of the drain line including the exit into an
appropriate drain.
•
Condensate lines must be free and clear of debris
and must not allow back flow through the hose.
The condensate lines must be able to flow freely
to an appropriate drain.
•
Do not obstruct water heater air intake with
insulating jacket.
•
Do not place chemical vapor emitting products
near water heater.
•
Do not allow condensate lines to become
crimped closed.
•
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.
•
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.
5
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• AHRI - Air Conditioning, Heating and Refrigeration Institute
• UL - Underwriters Laboratories Inc.
This gas-red water heater is design certied by Underwriters
Laboratories Inc. under American National Standard/CSA Standard
for Gas Water Heaters ANSI Z21.10.3 • CSA 4.3 (current edition).
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability equivalent
to that of a Qualied Agency (as dened by ANSI below) in the eld
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: “Qualied Agency” - “Any individual,
rm, 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 qualied (as dened by ANSI above) and licensed or
certied 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 “General Safety Information” section, page 3 and 4 of this manual
rst 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-red water heater. It also contains
warnings throughout the manual that you must read and be
aware of. All warnings and all instructions are essential to proper
operation of the water heater and your safety. Since we cannot
put everything on the rst 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 Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
3. The water heater when installed must be 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 res, see Figures 1 and 2.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
6. 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 California Ofce of the State
Architect, 400 P Street, Sacramento, CA 95814.
7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
8. Complies with SCAQMD rule #1146 and districts having equivalent
NOx requirements.
INTRODUCTION
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE................................................ 2
APPROVALS ................................................................................................ 2
GENERAL SAFETY INFORMATION ......................................................... 3-4
TABLE OF CONTENTS ................................................................................5
INTRODUCTION .......................................................................................... 5
Qualied Installer or Service Agency ................................................... 5
Preparing for the Installation ................................................................ 5
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH
OF MASSACHUSETTS ................................................................................6
TYPICAL INSTALLATION ..........................................................................7-9
Mixing Valves ....................................................................................... 9
LOCATING THE NEW WATER HEATER .............................................. 10-13
Facts to Consider About Location ................................................. 10-11
Insulation Blankets ............................................................................. 11
Air Requirements .......................................................................... 11-12
Unconned Space .............................................................................12
Conned Space .................................................................................12
Fresh Air Openings for Conned Spaces .......................................... 12
Outdoor Air Through Two Openings .................................................. 12
Outdoor Air Through One Opening ...............................................12-13
Outdoor Air Through Two Horizontal Ducts .......................................13
Outdoor Air Through Two Vertical Ducts ............................................ 13
Air from Other Indoor Spaces ............................................................13
INSTALLING THE NEW WATER HEATER ...........................................14-27
Chemical Vapor Corrosion ................................................................. 14
Water Piping ......................................................................................14
Space Heating & Potable Water System ........................................... 14
Closed Water Systems ......................................................................14
Thermal Expansion ............................................................................ 15
Temperature-Pressure Relief Valve ..............................................15-16
High Altitude Installation .................................................................... 16
Gas Piping ....................................................................................16-17
Sediment Traps ..................................................................................17
Filling the Water Heater ................................................................17-18
Vent Pipe Assembly ........................................................................... 18
Venting ............................................................................................... 18
Vent Pipe Termination ........................................................................ 19
Planning the Vent System .................................................................. 20
Polypropylene Installations ................................................................21
Condensate .......................................................................................21
Blower Assembly Installation ............................................................. 22
Installation of Vent System ................................................................ 22
Vent Terminal Installation, Sidewall .................................................... 22
Installation of Vent System, Sidewall ................................................. 24
Installation of Vertical Vent System ....................................................24
Vent Pipe Preparation ........................................................................ 25
LIGHTING & OPERATING LABEL ............................................................. 27
TEMPERATURE REGULATION ................................................................ 28
FOR YOUR INFORMATION ....................................................................... 29
Start Up Conditions ............................................................................29
Operational Conditions ......................................................................29
PERIODIC MAINTENANCE ....................................................................... 29
Venting System Inspection ................................................................ 29
Burner Operation and Inspection ....................................................... 30
Burner Cleaning ................................................................................. 30
Housekeeping .................................................................................... 30
Anode Rod Inspection .......................................................................30
Temperature-Pressure Relief Valve Test ............................................ 31
Draining and Flushing ........................................................................ 31
Service ............................................................................................... 32
LEAKAGE CHECKPOINTS ........................................................................32
REPAIR PARTS LIST .................................................................................33
TROUBLESHOOTING GUIDELINES ....................................................34-36
NOTES ..................................................................................................37-38
6
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 nished grade in the area of
the venting, including but not limited to decks and porches, the
following requirements shall be satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gastter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the oor level where
the gas equipment is to be installed. In addition, the installing
plumber or gastter 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 qualied 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 oor 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 certied.
SIGNAGE
A metal or plastic identication 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 a Product Approved side wall
horizontally vented gas fueled equipment does not provide the
parts for venting the ue gases, but identies “special venting
systems,” the following requirements shall be satised 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.
7
TYPICAL INSTALLATION
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See “PLANNING THE VENT SYSTEM”, “CONDENSATE” and “BLOWER ASSEMBLY INSTALLATION” for more
information.
*** The side recirculation loop connections may not be used as the primary water inlet and outlet connections.
For your convenience, plugs are installed in these ttings at the factory. Remove these plugs if needed for
your specic installation. Otherwise (as with all connections) check for leaks while lling the tank with water
and after completing the installation.
FIGURE 1.
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
(W)
Q Rating Plate
R Insulation
S Vent Terminal
T Drain Valve
U Igniter And Main Burner
V Drain Pan
W Gas Control Valve
X Temperature Probe Harness
Y Control Harness*
Z Temperature Probe
A A Motor & Blower
CC Condensate Fitting
(4 Places Shown)**
DD Plastic Top
EE On/Off Switch
FF Exhaust Tee
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Anode
C Hot Water Outlet
D Outlet (120 VAC)
F Gas Supply
G Main Manual Gas Shuttoff Valve
H Ground Joint Union
J Sediment Trap
K Outer Door
L Union
M Inlet Water Shuttoff Valve
N Cold Water Inlet
O Inlet Dip Tube
P Temperature & Pressure
Relief Valve
GG Elbow
H H Bushing
II Nipple
JJ Condensate Tee
K K Adapter
LL Plug
MM Vent Pipe Assembly #1
NN Vent Pipe Assembly #2
OO Vent Pipe Assembly #3
PP Side Recirculation Loop
Inlet***
QQ Side Recirculation Loop
Outlet*** (not shown)
RR Vent Sound Silencer
(Optional)
SS Access Door
CONDENSATE ASSEMBLY
(U) NATURAL GAS MAIN BURNER
WITH IGNITER ASSEMBLY
SIDE VIEW
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.
TEMPERATURE ADJUSTMENT BUTTONS
TEMPERATURE INDICATORS
8
TYPICAL INSTALLATION
CONDENSATE HOSE AND DRAIN PAN
FIGURE 1 (continued).
9
TYPICAL INSTALLATION
FIGURE 2.
MIXING VALVE / THERMAL EXPANSION TANK USAGE AND SPACE HEATING
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 physically
or mentally disabled are at highest risk
for 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.
Water heated to a temperature which will satisfy 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 temperatures at the point of use to exceed
the water heater’s temperature setting by up to 20°F (11°C).
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the inrm and the
physically/mentally disabled. Table 1 shows the approximate time-
to-burn relationship for normal adult skin. If anyone using hot water
provided by the water heater being installed ts 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.
In addition to
using lowest possible temperature setting that
satises
demand of application a Mixing Valve should be installed at water
heater (see Figure 3) or at hot water 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.
TABLE 1.
Water Temperature °F
Time for 1
st
Degree Burns
(Less Severe Burns)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110 (normal shower temp.)
116 (pain threshold)
116 35 minutes 45 minutes
122 1 minute 5 minutes
131 5 seconds 25 seconds
140 2 seconds 5 seconds
149 1 second 2 seconds
154 instantaneous 1 seconds
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
HOT WATER
OUTLET
TO TANK
INLET
CHECK
VALVE
MIXING
VALVE
COLD
WATER
INLET
TEMPERED WATER
OUTLET
12” TO 15”
(30-38 cm)
CHECK
VALVE
FIGURE 3.
10
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 terminal 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.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the ow will not cause
damage to the structure. For this reason, it is not advisable to install
the water heater in an attic or upper oor. When such locations cannot
be avoided, a metal drain pan should be installed under the water
heater. Drain pans are available at your local hardware store. Such
a drain pan must have a clearance of at least 1.0” (2.5cm) greater
than any point on the water heater’s outer jacket and must be piped
to an adequate drain. The pan must not restrict combustion air ow.
For example, if a circular pan is used, it must be a minimum of 27”
(69cm) in diameter. See Figure 1.
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 drain pan piped to a drain.
However, unanticipated damage can be reduced or prevented by
a leak detector or water shuttoff device used in conjunction with a
piped 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 drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to
the entire building when water is detected in the drain pan.
• Water supply shuttoff 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.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable
liquids (such as gasoline, solvents, propane (LP or butane, etc.) and
other substances (such as adhesives, etc.) emit ammable vapors
which can be ignited by a gas water heater’s hot surface igniter or
main burner. The resulting ashback and re can cause death or
serious burns to anyone in the area.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
LOCATING THE NEW WATER HEATER
Fire Hazard
For continued protection against risk
of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if any
part has been exposed to flooding
or water damage.
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
appliance extending beyond the full width and depth of the appliance
by at least 3” (7.6 cm) in any direction, or if the appliance is installed
11
in an alcove or closet, the entire oor must be covered by the panel.
Failure to heed this warning may result in a re hazard.
Minimum clearances between water heater and combustible
construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from the
front and 12” (30.5 cm) from top. (Standard clearance.) If clearances
stated on the heater differ from standard clearances, install water
heater according to clearances stated on the heater.
Adequate clearance 24” (61.0 cm) for servicing this appliance should
be considered before installation, such as changing the anodes, etc.
A minimum clearance of 5.5” (14.0 cm) must be allowed for access
to replaceable parts such as thermostats, drain valve, relief valve
and condensate drain.
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.
FIGURE 4.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Do not install in a conned area such as a closet,
unless you provide air as shown in the “Locating The New Water
Heater” section. Never obstruct the ow of ventilation air. 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 re or explosion
and cause death, serious bodily injury, or property damage.
FIGURE 5.
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
ammable 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 Energy Policy Act 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 identication of components
mentioned below, see Figure 1). Failure to follow these instructions can
restrict the air ow required for proper combustion, potentially resulting
in re, 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 temperature & pressure
relief valve.
• Do not allow insulation to come within 2” (5.1 cm) of the oor to
prevent blockage of combustion air ow to the burner.
• Do not cover the instruction 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 ow.
AIR REQUIREMENTS
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
An insufficient supply of air can cause recirculation of combustion
products resulting in contamination that may be hazardous to life.
12
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 conned space unless an
adequate supply of air for combustion and ventilation is brought in
to that space using the methods described in the Conned Space
section that follows.
Never obstruct the ow of ventilation air. 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 re or explosion and cause
property damage, serious bodily injury or death.
UNCONFINED SPACE
An Unconned Space is one whose volume is not less than 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters per 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
unconned space.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and replaces should also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconned spaces in buildings, inltration may be adequate to
provide air for combustion, ventilation and dilution of ue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in the
Conned Space section that follows.
CONFINED SPACE
A Conned Space is one whose volume is less than 50 cubic feet
per 1,000 Btu/hr (4.8 cubic meters per 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 conned spaces. The required size for the
openings is dependent on the method used to provide fresh air to
the conned space and the total Btu/hr input rating of all appliances
installed in the space.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration 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 conned 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, sufcient 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 re or explosion may result. It can
also create a risk of asphyxiation.
LOUVERS AND GRILLES
The free areas of fresh air openings in instructions that follow do not take
in to account presence of louvers, grilles or screens in openings.
The required size of openings for combustion, ventilation and dilution
air should be based on the “net free area” of each opening. Where
the free area through a design of louver or grille or screen is known, it
should be used in calculating the size of opening required to provide the
free area specied. Where the louver and grille design and free area
are not known, it should be assumed that wood louvers will have 25%
free area and metal louvers and grilles will have 75% free area. Non
motorized louvers and grilles should be xed in the open position.
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 conned spaces. The illustrations shown in
this section of the manual are a reference for the openings that provide
fresh air into conned spaces only. Do not refer to these illustrations
for the purpose of vent installation. See Installation of Vent System on
pages 18-27 for complete venting installation instructions.
OUTDOOR AIR THROUGH TWO OPENINGS
FIGURE 6.
The confined space should be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings should communicate directly with
the outdoors. See Figure 6.
Each opening should have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm
2
per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening should
not be less than 100 square inches (645 cm
2
).
OUTDOOR AIR THROUGH ONE OPENING
FIGURE 7.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, should be provided. See
13
Figure 7. The water heater should have clearances of at least 1 inch
(25 mm) from the sides and back and 6 inches (150 mm) from the front
of the appliance. The opening should directly communicate with the
outdoors or should communicate through a vertical or horizontal duct
to the outdoors or spaces that freely communicate with the outdoors
and should have a minimum free area of the following:
1. 1 square inch per 3000 Btu/hr (700 mm
2
per kW) of the total input
rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
FIGURE 8.
Conned space should be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of top and one
commencing within 12 inches (300 mm) of bottom of enclosure. Horizontal
ducts should communicate directly with outdoors. See Figure 8.
Each duct opening should have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm
2
per kW) of the aggregate input rating of all
appliances installed in the enclosure.
When ducts are used, they should be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts should be not less than 3 inches.
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
The illustrations shown in this section of the manual are a reference for
the openings that provide fresh air into conned spaces only.
Do not refer to these illustrations for the purpose of vent installation.
See Installation of Vent System on pages 18-27 for complete venting
installation instructions.
FIGURE 9.
The conned space should be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The vertical ducts should communicate directly with the
outdoors. See Figure 9.
Each duct opening should have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm
2
per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they should be of the same cross sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts should be not less than
3 inches.
AIR FROM OTHER INDOOR SPACES
FIGURE 9A.
The confined space should be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 9A.
Each opening should communicate directly with an additional room(s)
of sufcient volume so that the combined volume of all spaces meets
the criteria for an Unconned Space.
Each opening should have a minimum free area of 1 square inch per
1,000 Btu/hr (1100 mm
2
per kW) of the aggregate input rating of all
appliances installed in the enclosure. Each opening should not be
less than 100 square inches (645 cm
2
).
14
This water heater should not be connected to any heating systems
or component(s) 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 should not
be introduced into this system.
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 Figure 2 for suggested
piping arrangement.
This water heater cannot be used in space heating applications only.
SPACE HEATING AND POTABLE WATER SYSTEM
This appliance has been design certied as complying with
American National Standard/CSA Standard for water heaters and is
considered suitable for Water (Potable) Heating and Space Heating.
Your water heater is equipped with inlet/outlet connections
for use in space heating applications (see Figure 2). If this
water heater is to be used to supply both space heating and
potable (drinking) 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
ow of water through the air handler circuit during the off cycle.
Weeping (blow off) of the temperature and pressure relief valve
(T & P) or higher than normal water temperatures are the rst 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.
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
ow preventers. Devices such as these cause the water system to
be a closed system.
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 these
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).
WATER PIPING
DANGER
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the physically
or mentally disabled are at highest
risk for scald injury.
Feel water before bathing or showering.
Temperature limiting valves are
available.
Read instruction manual for safe
temperature setting.
HOTTER 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 inrm, or physically/mentally handicapped.
If anyone using hot water ts into one of these groups or if there is
a local code or state law requiring a certain temperature water at the
hot water tap, then you must take special precautions. In addition to
using lowest possible temperature setting that satises 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 Figure 2. Valves
for reducing point of use temperature by mixing cold and hot water are
also available:
Consult a Qualied Installer or Service Agency. Follow manufacturer’s
instructions for installation of valves. Before changing the factory setting
on thermostat, read “Temperature Regulation” section in this manual.
INSTALLING THE NEW WATER HEATER
15
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed system
the volume of water will grow when it is heated. As the volume of water
grows 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 valve due to excessive
pressure build up. This condition is not covered under the limited warranty.
The Temperature-Pressure Relief Valve is not intended for constant relief
of thermal expansion.
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed.
NOTE: To protect against untimely corrosion of hot and cold water
ttings, it is strongly recommended that di-electric unions or couplings
be installed on this water heater when connected to copper pipe.
All gas piping must comply with local codes and ordinances or with the
National Fuel Gas Code (ANSI Z223.1/ NFPA-54). Copper and brass tubing
and ttings (except tin lined copper tubing) should not be used.
FIGURE 10.
Figure 10 shows typical attachment of water piping to the water heater.
The water heater is equipped with 3/4 inch 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 damage the tank.
T & P Valve and Pipe Insulation
1. Locate the temperature and pressure relief valve on the water heater
(also known as a T&P relief valve). See Figure 11.
2. Locate the slit running the length of the T&P relief valve insulation.
3. Spread the slit open and t the insulation over the T&P relief valve. See
Figure 11. 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 11). Ensure a discharge pipe is installed into
the T&P valve discharge opening per the instructions in this manual.
4. Locate the hot water (outlet) & cold water (inlet) pipes to the water heater.
5. Locate the slit running the length of a section of pipe insulation.
6. 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 ush with the water heater. Once seated, secure the
insulation with duct tape, electrical tape, or equivalent.
7. Repeat steps 5 and 6 for the hot water (outlet) pipe.
8. Add additional sections of pipe insulation as needed.
FIGURE 11.
TEMPERATURE-PRESSURE RELIEF VALVE
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized Temperature-Pressure
Relief Valve must be installed in
opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
This water heater is provided with a properly rated/sized and certied
combination Temperature-Pressure Relief Valve (T&P valve) by the
manufacturer. The valve is certied 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 Temperature-Pressure Relief
Valve rated/sized and certied 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.
Note: In addition to the factory installed Temperature-Pressure Relief
Valve on the water heater, each remote storage tank that may be
installed and piped to a water heating appliance must also have its
own properly sized, rated and approved Temperature-Pressure Relief
Valve installed. Call the toll free technical support phone number listed
on the back cover of this manual for technical assistance in sizing a
Temperature-Pressure Relief Valve for remote storage tanks.
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening nor
plugged. The Temperature-Pressure Relief Valve must be installed
directly into the tting of the water heater designed for the relief
valve. Install discharge piping so that any discharge will exit the
pipe within 6 inches (15.2 cm) above an adequate oor 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
16
discharge opening must not be blocked or reduced in size under any
circumstances. Excessive length, over 30 feet (9.14 m), 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
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm) 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 ow
may cause property damage.
CAUTION
•
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
Water Damage Hazard
T&P Valve Discharge Pipe Requirements:
• Should not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
• Should not be plugged or blocked.
• Should not be exposed to freezing temperatures.
• Should be of material listed for hot water distribution.
• Should 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 oor 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.
• Should not have any valve or other obstruction between the relief
valve and the drain.
DANGER
• Burn hazard.
• Hot water discharge.
• Keep clear of Te mperature-
Pressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually operated at
least twice a year. Caution should be taken to ensure that (1) no one
is in front of or around the outlet of the Temperature-Pressure Relief
Valve 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.
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 on page 14 and 15.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the
toll free number listed on the back cover of this manual for
technical assistance.
HIGH ALTITUDE INSTALLATION
This heater is approved for operation up to 5,300 feet (1,615 m)
without alteration. High altitude models are available from the factory
for elevations between 5,300 feet (1,615 m) and 10,100 feet (3,079
m). For elevations above 10,100 feet (3,079 m) the input rating
should be reduced at the rate of 4 percent for each 1,000 feet (305
m) above sea level which requires replacement of the burner orice
in accordance with National Fuel Gas Code (ANSI Z223.1/NFPA 54).
Contact your local gas supplier for further information.
Failure to replace standard orice with a high altitude orice when
installed above 10,100 feet (3,079 m) could result in improper and
inefcient 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 specic changes which
may be required in your area.
GAS PIPING
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.
Make sure the gas supplied is the same type listed on the model
rating plate. The inlet gas pressure must not exceed 14 inch water
column (3.5 kPa) for natural and propane gas (L.P.). The minimum
inlet gas pressure shown on the rating plate is that which will permit
ring at rated input.
All gas piping must comply with local codes and ordinances or with the
National Fuel Gas Code (ANSI Z223.1/ NFPA-54). Copper or brass
tubing and ttings (except tin lined copper tubing) should not be
used.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a re
or explosion from leaking gas.
If the main gas line Shuttoff 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.
17
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.
There must be:
• A readily accessible manual shuttoff valve in the gas supply line
serving the water heater, and
• A sediment trap ahead of gas control valve to help prevent dirt and
foreign materials from entering the gas control valve.
• A exible gas connector or a ground joint union between the shuttoff
valve and control valve 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 ame. Rinse
off soapy solution and wipe dry.
Use pipe joint compound or teon tape marked as being resistant
to the action of petroleum [Propane (L.P.)] gases.
The appliance and its gas connection must be leak tested before
placing the appliance in operation.
The appliance and its individual Shuttoff valve should be disconnected
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of 1/2 pound per square inch (3.5 kPa).
It should be isolated from the gas supply piping system by closing its
individual manual Shuttoff valve during any pressure testing of the gas
supply piping system at test pressures equal to or less than 1/2 pound
per square inch (3.5 kPa).
Connecting gas piping to the gas control valve of water heater can be
accomplished by either of two methods shown in Figures 12 and 13.
FIGURE 12. GAS PIPING WITH
FLEXIBLE CONNECTOR.
FIGURE 13. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
SEDIMENT TRAPS
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 12 and 13.
Contaminants in the gas lines may cause improper operation of
the gas control valve 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 dirt or foreign material in the gas supply
line, a sediment trap 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 54).
FIGURE 14.
FILLING THE WATER HEATER
18
Never use this water heater unless it is completely full of water. To prevent
damage to the tank, the tank must be lled with water. Water must ow
from the hot water faucet before turning “ON” gas to the water heater.
To ll 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.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when the
water heater is in use.
3. To insure complete lling of the tank, allow air to exit by opening nearest
hot water faucet. Allow water to run until a constant ow is obtained.
This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as needed.
VENT PIPE ASSEMBLY
There are three parts of the vent pipe assembly that connect the water
heater exhaust (located on lower back side of water heater) to inlet of the
blower assembly (mounted on top of water heater) as shown in Figure
1. These parts will need to be assembled according to the instructions
in the VENT PIPE PREPARATION section of this manual. These PVC
parts should be assembled with ASTM D-2564 grade cement.
Assemble Vent Pipe Assemblies #1, #2 and #3 (See Figure 1) prior
to cementing. The preferred orientation of Vent Pipe Assembly #1
(Condensate U-Assembly) is shown in Figure 16. However this
assembly may be rotated to a different orientation as needed for the
specic installation requirements. Note the rotational orientation of
each part by marking a line several inches long across the joints.The
long tube of Vent Pipe Assembly #2 should be approximately
vertical. If it is found that either of the two pieces of pipe in Vent
Pipe Assembly #2 are too long for proper t-up, then remove as
little material as possible to improve the t-up. Keep in mind that
the pipes will insert slightly further into the elbows when cement
is applied as it acts as a lubricating agent. The vertical distance
from the bottom of the Condensate U-Assembly to the oor that
supports the water heater should be approximately 0.25” (0.64 cm),
see Figure 16. Disassemble the parts and cement back together
using the alignment marks. After the cement dries, attach the
assembly to the blower and the water heater exhaust using the
supplied rubber boots and hose clamps.
A condensate trap is incorporated in the bottom of this vent pipe assembly.
See the CONDENSATE section of this manual for further details.
VENTING
Breathing Hazard - Carbon Monoxide Gas
•
Install vent system in accordance with codes.
•
Do not operate water heater if exposed to flooding
or water damage.
•
High altitude models should be installed at
elevations above 5,300 feet (1,615 m). For
operation above 10,100 feet (3,079 m), a high
altitude orifice must be installed.
•
Do not operate if soot buildup.
•
Do not obstruct water heater air intake with
insulating jacket.
•
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.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
19
TERMINATION CLEARANCES SIDEWALL POWER VENT
FIGURE 15.
Vent terminal clearances for “Power Vent” installations. Power Vent congurations use room air for combustion.
US INSTALLATIONS
2
US INSTALLATIONS
2
A
Clearance above grade, veranda,
porch, deck or balcony
12 inches (30 cm)
H
Clearance to each side of center
line extended above meter/regulator
assembly
Clearance in accordance with
local installation codes and the
requirements of the gas supplier
B
Clearance to window or door
that may be opened
4 feet (1.2 m) below or to side of
opening; 1 foot (30 cm) above
opening
I
Clearance to service regulator vent
outlet
Clearance in accordance with
local installation codes and the
requirements of the gas supplier
C
Clearance to permanently
closed window
12 inches (30 cm)*
J
Clearance to a non mechanical air
supply inlet into building or combustion
air inlet to any other appliance
4 feet (1.2 m) below or to side of
opening; 1 foot (30 cm) above
opening
D
Vertical clearance to ventilated
soft located above the terminal
within a horizontal distance of 2
feet (61 cm) from the center line
of the terminal
12 inches (30 cm)*
K
Clearance to a mechanical air supply
inlet
3 feet (91 cm) above if within 10 feet
(3 m) horizontally
E
Clearance to unventilated soft 12 inches (30 cm)*
L
Clearance above paved sidewalk or
paved driveway located on public
property
7 feet (2.13 m)
F
Clearance to outside corner 2 feet (60 cm)*
M
Clearance under veranda, porch, deck,
or balcony
12 inches (30 cm) ‡
G
Clearance to inside corner 18 inches (45 cm)*
2 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.
Where it may cause hazardous frost or ice accumulations on adjacent property surfaces.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.
* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.
VENT PIPE TERMINATION
The first step is to determine where the vent pipe will terminate.
See Figures 15, 20 and 21. The vent may terminate through a
sidewall as shown in Figure 20 or through the roof as shown in
Figure 21.
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the
National Fuel Gas Code.
Instructions on proper installation through a sidewall are provided in
Figure 15.
Plan the vent system layout so that proper clearances are
maintained from plumbing and wiring.
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 LOCATING THE NEW
WATER HEATER and INSTALLING THE WATER HEATER, and
with the National Fuel Gas Code and local codes.
20
PLANNING THE VENT SYSTEM
Plan the route of the vent system from the discharge of the blower
to the planned location of the vent terminal. Water heaters covered
by these instructions are Category IV appliances.
1. Layout total vent system to use a minimum of vent pipe and elbows.
Water heaters covered by these instructions are Category IV appliances.
2. This water heater is capable of venting ue gases equivalent to
25’ (7.6 m) of 2” pipe, 65’ (19.8 m) of 3” pipe, or 128’ (39.0 m) of
4” pipe as listed in Table 2.
TABLE 2.
Number of 2” Maximum 3” Maximum 4” Maximum
90° Elbows Pipe - ft. (m) Pipe - ft. (m) Pipe - ft. (m)
1 20 (6.1) 60 (18.3) 120 (36.6)
2 15 (4.6) 55 (16.8) 112 (34.1)
3 10 (3.0) 50 (15.2) 104 (31.7)
4 -- 45 (13.7) 96 (29.3)
5 -- 40 (12.2) 88 (26.8)
6 -- 35 (10.7) 80 (24.3)
The minimum vent lengths for each of the pipe sizes is one
90° on top of the unit plus 2′ (61cm) of straight pipe and the
appropriate termination.
NOTE: The equivalent feet (m) of pipe listed above are exclusive
of the termination. That is, the termination, with an installed
screen, is assumed to be in the system and the remainder of the
system must not exceed the lengths discussed above.
3. The blower discharge adapter is made to accept only straight
sections of 2″ pipe. To start, a minimum of 2 inches (5.1 cm) of 2″
pipe must be attached to the blower discharge, see Figure 17.
If using 2” inch vent pipe:
A minimum of 2 inches (5.1 cm) must be attached to the blower
before the rst elbow. After the rst elbow add the additional
venting required for the installation. The total system cannot
exceed the lengths discussed above, where each elbow is equal
to 5 feet (1.5 m) of straight pipe. The SS2 tting, if used, counts
as being one 90 degree elbow.
If using 3” or 4” inch vent pipe:
Two inches (5.1 cm) of pipe must be attached to the blower
discharge before adding a reducer to acquire the desired pipe
diameter. An appropriately sized 45 degree schedule 40 DWV
elbow (field supplied) vent terminal must be obtained with an
equivalent screen (supplied in the vent kit). The total system
cannot exceed the equivalent pipe lengths discussed above
where each elbow is equal to 5 feet (1.5 m) of straight pipe
(3” vent pipe) or 8 feet (2.4 m) of straight pipe (4” vent pipe).
The SS2 fitting, if used, counts as one 90 degree elbow.
Approved vent pipe materials:
PVC pipe materials:
• DWV ASTM-D2665 or CSA B181.2
• Schedule 40, 80, 120 ASTM-D1785 or CSA B137.3
• SDR Series ASTM-2241 or CSA B137.3
CPVC pipe materials:
• CPVC 41 ASTM-D2846 or CSA B137.6
• Schedule 40, 80 ASTM-F441 or CSA B137.6
• SDR Series ASTM-F442
ABS pipe materials:
• Schedule 40 DWV ASTM-D2661 or CSA B181.1
Polypropylene - See tables 3 and 4 on page 20.
• M & G Duravent PolyPro vent system
• Centrotherm InnoFlue vent system
NOTE: The use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel® (polyphenolsulfone) in non-metallic venting
systems is prohibited. Covering non-metallic vent pipe and ttings
with thermal insulation is prohibited.
PVC Materials should use ASTM D-2564 Grade Cement; CPVC
Materials should use ASTM F-493 Grade Cement and ABS
Materials should use ASTM D-2235 Grade Cement.
If 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 above
has been used, and that minimum or maximum vent lengths and
terminal location as detailed in this manual have been met. Carefully
inspect entire venting system for any signs of cracks or fractures,
particularly at joints between elbows and other ttings 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
TABLE 3.
M&G Duravent Polypro
Nominal Pipe
Diameter
Flue Outlet
Adapter
Adapter
Connector
Ring
Connector
45° elbow 90° elbow Adapter to PVC
Adapter
Connector
2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E45 2PPS-E90 2PPS-AD-PVC PPS-PAC
3” 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E45 3PPS-E90 3PPS-AD-PVC PPS-PAC
4” 4PPS-AD PPS-PAC 4PPS-LB 4PPS-E45 4PPS-E90 4PPS-AD-PVC PPS-PAC
TABLE 4.
Centrotherm InnoFlue
Nominal Pipe
Diameter
Flue Outlet
Adapter
Adapter
Connector
Ring
Connector
45° elbow 90° elbow Adapter to PVC
Adapter
Connector
2” ISAGL 0202 IAFC02 IANS02 ISELL0245 ISELL0287 ISTAGL0202 ISAGL0202
3” ISAGL 0303 IAFC03 IANS03 ISEL0345
ISEL0387 **
ISTAGL0303 ISAGL0303
ISELL0387
4” ISAGL 0404 IAFC04 IANS04 ISEL0445 ISEL0487 ** ISTAGL0404 ISAGL0404
21
in system. If any of these conditions are found, they must be
corrected in accordance with venting instructions in this manual
before completing installation and putting water heater into service.
NOTE: A. For water heaters in locations with high ambient
temperatures (above 100°F) it is recommended that CPVC or
ABS pipe and ttings be used. B. A 22.5 degree elbow (2” vent
pipe) or a 45 degree elbow (3” and 4” vent pipe) with an installed
screen VENT TERMINAL must be used in all cases.
4. There will be some installations where condensate will be formed
in the horizontal runs of the vent system. This condensate will
run into the condensate boot attached to the blower and out the
tting. The water heater is shipped with condensate hose that
attaches to the tting on the condensate boot. No other Tee or
tting is required. See Figures 17, 20 and 21.
POLYPROPYLENE INSTALLATIONS
The water heater has been approved to be installed with
Polypropylene vent material as shown in Table 3 and Table
4. The approved application of single wall, non-exible, non-
concentric Polypropylene vent material is offered by two specic
manufacturers (Centrotherm ECO Systems and DuraVent
Polypropylene). These listed products must be installed by
following the vent manufacturer’s instructions. Refer to table 2
on page 20 to determine the maximum pipe length and number
of elbows that can be used.
Insulation should not be used on Polypropylene venting materials.
The use of insulation will cause increased vent wall temperatures,
which could result in vent pipe failure.
Use only the adapters and vent system listed in Tables below.
DO NOT mix vent systems of different types or manufacturers.
Failure to comply could result in severe personal injury, death,
or substantial property damage.
Installations must comply with applicable national, state, and local
codes. If Polypropylene vent is not required by your local code,
you may use either PVC, CPVC or ABS pipes for your water heater
that allows non-metallic venting material installations.
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. All vent connections MUST be secured by the vent
manufacturer’s joint connector. The installer must use a specic
vent starter adapter at the ue connection. The adapter is supplied
by the vent manufacturer to adapt to its vent system.
In order to be in full compliance with UL 1738 or ULC-S636 and
to meet the requirements of the water heater manufacturer, you
must use the metal joint connector rings, available from the
Polypropylene vent manufacturer, to stiffen the joints of 2”, and
3” diameter pipes.
CONDENSATE
This water heater is a condensing unit and requires a drain to
be located in close proximity to allow condensate to drain safely.
One hose from blower housing and two exible hoses from blower
outlet adaptor run to barb ttings on vent pipe assembly #2. Hose
is clamped by rubber clips and exible hoses by a clamp on jacket
top cover. See Figure 17. Condensate drains from the unit at
the exhaust tee located at the bottom of the unit, see gure 16.
Condensate from this water heater is mildly acidic. Please note
that some local codes require that condensate is treated by using
a pH neutralizing lter prior to disposal.
NOTE: It is important that the eld supplied drain lines beyond
the 1/2” adaptor of vent pipe assembly #1 should be installed
continuously tilted downward toward an appropriate drain. See
Figure 16. If these instructions are not followed or if condensate
drain line is blocked, water will spill from condensate trap. Do not
block the holes in the hex plug on top of a small tee in vent pipe
assembly #1. As with every water heater installation, a drain pan
should be used to prevent water damage to surrounding area. If
necessary, a condensate pump with an incorporated reservoir
may be used to pump water to an appropriate drain. To avoid
condensate spillage, select a pump with an overow switch.
Caution must be used to ensure that drain is free and clear
of debris and will not allow backflow through the condensate
drain line. Consideration must be given to avoid freezing of the
condensate lines which could result in excessive build up of
condensate inside the water heater. Waterproof heat tape may be
required to prevent freezing of condensate lines. Please ensure
that the outlet of condensate drain does not create a slippery
condition which could lead to personal injury. Care should be
taken to ensure there is no kink or twist in any condensate
hose. If a VAA is not installed, the unused barb fitting in vent
pipe assembly #2 should be plugged using one of the break-
away plugs.
Breathing Hazard - Carbon Monoxide Gas
•
Do NOT block the holes in the hex plug of vent pipe
assembly #1.
•
Do NOT elevate any portion of the field supplied drain
line beyond the 1/2" adaptor above the adaptor. This
must be true for entire length of the drain line including
the exit into an appropriate drain
.
•
Condensate lines must be free and clear of debris and
must not allow back flow through drain line. Condensate
lines must be able to flow freely to an appropriate drain.
•
Do not allow condensate lines to become crimped closed.
•
Analyze entire vent system to make sure that condensate
will not become trapped in a section of vent pipe and
therefore reduce open cross sectional area of vent.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
The condensate trap may be primed by filling the CONDENSATE
U-ASSEMBLY with tap water while the water heater is not
operating. The system is fully primed when the water level
reaches the adaptor connected into the Tee. In most installations
the water heater will self-prime the condensate trap during the
first full heat-up cycle. If a sound of air bubbling through water
(gurgling) is heard while the blower is operating after the first
heat-up cycle, then turn the unit off and contact your plumber
or service representative.
If these instructions are not followed, the condensate build-up
will block the exhaust outlet, which will cause improper operation.
Do NOT
block or
plug any
hole in this
hex plug.
DRAIN LINE
CONDENSATE
U-ASSEMBLY,
AKA. VENT PIPE
ASSEMBLY #1
*NO PORTION OF THE FIELD SUPPLIED DRAIN LINE BEYOND
THE 1/2" ADAPTOR MAY BE ELEVATED HIGHER THAN THE
ADAPTOR. THIS MUST BE TRUE FOR THE ENTIRE LENGTH
OF DRAIN LINE INCLUDING EXIT INTO AN APPROPRIAT E DRAIN.
APPROXIMATELY
0.25" (6.35 mm)
FIGURE 16.
22
Condensate is likely to form in the venting system attached to this
water heater. The vent pipe should be sloped downward away from
the blower assembly (not less than 1/8” (3.2 mm) nor greater than 1/2”
(12.7 mm) per foot (30 cm) maximum). If the vent piping is vented level
or sloped upwards away from the blower assembly, then adequate
means for draining and disposing of the condensate needs to be made
by the installer. Two 3/8” condensate hoses should be connected
to the built in drain ports of blower outlet adaptor. The unused barb
tting on vent pipe assembly #2 should be plugged with one of the
break-away plugs. See Figure 17.
Condensate neutralizer kits are available. Contact your distributor
or Service Agency.
BLOWER ASSEMBLY INSTALLATION
1. This power vented water heater comes with blower assembly installed.
2. After unit is set in place, make sure blower assembly is still
mounted securely. Make sure there is no damage to blower.
3. Condensate drains from three locations on blower assembly.
See Figure 17. One exible hose runs from bottom of blower
housing; two run from the ports of rubber connector at the outlet
of blower. All these three condensate hoses are connected to
barb ttings at vent pipe assembly #2. The hose from bottom
of blower housing is clamped by two clamps and the two hoses
from rubber connector are harnessed by another clamp. Make
sure there is no kink or twist.
FIGURE 17.
4. Make sure there is no packing material in the inlet or discharge
of the blower.
5. 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.
6. Make sure the ON/OFF switch is in the OFF position and that
the outer harness is connected from the blower control box to
the connector on the bottom side of the gas valve.
7. If the outer harness is not factory installed, make sure the ON/
OFF switch is in the OFF position and then connect the outer
harness from the blower control box to the connector on the
bottom side of the gas valve.
8. 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) exible power cord
supplied with the vent (See Figure 1). The power cord supplied
may be used on a unit only where local codes permit. If local
codes do not permit use of exible power supply cord:
A. Make sure the unit is unplugged from the wall outlet. Remove
the plastic top cap. Remove screws and open panel on the
front of the control box on the blower.
B. Cut the exible power cord, leaving enough to be able to make
connections. Remove the strain relief tting from the box.
C. Install a suitable conduit tting inside the enclosure.
D. Splice eld wiring into existing wiring using code authorized
method (wire nuts, etc).
E. Be certain that 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 grounding terminal or lead on
the water heater, see Figure 19.
G. Close the panel on the control box. Make sure that the access
panel is secured shut.
9. The blower discharge boot is made to accept only straight sections of
2” pipe. To start off with an elbow, a short section of the furnished
pipe, a minimum of 2 inches (5.1 cm), must be cut and glued into
the end of the elbow that will mount on the discharge boot.
VENT SOUND SILENCER
The Vent Sound Silencer (SS2) is optional. It is useful to reduce
the sound level outside, near the vent terminal. The SS2 must
always be installed directly above the blower outlet, with the closed
end horizontal to the ground. See Figure 1. The closed end that
contains the sound absorbing padding must never be mounted
pointed towards the ground since it would ll with condensate.
The SS2 counts as 5 equivalent feet in the overal length of the
vent system.
INSTALLATION OF VENT SYSTEM
Before beginning installation of piping system thoroughly read the
section of this manual VENT PIPE PREPARATION.
If you are installing your system so that it vents through roof, please
refer to section titled INSTALLATION OF VERTICAL VENT
SYSTEM.
VENT TERMINAL INSTALLATION, SIDEWALL
1. Install the vent terminal by using the 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.
2. If the Vent Terminal is being installed on outside of a nished wall,
it may be easier to mark both the inside and outside wall. Align
23
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
WARNING
DISCONNECT FROM ELECTRICAL SUPPLY BEFORE SERVICING UNIT.
R EPLACE ALL D OORS AND PANELS BEFORE OPERATING HEATER.
IF ANY OF THE ORIGINAL WIRES SUPPLIED WITH THE APPLIANCE MUST BE
REPLACED, IT MUST BE REPLACED WITH APPLIANCE WIRE MATERIAL WITH
MINIMUM TEMPERATURE RATING OF 105
º
C AND A MINIMUM SIZE OF NO. 18 AWG.
WATER HEATER CONTROL
IGN
IGN
RS
120V
120V
120V
120V
PS
PS
GROUND
GND
GND
NTC
NTC
NORMAL OPERATION SEQUENCE
INDICATED BY BOXED NUMERALS
IGNITOR
FLAME SENSE ROD
5
6
2
1
7
GAS VALVE
TEMPERATURE
SENSOR
ON/OFF
SWITCH
4
BLOWER
VACUUM
SWITCH
(EXHAUST
BLOCKAGE)
3
BLOWER
MOTOR
M
~
GNDL2L1
LEGEND
Y=YELLOW
Y/BK=YELLOW/BLACK
G/Y=GREEN/YELLOW
W/BK=WHITE/BLACK
T=TAN
BK=BLACK
BL=BLUE
W=WHITE
R=RED
G=GREEN
W
BK
BL
W
R
R
BLOWER
POWER
SWITCH
120 V
BK
W
G/Y
N.O.
PRESSURE SWITCHES
BK
GAS VALVE
R
R
BK
R
GG
R
TEMPERATURE
SENSOR
FLAME ROD
HOT SURFACE IGNITER
T
T
T
N.C.
VENT
TEMP.
LIMIT
SWITCH
4
VENT
TEMPERATURE
LIMIT
SWITCH
BK
BK
W
NTC
NTC
NTC
NTC
POWER VENT WIRING SCHEMATIC - FIGURE 19.
holes by drilling a hole through center of the template from the
inside through to the outside. The template can now be positioned
on the outside wall using the drilled hole as a centering point for
the template.
3. A) MASONRY SIDE WALLS
Chisel an opening approximately one half inch (1.3 cm) larger
than the marked circle.
B) WOODEN SIDE WALLS
Drill a pilot hole approximately one quarter inch (0.64 cm) outside
of the marked circle. This pilot hole is used as a starting point
for a saws-all or sabre saw blade. Cut around the marked circle
staying approximately one quarter inch (0.64 cm) outside of the
line. (This will allow the vent to easily slide through the opening.
The resulting gap will be covered up by the Vent Terminal cover
plate.) Repeat this step on inside wall if necessary.
SEQUENCE OF INSTALLATIONS, FIGURE 18
Cut a length of PVC pipe about 3.5 inches (8.9 cm) longer than wall
thickness at the opening. Glue vent terminal to this section of pipe. Slide
the wall plate over the pipe to stop against the vent terminal. Place a
bead of caulking (not supplied) around the gap between the pipe and
cover plate. Apply enough to ll some of the gap between the pipe
and wall. Place some of the caulking on the back of the plate to hold it
against the wall after installation. If the vent pipe is installed up to the
wall, with a coupling on the end against the wall opening, the pipe with
the vent terminal can be prepared for gluing before inserting through
the wall. Slide the pipe through the wall and insert into the coupling on
the other side of the wall, making sure that the vent terminal ends up
pointed in the correct position, see Figure 18.
VENT TERMINATION - FIGURE 18.
24
INSTALLATION OF VENT SYSTEM, SIDEWALL
With the route of the venting system and selection of materials completed,
as discussed in the section of this manual titled PLANNING THE VENT
SYSTEM, the through the wall vent terminal in place and the rst section
of piping, up to rst elbow, installed at the blower it is time to complete the
installation of the venting system for the sidewall installation.
FIGURE 20.
It is recommended that the completion of the venting system start
at the blower assembly and run to the coupling on the inside wall
of the vent terminal, Figure18.
The vent system piping should be supported every 5 feet (1.5 m)
of vertical run and every 3 feet (91 cm) of horizontal run. Follow vent
pipe manufacturer’s instructions for proper joining procedures.
If necessary to achieve the 12” minimum clearance above
the highest anticipated snow level, install a snorkel as shown
in bottom portion of Figure 20.
NOTE: With the installation of a snorkel it is necessary to
use two 90° elbows that shall be considered along with the
additional vent pipe when calculating maximum equivalent
feet of venting.
INSTALLATION OF VERTICAL VENT SYSTEM
A proper flashing or “BOOT” should be used to seal the pipe
where it exits the roof. The total vent system should not exceed
the equivalent feet of pipe as listed in Table 1.
Provide support for all pipe protruding through the roof. All piping should
be properly secured. The vent system piping should be supported
every 5 feet (1.5 m) of vertical run and every 3 feet (91 cm) of
horizontal run. Follow vent pipe manufacturer’s instructions for proper
joining procedures.
FIGURE 21.
IMPORTANT
The vent system must terminate so that proper clearances
are maintained as cited in local codes or the current edition
of the National Fuel Gas Code (ANSI Z223.1) and as
listed below:
1. Vent Termination must extend a minimum of 12 inches (30 cm)
above roof or 12 inches (30 cm) above the anticipated snow level
to prevent blockage of the vent termination, as shown in Figures
20 and 21.
25
VENT PIPE PREPARATION
1. INITIAL PREPARATION
A. Make sure the solvent cement you are planning to use is
designed for the specic application you are attempting.
B. Know the physical and chemical characteristics and limitations of
the PVC and CPVC piping materials that you are about to use.
C. Know the reputation of your manufacturer and their products.
D. Know your own qualications or those of your contractor. The
solvent welding technique of joining PVC and CPVC pipe is a
specialized skill just as any other pipe tting technique.
E. Closely supervise the installation and inspect the nished
job before start-up.
F. Contact the manufacturer, supplier, or competent consulting
agency if you have any questions about the application or
installation of PVC and CPVC pipe.
G. 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
• 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
• 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 ttings 6
inches (15.2 cm) and above.
PRIMER
It is recommended that Tetrahydrofuran (THF) be used to prepare the
surfaces of pipe and ttings 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.
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 ttings.
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.
TABLE 5.
RECOMMENDED BRUSH* SIZE FOR PRIMER
AND CEMENT APPLICATIONS
Nominal Pipe Size Brush Width
(IPS)
2 1.5” (3.8 cm)
3 1.5” - 2.5” (3.8 cm - 6.4 cm)
*USE ONLY NATURAL BRISTLE
3. MAKING THE JOINT
A. Cutting
Pipe must be squarely cut to allow for the proper interfacing of the
pipe end and the tting 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 are the corner of the pipe end. If this type of cutter is used,
the are on the end must be completely removed.
NOTE: Power saws should be specically designed to cut plastic pipe.
STEP A
26
B. Deburring
Use a knife, plastic pipe deburring tool, or le 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 tting. Failure to chamfer the edge of the pipe may
remove cement from the tting socket, causing the joint to leak.
STEP B
C. Test dry t of the joint
Tapered tting sockets are designed so that an interfaced t should
occur when the pipe is inserted about 1/3 to 2/3 of the way into the
socket. Occasionally, when pipe tting dimensions are at the tolerance
extremes, it will be possible to fully insert dry pipe to the bottom of
the tting socket. When this happens, a sufcient quantity of cement
must be applied to the joint to ll the gap between the pipe and tting.
The gap must be lled to obtain a strong, leak-free joint.
D. Inspection, cleaning, priming
Visually inspect the inside of the pipe and tting 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 tting socket in Step F. Measure the tting 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 rst one.
Apply primer to the surface of the pipe and tting 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 tting socket.
• Apply a light coat of cement evenly around the inside of the
tting socket. Avoid puddling.
• Apply a second coat of cement to the pipe end.
STEP E
F. Joint assembly
Working quickly, insert the pipe into the tting socket bottom and
give the pipe or tting a 1/4 turn to evenly distribute the cement.
Do not continue to rotate the pipe after it has hit the bottom of the
tting socket. A good joint will have sufcient cement to make a
bead all the way around the outside of the tting hub. The tting
will have a tendency to slide back while the cement is still wet
so hold the joint together for about 15 seconds.
STEP F
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 sufcient time should be allowed for proper curing
of the joint. Exact drying time is difcult to predict because it
depends on variables such as temperature, humidity and cement
integrity. For more specic information, you should contact your
solvent cement manufacturer.
STEP G
27
1. Set the thermostat to the lowest setting by first
pressing the COOLER and HOTTER
buttons together and holding for 1 second. Then
press the COOLER button until the VAC
indicator light appears.
2. Set the ON/OFF switch on the control box to the
“OFF” position.
3. Turn off all electrical power to the appliance if
service is to be performed.
TO TURN OFF GAS TO APPLIANCE
ELBAMMALF
:GNINRAW
ro erif a ,yltcaxe snoitcurtsni eseht wollof ton od uoy fI
yrujni lanosrep ,egamad ytreporp gnisuac tluser yam noisolpxe
.efil fo ssol ro
A. This appliance does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
gas is heavier than air and will settle to the floor.
“WHAT TO DO IF YOU SMELL GAS”
● Do not try to light the appliance
● Do not touch any electrical switch; do not use any
telephone 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.
C. Use only your hand to push in the control buttons.
Never use tools. If the control buttons will not push in,
don’t try to repair them, call a qualified service
technician. Force or attempted repair may result in
fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately contact a qualified installer or
service agency to replace a flooded water heater.
Do not attempt to repair the service unit. It must be
replaced.
FOR YOUR SAFETY READ BEFORE LIGHTING
1. STOP! Read the safety information above on
this label.
2. Set the ON/OFF switch on the control box to the
“ON” position.
3. Set the thermostat to the lowest setting by first
pressing the COOLER and HOTTER
buttons together and holding for 1 second. Then
press the COOLER button until the VAC indicator
light appears.
4. Set the ON/OFF switch on the control box to the
“OFF” position.
5. This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
6. Wait five (5) minutes to clear out any gas. If you
then smell gas , STOP! Follow “B” in the safety
information above this label. If you don’t
smell gas go to the next step.
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control box to the
“ON” position.
9. Set the thermostat to the desired setting by first
setting the COOLER and HOTTER
buttons together and holding for 1 second. Then
press the HOTTER button.
10.WATER TEMPERATURE ADJUSTMENT is
approximately 120°F.
CAUTION: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature.
11. If the appliance will not operate, follow the
instructions “TO TURN OFF GAS APPLIANCE” and
call your technician or gas supplier.
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING.
OPERATING INSTRUCTIONS
VAC
COOLER
SCALDING RISK INCREASES
WITH HOTTER WATER
HOTTER
ABC
28
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 satises
your hot water needs. This will also provide the most energy efcient
operation of the water heater.
Short repeated heating cycles caused by small hot water uses can
cause temperatures at the point of use to exceed the thermostat setting
by up to 20°F (11°C). If you experience this type of use you should
consider using lower temperature settings to reduce scald hazards.
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 inrm, or physically/mentally handicapped. If anyone using
hot water from this heater ts into one of these groups or if there is a
local code or state law requiring a certain temperature water at the
hot water tap, then you must take special precautions. In addition
to using the lowest possible temperature setting that satises 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 2. Follow manufacturer’s instructions for installation of
the valves. Before changing the factory setting on the thermostat,
in this manual, see Figure 22.
Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended
in a bathtub or shower.
The water heater should be located in an area where the general
public does not have access. If a suitable area is not available, a cover
should be installed over the thermostat to prevent tampering.
The water temperature setting was factory set at the lowest temperature;
Pressing the “COOLER” button decreases temperature and
pressing the “HOTTER”
button increases the temperature.
Setting water heater temperature at 120°F (49°C) (Approx. “ ” mark
on temperature setting of gas valve) will reduce risks of scalds. Some
states or local codes require settings at specic lower temperatures.
TEMPERATURE REGULATION
To avoid any unintentional changes in water temperature settings, the
control has a tamper resistant feature for changing the temperature
setting. To change the temperature setting follow these instructions:
1. “Wake Up” the temperature indicators by holding down both
“COOLER” and “HOTTER” temperature adjustment buttons at
the same time for one second, see Figure 22. One or two of the
temperature indicators will light up. These indicators will only
remain on for 30 seconds if no further buttons are pressed. After
30 seconds the control will go back to “Sleep” mode.
2. Release both of the temperature adjustment buttons.
a. To decrease the temperature press and release the “COOLER”
button until the desired setting is reached.
b. To increase the temperature press and release the “HOTTER”
button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or raise
the temperature setting. The button must be pressed and released
for each temperature change desired.
Should overheating occur or the gas supply fail to shuttoff, turn off
the manual gas control valve to the appliance.
Figure 22.
C-Flashing = approx. 160°F (71°C) About 1/2 second
C = approx. 150°F (66°C) About 1-1/2 seconds
B = approx. 140°F (60°C) Less than 5 seconds
A = approx. 130°F (54°C) About 30 seconds
= approx. 120°F (49°C) More than 5 minutes
VAC = approx. 80°F (27°C) - - - - - - - - - - - - - -
Time to Produce
2nd & 3rd Degree
Water Temperature Burns on Adult Skin
Display
ABC
GAS CONTROL VALVE - FRONT VIEW
29
FOR YOUR INFORMATION
START UP CONDITIONS
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” in this manual.
OPERATIONAL CONDITIONS
SMELLY WATER
In each water heater there is installed 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.
“AIR” IN HOT WATER FAUCETS
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, we recommend 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 hot water faucet is opened.
There must be no smoking or open flame near the faucet at the
time it is open.
HIGH WATER TEMPERATURE SHUTOFF SYSTEM
A high temperature limit switch or ECO (Energy Cut Off) in the
tank is used to shut off the unit if the water temperature exceeds
195°F (91°C). The ECO is a single use switch and requires
complete replacement of the entire gas control valve/thermostat.
If the ECO should acuate, the water heater cannot be used until
the gas control valve/thermostat is replaced by a qualified service
agent. Contact the local water heater supplier or service agency
for service information.
VENTING SYSTEM INSPECTION
PERIODIC MAINTENANCE
At least once a year a visual inspection should be made of the venting
system. You should look for:
1. Obstructions which could cause improper venting. The combustion
and ventilation air ow must not be obstructed.
2. 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 ue gasses which could cause deadly asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the ue 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.
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 ue and venting before resuming operation
of the water heater.
30
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 ooded water heater will
create dangerous conditions which can cause DEATH, SERIOUS
BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualied installer
or service agency to replace a ooded 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 ame 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 1. The main burner should provide complete
combustion of gas, ignite rapidly, give reasonably quiet operation, and
cause no excessive ame lifting from the burner ports. If the proper ame
characteristics are not evident (see Figure 23), make sure that the ow
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 HSI should
also be done at least once a year, see Figure 23.
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until repairs
are made, because failure to correct the cause of the sooting can result
in a re causing death, serious injury, or property damage.
Figure 23.
BURNER CLEANING
In the event your burner or burner air openings require cleaning, turn
the blower switch to the “OFF” position and allow the burner to cool.
Call a service agency to remove and clean the burner and correct the
problem that required the burner to be cleaned.
HOUSEKEEPING
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
INSTALLED IN SUITABLE AREA: To insure sufcient 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
ammable liquids, etc. must not be placed against or adjacent to the
water heater which can cause a re.
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, 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
sulde gas dissolved in the water. IMPORTANT: Do not remove this
rod
permanently as it will void any warranties. The parts list includes a
special anode rod that can be ordered if water odor or discoloration occurs.
NOTE: This rod may reduce but not eliminate water odor problems.
The
water supply system may require special ltration equipment from a water
conditioning company to successfully eliminate all water odor problems.
Articially softened water is exceedingly corrosive because the process
substitutes sodium ions for magnesium and calcium ions. The use of
a water softener may decrease the life of the water heater tank.
The anode rod should be removed from the water heater tank every
3 years for inspection. NOTE: articially softened water requires the
anode rod to be inspected annually.
The following are typical (but not all) signs of a depleted anode rod:
* The majority of the rods diameter is less than 3/8”.
* Signicant sections of the support wire (approx. 1/3 or more of the
anode rod’s length) are visible.
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.
In replacing the anode:
1. Turn off gas supply to the water heater.
2. Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons of water from tank (Refer to “Draining
and Flushing” for proper procedures). Close drain valve.
4. Remove old anode rod.
5. Use Teon® tape or approved pipe sealant on threads and install
new anode rod.
6. Turn on water supply and open nearby hot water faucet to purge air
from water system. Check for any leaks and immediately correct
any if found.
Restart the water heater as directed under “Operating Your Water Heater.”
See the Repair Parts Illustration for anode rod location.
Figure 24. ANODE ROD DEPLETION.
31
TEMPERATURE-PRESSURE RELIEF VALVE TEST
DANGER
• Burn hazard.
• Hot water discharge.
• Keep clear of Temperature-
Pressure Relief Valve
discharge outlet.
It is recommended that the Temperature-Pressure Relief Valve should be
checked to ensure that it is in operating condition every 6 months.
When checking the Temperature-Pressure Relief Valve operation, make
sure that (1) no one is in front of or around the outlet of the Temperature-
Pressure Relief 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 25. The valve should seat properly and operate freely.
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
on page 32. Replace the Temperature-Pressure Relief Valve with a
properly rated/sized new one, see Temperature-Pressure Relief Valve
on page 15 for instructions on replacement.
DISCHARGE PIPE
TEMPERATURE-PRESSURE
RELIEF VALVE
Figure 25.
If the Temperature-Pressure Relief Valve on the water heater weeps
or discharges periodically, this 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 on page
14-15. The Temperature-Pressure Relief Valve is not intended for the
constant relief of thermal expansion.
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.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF VALVE
OPENING. THIS CAN CAUSE PROPERTY DAMAGE, SERIOUS
INJURY OR DEATH.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22-
CSA 4.4 and ASME code.
Properly sized Temperature-Pressure
Relief Valve must be installed in
opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
DRAINING AND FLUSHING
It is recommended that the water heater storage tank be drained and
ushed every 6 months to reduce sediment buildup. 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.
• 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 Shutoff Valve if
the water heater is going to be shut down for an extended
period.
3. Ensure the cold water inlet valve is open.
4. Open a nearby hot water faucet and let the water run until the
water is no longer hot.
5. Close the cold water inlet valve to the water heater.
6. Connect a hose to the water heater drain valve and terminate
it to an adequate drain.
7. Open the water heater drain valve and allow all the water to
drain from the storage tank.
8. Close the water heater drain valve when all water in the storage
tank has drained.
9. Close the hot water faucet opened in Step 4.
10. If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
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. Open a nearby hot water faucet and let the water run until the
water is no longer hot. Then close the hot water faucet.
4. Connect a hose to the drain valve and terminate it to an
adequate drain.
5. 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.
6. Open the water heater drain valve to flush the storage tank.
7. Flush the water heater storage tank to remove sediment and
allow the water to flow until it runs clean.
8. Close the water heater drain valve when flushing is completed.
9. Remove the drain hose.
10. Fill the water heater - see Filling The Water Heater in this
manual.
11. Turn on electrical supply to place water heater back in
operation.
12. Allow the water heater to complete several heating cycles to
ensure it is operating properly.
32
LEAKAGE CHECKPOINTS
Never use this water heater unless it is completely lled with water.
To prevent damage to the tank, the tank must be lled with water.
Water must ow from the hot water faucet before turning “ON” gas
to the water heater.
A *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
B. *The anode rod tting may be leaking.
C. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
D. *The temperature-pressure relief valve may be leaking at the
tank tting.
E. Water from a drain valve may be due to the valve being slightly
opened.
F. *The drain valve may be leaking at the tank tting.
G. Combustion products contain water vapor which can condense
on the cooler surfaces of the tank. Droplets form and drip onto
the burner or run on the oor. This is common at the time of
start-up after installation and when incoming water is cold.
H. Water in the water heater bottom or on the floor 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.
I. The temperature probe may be leaking at the tank fitting.
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 tting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove tting. Put pipe dope or teon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
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 qualied installer
to check the water heater.
Read this manual rst. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
33
REPAIR PARTS LIST
Now that you have purchased this water heater, should a need ever exist for
repair parts or service, simply contact the company it was purchased from
or direct from the manufacturer listed on the rating plate on the water heater.
Be sure to provide all pertinent facts when you call or visit.
Selling prices will be furnished on request or parts will be
shipped at prevailing prices and you will be billed accordingly.
The model number of your Gas Water Heater will be found on the
rating place located above the gas control valve.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
• MODEL NUMBER
• TYPE GAS (NATURAL OR PROPANE (L.P.)
• SERIAL NUMBER
• PART DESCRIPTION
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST. PARTS
ARE NOT DRAWN TO SCALE.
Key No. Part Description
1 Outer Door
2 Anode
3 Control Valve Assembly
4 Plastic Top
5 Blower Assembly
6 Switch and Harness Assembly
7 T&P Valve
8 Drain Valve
9 Wiring Harness
10 Anode Outlet
11 Vent Pipe Assembly #1
12 Vent Pipe Assembly #2
13 Vent Pipe Assembly #3
14 Inlet Tube
15 Pipe Nipple
16 Temperature Probe
17 Burner Tube Assembly
18 Hot Surface Igniter
19 Burner Head Assembly
20 Embossed Inner Door
21 Insulation - Inner Door
22 Insulation - Viewport
23 Window - Observation
24 Viewport
25 Nut - Serrated Hex Flange
26 Screw - Sheet Metal, # 8-15
27 Orice - Burner
28 Vent Kit Assembly
29 Wall Plate 2”
30 Wall Plate 3”
31 Screen and Vent Terminal Assembly
32 Instruction Tag-Wire Screen F/E 3”
33 Instruction Tag-Wire Screen F/E 4”
34 Instruction Sheet
35 Wire Screen 3”
36 Wire Screen 4”
37 Wall Plate 4”
38 Flexible Tubing
34
TROUBLESHOOTING GUIDELINES
TROUBLE SHOOTING
Please check guidelines below. For your safety, water heater service should be performed only by a qualied service technician.
Read the GENERAL SAFETY INFORMATION section rst.
INTELLI-VENT TROUBLESHOOTING CHART - USER CONTROL
# LED STATUS PROBLEM SOLUTION
1 Inadequate or no earth ground.
1 Ensure the wall outlet (power supply) is properly
grounded.
2 Ensure all ground connections/wires on the water
heater are securely connected.
2
High resistance to earth ground or
reversed polarity in the 120 VAC
power supply.
1 Ensure that the water heater is securely connected to
earth ground.
2 Ensure that the wall outlet/power supply is properly wired.
Also, ensure that internal 120 VAC wiring connections
and the wiring harness have no reversed wires. 120 VAC
“hot” wire must connect to the on/off switch.
3
Pressure switch circuit remaining
closed for more than 5 seconds
after heating cycle begins.
Blower may not start in this
condition.
1 Ensure air pressure switch circuit wiring is correct and
the air pressure switch is not jumpered.
2 Replace the air pressure switch.
4
Pressure switch circuit remains
open longer than 5 seconds after
the blower is energized.
Blower may run continuously in
this condition.
1 Ensure the air pressure switch sensing tube is properly
connected at both ends and is not kinked or damaged.
2 Ensure the correct size of vent and intake air pipe (direct
vent products) was used per the installation instructions
in the manual that came with the water heater.
3 Ensure maximum number of elbows or maximum
equivalent feet of vent or intake air pipe have not been
exceeded per the installation instructions in the manual
that came with the water heater.
4 Ensure there are no obstructions in the vent or intake air pipe.
5 Open igniter circuit.
1 Check wiring to the hot surface igniter assembly -
replace igniter assembly if wiring is damaged or worn.
2 Check resistance of the igniter at igniter assembly
plug - should be between 11 and 18 ohms at room
temperature (77° F at plug end) - replace igniter if open
or shorted.
3 Check igniter assembly plug and the socket on the gas
control valve/thermostat for good connection. Replace
igniter assembly if the plug is worn or damaged.
4 Replace the gas control valve/thermostat if the igniter
assembly socket on the bottom of the control is worn or
damaged.
6
Ignition/ame failure.
The gas control valve/thermostat
has reached the maximum number
of retries (3) for ignition and is
currently locked out for one hour.
Cycle the power to the water
heater off and on to reset.
1 Ensure ame sensor is making good contact with the
burner ame and ensure ame is steady. Also ensure
supply and manifold gas pressures are within the
requirements in the installation manual.
2 Gas supply is turned off - pressure is too low. For low
gas pressure, consult with your gas utility.
3 Ensure the ame sensor is clean - use ne steel wool to
clean the ame sensor.
4 Check igniter assembly plug and the socket on the bottom
of the gas control valve/thermostat for good connection.
Replace igniter assembly if the plug is worn or damaged.
Replace the gas control valve/thermostat if socket is worn
or damaged.
5 Replace igniter assembly.
A B CVAC
A B CVAC
A B CVAC
A B CVAC
A B CVAC
A B CVAC
35
# LED STATUS PROBLEM SOLUTION
7
8
9
Self diagnostic check has detected
a problem with the gas valve driver
circuit, internal microprocessor, or
other internal circuits.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 If any of these error codes persist or cannot be cleared -
replace the gas control valve/thermostat.
10
Flame signal sensed out of proper
sequence.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if this error
code persists.
11
Water in the tank has exceeded
the maximum allowable
temperature, activating the ECO
(energy cut off).
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if the error
code persists.
12
One or both of the temperature
adjust buttons are stuck.
1 Press and release both temperature adjust buttons
several times - cycle water heater power off and on.
2 Replace the gas control valve/thermostat if the error
code persists.
13
The self diagnostic test has
detected the water temperature
sensor (thermistor) is either open
or shorted.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the temperature/ECO probe if the error code
persists.
A B CVAC
A B CVAC
A B CVAC
A B CVAC
A B CVAC
A B CVAC
A B CVAC
36
These guidelines should be utilized by a qualied service agent.
TROUBLESHOOTING GUIDELINES
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualied service agent.
PROBLEM CAUSE SOLUTION
1.) Blower will not run
NOT ENOUGH HOT WATER
a. “ON/OFF” control switch turned off. Turn switch to the “ON” position.
b. Blower unplugged. Plug blower back into 115 VAC outlet.
c. No power at outlet. Repair service to outlet.
d. Thermostat defective. Replace thermostat.
e. Control harness defective. Replace control harness.
f. High limit control circuit open.
Reduce water temperature below 140°F (60°C).
Turn the power switch to the off position. Wait
10 seconds. Turn the power switch to the on
position. Reduce the temperature set point to
minimize likelihood of reoccurrence. If this does
not solve the problem, replace thermostat.
g. Blower motor defective. Replace blower assembly.
h. Temperature/ECO probe defective. Replace temperature probe.
2.) Thermostat problems
a. Thermostat set too low. Adjust temperature control higher.
b. Thermostat or ECO defective. Replace thermostat.
c. Temperature/ECO probe defective Replace temperature probe.
3.) Others
a. Heater undersized. Reduce hot water use.
b. Low gas pressure. Contact dealer.
c. Incoming water is usually cold. Allow more time for the heater to reheat.
d. Leaking hot water pipes of xtures. Have plumber check and repair leaks.
e. Heater not lit or thermostat not on. Refer to Lighting & Operating label.
VENT PIPE TOO HOT (ABOVE 170° F [77° C]) Wrong burner orice. Install correct orice.
YELLOW FLAME
Dirt in burner ports. Turn off heater and gas, clean burner head.
Combustion air path restricted.
Check exhaust venting and air openings in
bottom base pan for obstructions or blockage.
CONDENSATION
Water on the oor under heater. See CONDENSATION section.
Water dripping from blower assembly.
Check the hose connections at blower and vent
pipe assembly #2.
WATER LEAKS
Improperly sealed, hot or cold supply
connections, relief valve, drain valve or
temperature probe threads.
Check for leaks at all condensate points.
See Figure 1. Also see LEAK CHECKPOINTS
section.
Leakage from other appliances or water lines. Inspect other appliances near water heater.
Condensation of ue products. Refer to CONDENSATION section.
LEAKING T&P
Thermal expansion in closed water system.
Install thermal expansion tank (Do not plug T&P
valve).
Improperly sealed valve.
Check relief valve for proper operation (Do not
plug T&P valve).
HOT WATER ODORS
(refer to Smelly Water)
High sulfate or mineral content in water supply. Drain and ush heater thoroughly then rell.
Bacteria in water supply. Chlorinate water supply.
WATER TOO HOT Thermostat set too high.
Refer to TEMPERATURE REGULATION
section.
WATER HEATER SOUNDS Condensation dripping on burner. Refer to CONDENSATION section.
SIZZLING - RUMBLING Sediment at bottom of heater tank. Clean sediment from tank. Refer to DRAINING.
SOOTING Improper combustion. Refer to Combustion Air and Ventilation.
BURNER WILL NOT STAY LIT -
GOES OUT 4-5 SECONDS
Outlet polarity is reversed. Test polarity and correct.
High ambient room temperature. Contact a service agency to determine cause.
Combustion air path restricted.
Check exhaust venting and air openings in
bottom base pan for obstructions or blockage.
Defective gas valve. Replace gas valve.
VENT GAS ODORS
Lack of air supply.
Shut off water heater immediately and contact a
service agency to determine cause.
Improperly installed vent piping.
Downdraft.
Poor combustion.
37
NOTES
38
NOTES
39
NOTES
