AO Smith G6-PVS4040NV Signature 500 Short 40-Gallon 6-Year User Manual

RESIDENTIAL GAS WATER HEATERS

Installation Instruction and Use & Care Guide

February, 2023

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

POWER VENTED GAS MODELS

WITH HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

DO NOT RETURN THIS UNIT TO THE STORE. To obtain technical, warranty, or service assistance during or after the installation

of this water heater, visit our website at: http:// www.AOSmithAtLowes.com or call toll free 1-877-817-6750.

100366722_2000622622_REV.A

TABLE OF CONTENTS

TABLE OF CONTENTS 2

SAFE INSTALLATION, USE AND SERVICE 3

GENERAL SAFETY 4

INTRODUCTION 6

 QualiedInstallerOrServiceAgency ............ 6

 PreparingForTheInstallation.................. 6

INSTALLATION REQUIREMENTS FOR THE

COMMONWEALTH OF MASSACHUSETTS 7

TYPICAL INSTALLATION 9

 GetToKnowYourWaterHeater-GasModels

(ListReferencingFigures1-7).................. 9

 ReplacementPartsAndDelimingProducts ...... 10

 ComboHeatingInletAndOutletSideTaps ....... 10

 WaterPiping-MixingValveUsage ..............11

 MixingValves

 WaterHeaterOperation ..................... 12

 ElectricalRequirements&WiringDiagram ....... 13

SAFETYLOCKOUTS 14

 HighLimitControls(EnergyCutO󰀨)............ 14

 Thermostat/WaterTemperature

 BlowerHighLimitSwitch

 BlowerAirPressureSwitch ................... 14

 FlammableVaporSensor .................... 14

LOCATINGTHENEWWATERHEATER 15

 FactsToConsiderAboutTheLocation .......... 15

 StorageOfFlammableLiquids ................ 15

 Clearancestocombustibles

 Floorswithcarpeting

 Clearanceforservicing

 InsulationBlankets ......................... 17

 AirRequirements .......................... 17

 UnconnedSpace.......................... 17

 UnusuallyTightConstruction ................. 17

 ConnedSpace............................ 17

 DirectVentAppliances ...................... 18

 ExhaustFans ............................. 18

 FreshAirOpeningsForConnedSpaces........ 18

 ChemicalVaporCorrosion ................... 19

INSTALLINGTHENEWWATERHEATER 20

 WaterPiping .............................. 20

 SpaceHeatingAndPotableWaterSystems...... 20

 ComboHeating ............................ 21

 SystemRequirements

 Installation

 ClosedWaterSystems ...................... 22

 ThermalExpansion ......................... 22

 Temperature-PressureReliefValve............. 23

 T&Pvalvedischargepiperequirements:

 Temperature-PressureReliefValveand

PipeInsulation

 HighAltitudeInstallation ..................... 24

 GasPiping................................ 24

 SedimentTraps/DirtLeg ..................... 25

 FillingTheWaterHeater ..................... 26

 Venting .................................. 26

 TerminationClearancesSidewallPowerVent..... 27

 BlowerAssemblyInstallation.................. 28

 InstallationOfVentSystem ................... 28

 PlanningTheVentSystem ................... 28

 HighAmbientTemperatureInstallations ......... 28

 PolypropyleneVentSystems ................. 29

 Condensate............................... 29

 ExhaustVenting ........................... 30

 ImportantNotesandWarnings

 Ventingterminationsandsizing

 Ventscreeninstallation

 CalculatingEquivalentFeet

 Ventinginstructions

 Ventpipeconnectiontoblower

 Di󰀨erentcouplinginstallationsaccording

toventsizes

 BlowerExhaustDirection .................... 35

 VentPipePreparation ....................... 35

 InstallationChecklist ........................ 38

LIGHTING INSTRUCTIONS 39

OPERATING THE TEMPERATURE

CONTROLSYSTEM 40

 GasControlValve/Thermostat ................ 41

FOR YOUR INFORMATION 42

 StartUpConditions ......................... 42

 Condensate

 Thermalexpansion

 Closedwatersystems

 Smoke/odor

 Strangesounds

 OperationalConditions ...................... 42

 Smellywater

 “Air”InHot-WaterFaucets ................... 43

PERIODIC MAINTENANCE 44

 GeneralUpkeep ........................... 44

 VentingSystemInspection ................... 44

 BlowerMaintenance ........................ 44

 CleaningTheBlower. ....................... 44

 BurnerOperationAndInspection .............. 45

 CombustionChamberAndBurnerCleaning ...... 46

 Housekeeping ............................. 46

 AnodeRodInspection....................... 46

 AnodeRod ............................... 46

 RemovingAnodeRod:

 InstallingAnodeRod:

 Temperature-PressureReliefValveTest ......... 47

 DrainingAndFlushing ....................... 48

 Todrainthewaterheaterstoragetank:

 Toushthewaterheaterstoragetank:

LEAKAGECHECKPOINTS 49

 Service .................................. 49

REFERENCEPARTSLISTING 50

TROUBLESHOOTINGGUIDELINES 52

 ResettingTheHeaterControl ................. 54

 Lockouts ................................. 54

 SoftLockout

 HardLockout

 IgnitionStateAndTiming .................... 55

 SystemStatusAndErrorCodes ............... 55

LIMITEDWARRANTY 58

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and

others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important

that the meaning of each safety message is understood by you and others who install, use or service this water heater.

This is the safety alert symbol. It is used to alert you

to potential personal injury hazards. Obey all safety

messages that follow this symbol to avoid possible

injury or death.

CAUTION used without the safety alert

symbol indicates a potentially hazardous

situation which, if not avoided, could

result in property damage

CAUTION indicates a potentially hazardous

situation which, if not avoided, could

result in minor or moderate injury.

WARNING indicates a potentially

hazardous situation which, if not avoided,

could result in death or injury.

DANGER indicates an imminently

hazardous situation which, if not avoided,

will result in death or injury.

CAUTION

WARNING

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.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances

known to the State of California to cause cancer, birth defects or other reproductive harm and requires businesses to warn

of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.

This appliance can cause low level exposure to some of the substances listed in the Act.

IMPORTANT DEFINITIONS

Qualied Installer:Aqualiedinstallermusthaveabilityequivalenttoalicensedtradesmanintheeldsofplumbing,

airsupply,ventingandgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGas

Codeasitrelatestothe installation of gasredwaterheaters.Thequaliedinstallermustalso be familiar withthe

designfeaturesanduseofammablevaporignitionresistantwaterheatersandhaveathoroughunderstandingofthis

InstallationandOperatingmanual.

Service Agency:Aserviceagencyalsomusthaveabilityequivalenttoalicensedtradesmanintheeldsofplumbing,air

supply,ventingandgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGasCode

asitrelatestotheinstallationofgasredwaterheaters.Theserviceagencymustalsohaveathoroughunderstanding

ofthisInstallationandOperatingmanual,andbeabletoperformrepairsstrictlyinaccordancewiththeserviceguidelines

providedbythemanufacturer.

Gas Supplier:TheNaturalGasorPropaneUtilityorservicewhosuppliesgasforutilizationbythegasburningappliances

withinthisapplication.Thegassuppliertypicallyhasresponsibilityfortheinspectionandcodeapprovalofgaspiping

uptoandincludingtheNaturalGasmeterorPropanestoragetankofabuilding.Manygassuppliersalsoo󰀨erservice

andinspectionofapplianceswithinthebuilding.

SAFE INSTALLATION, USE AND SERVICE

GENERAL SAFETY

Installation: Do not install the water heater where flammable

products will be stored or used.

Vapors from flammable

liquids may explode and

catch fire causing death or

severe burns.

Do not use or store

flammable products such as

gasoline, solvents or adhe-

sives in the same room or

area near the water heater.

Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

Water heater has a main

burner and hot surface igniter.

The hot surface igniter:

1. can be triggered at any

time and

2. the hot surface will ignite

flammable vapors.

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor

and

4. can be carried from other

rooms to the the

electodes by air currents.

Flammable Vapors

FLAMMBLE

DANGER

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

• Install vent system in accordance with codes.

• Do not operate water heater if flood damaged.

• For operation above 10,100’, a high altitude

orifice must be installed.

• Do not operate if soot buildup is present.

• Do not obstruct water heater air intake with

insulating jacket.

• Do not obstruct blower air intake.

• Do not place chemical vapor emitting products

near water heater.

• Gas and carbon monoxide detectors are

available.

• No vent damper installation is compatible with

this power vented water heater.

Breathing Hazard - Carbon Monoxide Gas

WARNING

 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 Installation and Operating

manual:

• CSA-CanadianStandardsAssociation

• ANSI-AmericanNationalStandardsInstitute

• NFPA-NationalFireProtectionAssociation

• ASME-AmericanSocietyofMechanicalEngineers

• UL-UnderwritersLaboratoriesInc.

• AHRI -Air Conditioning, Heating and Refrigeration

Institute.

This gas-red water heater is design certied by CSA

International, under Water Heater Standard ANSI

Z21.10.1 • CSA 4.1(currentedition).

QUALIFIED INSTALLER OR SERVICE AGENCY

Installationandserviceofthiswaterheaterrequiresability

equivalentto thatof a QualiedAgency (asdened 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:“Qualied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qualied(asdenedbyANSIabove)and

licensed or certified as required by authority having

jurisdiction to perform a given task, do not attempt to

performanyoftheproceduresdescribedinthismanual.

If you do not understand the instructions given in this

manualdonotattempttoperformanyproceduresoutlined

inthismanual.

PREPARING FOR THE INSTALLATION

1. Readthe“GeneralSafetyInformation”sectionofthis

manual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 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:

CSAInternational,

8501EastPleasantValleyRoad,

Cleveland,Ohio,UnitedStates

44131-5575.

NFPAdocumentsarealsoavailablefrom:

NationalFireProtectionAssociation,

1BatterymarchPark,

Quincy,MA02269.

3. Thewaterheater,wheninstalled,mustbeelectrically

groundedinaccordancewiththelocalcodesorinthe

absenceoflocalcodes:theNationalElectricalCode

(NFPA70).

4. Ifafterreadingthismanualyouhaveanyquestionsor

donotunderstandanyportionoftheinstructions,call

thelocalgasutilityorthemanufacturerwhosename

appearsontheratingplate.

5. Carefullyplantheplacewhereyouaregoingtoput

thewaterheater.Correctcombustion,ventaction,and

ventpipeinstallationareveryimportantinpreventing

deathfrompossiblecarbonmonoxidepoisoningand

res(seeFigure14&Figure15).Examinethelocation

toensurethewaterheatercomplieswiththe“Locating

theNewWaterHeater”sectioninthismanual.

6. ForinstallationinCalifornia,thiswaterheatermust

bebraced,anchored,orstrappedtoavoidfallingor

moving during an earthquake. See instructions for

correctinstallation procedures.Instructions maybe

obtainedfrom:

CaliforniaO󰀩ce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 California Health and Safety code

116875 (known asAB-1953) and with weighted

averagemaximumof0.25%lead.

INTRODUCTION

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satised:

INSTALLATION OF CARBON MONOXIDE DETECTORS

Atthetimeofinstallationofthesidewallhorizontalventedgasfueledequipment,theinstallingplumberorgastter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gastter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qualied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certied.

SIGNAGE

Ametalorplasticidenticationplateshallbepermanentlymountedtotheexteriorofthebuildingataminimumheight

ofeight(8)feetabovegradedirectlyinlinewiththeexhaustventterminalforthehorizontallyventedgasfueledheating

applianceorequipment.Thesignshallread,inprintsizenolessthanone-half(1/2)inchinsize,“GASVENTDIRECTLY

BELOW.KEEPCLEAROFALLOBSTRUCTIONS.”

INSPECTION

Thestateorlocalgasinspectorofthesidewallhorizontallyventedgasfueledequipmentshallnotapprovetheinstallation

unless,uponinspection,theinspectorobservescarbonmonoxidedetectorsandsignageinstalledinaccordancewith

theprovisionsof248CMR5.08(2)(a)1through4.

EXEMPTIONS

Thefollowingequipmentisexemptfrom248CMR5.08(2)(a)1through4:

1. TheequipmentlistedinChapter10entitled“EquipmentNotRequiredToBeVented”inthemostcurrenteditionof

NFPA54asadoptedbytheBoard;and

2. ProductApprovedsidewallhorizontallyventedgasfueledequipmentinstalledinaroomorstructureseparatefrom

thedwelling,building,orstructureusedinwholeorinpartforresidentialpurposes.

MANUFACTURERREQUIREMENTS-GASEQUIPMENTVENTINGSYSTEMPROVIDED

WhenthemanufacturerofProductApprovedsidewallhorizontallyventedgasequipmentprovidesaventingsystem

designorventingsystemcomponentswiththeequipment,theinstructionsprovidedbythemanufacturerforinstallation

oftheequipmentandtheventingsystemshallinclude:

1. Detailedinstructionsfortheinstallationoftheventingsystemdesignortheventingsystemcomponents;and

2. Acompletepartslistfortheventingsystemdesignorventingsystem.

MANUFACTURERREQUIREMENTS-GASEQUIPMENTVENTINGSYSTEMNOTPROVIDED

WhenthemanufacturerofProductApprovedsidewallhorizontallyventedgasfueledequipmentdoesnotprovidethe

partsforventingtheuegases,butidenties“specialventingsystems,”thefollowingrequirementsshallbesatised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.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

REMOVE A

MUST BE VERTICAL TO

IR BUBBLES

OUT

AIR

HANDLER

AIR

HANDLER

SHUT-OFF

VALVE

EXPANSION TANK

VACUUM

RELIEF

VALVE

COLD WATER INLET

FLOW CONTROL

PUMP

SHUT-OFF

CHECK VALVE

†

(1/8” HOLE

DRILLED IN CLAPPER)

VALVE

CHECK

VALVE

†

TEMP/

PRESSURE

RELIEF

VALVE

TEMPERED WATER

TO FIXTURES

(MUST MEET TEMPS LISTED

IN MASS. CODE 248 CMR

†

)

MIXING VALVE

(MUST BE INSTALLED BELOW

TOP OF WATER HEATER

AS PER MANUFACTURER’S

RECOMMENDATIONS)

UNION

HOT

WATER

OUT

MASSACHUSETTS INSTALLATION REQUIREMENTS:

1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS

FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.

2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR

& 780 CMR).

3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.

† REQUIRED FOR MASSACHUSETTS.

‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.

WATER HEATER ACCEPTED

BY THE BOARD FOR

INSTALLATION IN

MASSACHUSETTS.

†

TYPICAL MIXING VALVE INSTALLATION

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

SEE

NOTE ‡

100’-0” MAXIMUM DISTANCE

FROM WATER HEATER

TO FAN COIL AND BACK

(DEVELOPED LENGTH) NOT

INCLUDING COIL IN HEATING UNIT.

†

Some water heater models are equipped with inlet/outlet

connectionsforusewithspaceheatingapplications.Ifthis

waterheateristobeusedtosupplybothspaceheatingand

domestic potable (drinking) water, the instructions listed

belowmustbefollowed.

• This water heater is suitable for combination water

(potable)heatingandspaceheatingapplicationonly.

• Be sure to follow the manual(s) shipped with the air

handler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,installaThermostaticMixingValve

inthedomestic(potable)hotwatersupplyateachpoint-

of-usetolimittheriskofscaldinjury.Installthemixing

valveperthemanufacturersinstructions.

• Pumps,valves,piping,andfittingsmustbecompatible

withpotablewater.

• A properly installed flow control valve is required to

preventthermosiphoning.Thermosiphoningistheresult

of a continuous flow of water through the air handler

circuitduringtheoffcycle.

• Thedomestichotwaterlinefromthewaterheatershould

beverticalpastanymixingvalveorsupplylinetothe

air handler to remove air bubbles from the system.

Otherwise, these bubbles will be trapped in the air

handlerheatexchangercoil,reducingefficiency.

• 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.

Solar Installation

If this water heater is used as a solar storage heater

or as a backup for the solar system, the water supply

temperaturestothewaterheatertankmaybeinexcessof

120°F.AThermostaticMixingValveorothertemperature

limitingvalvemustbeinstalledinthewatersupplylineto

limitthesupplytemperatureto120°F.

NOTICE:Solarwaterheatingsystemscanoftensupply

waterwithtemperaturesexceeding180°Fandmayresult

inwaterheatermalfunction.

8 

GET TO KNOW YOUR WATER HEATER - GAS MODELS (list referencing Figures 1-7)

TYPICAL INSTALLATION

1. VentTerminationElbowwithRodent

Screen

2. *VentPipe

3. *VentPipeCoupling(ifrequired)

4. *VentPipeElbow(longradius)

5. BlowerHighLimitSwitch(see

Figure6)

6. T&PValve

7. Cold-WaterInletNipple/Diptube

8. Ba󰀪eAssembly

9. *DischargePipe

10.GasControlValve/Thermostat

(Honeywell/Resideo)

11.GasValveElectronicControl

ModuleAndCover(Honeywell/

Resideo)

12.DrainValve

13.OuterGasDoor

14.ManifoldDoorAssembly(behind

outerdoor)(seeFigure3&

Figure4)

15.*FloorDrain

16.*MetalDrainPan

17.FlammableVaporSensor(under

cover)(seeFigure5)

18.**ComboHeatingSystemReturn

Inlet(Optional)

19.AirInletSnorkel

20.**ComboHeatingSystemSupply

Outlet(Optional)

21.BlowerwithPowerCord(seealso

Figure6)

22.AirSwitch(insidebox)(see

Figure6)

23.JunctionBox(seeFigure6)

24.JunctionBoxCover(seeFigure6)

25.AirTubing(seeFigure6)

26.RubberCoupling(seealsoFigure

27.GearClamp(seealsoFigure6)

28.FlueCollector

29.Hot-WaterOutletNipple

30.Anode(undercap)

31.***ControlHarness

32.FlexibleManifoldTube(see

Figure3&Figure4)

33.Viewport(seeFigure3&Figure4)

34.FlameSensorRod(seeFigure3&

Figure4)

35.GasOrice(seeFigure3&

Figure4)

36.SheetMetalBurner(seeFigure3&

Figure4)

37.GasManifold(seeFigure3&

Figure4)

38.Hot-SurfaceIgniter(seeFigure3&

Figure4)

39.ManifoldDoorGasket(seeFigure3

&Figure4)

40.ManifoldDoor(seeFigure3&

Figure4)

41.TwoPieceGrommetWithClip(see

Figure3&Figure4)

42.*InletWaterShut-o󰀨Valve

43.*GasSupply*

44.*MainManualGasShut-o󰀨Valve

45.*GroundJointUnion(gas

connection)

46.*SedimentTrap/DirtLeg

47.*Union(waterconnection)

48.RatingPlate

49.*ThermalExpansionTank(required

forallclosedsystems)

*,**,***,****seenotesonfollowing

page

FrontView RearView

Figure 1. Figure 2.

Combustion

AirInlets

Blower

DilutionAir

Inlets

NaturalgasandPropanemain

burnerwithigniterassemblyfor

40kto50kBtu/hrmodels

Figure 3.

32 34

NaturalgasandPropane

mainburnerwithigniter

assemblyfor60kto75k

Btu/hrmodels

Figure 4.

Figure 5.

Figure 6.

Vacuumreliefvalve

installperlocal

codes(notsupplied

withheater).

Figure 7.

Notes:

* Itemsnotsuppliedwiththewaterheater.

** Thesiderecirculationloopconnectionsmaynotbe

usedastheprimarywaterinletandoutletconnections.

See “Combo Heating InletAnd Outlet Side Taps”

below.

*** Cautionharnesshas120VACInoperation.

****See“PlanningTheVentSystem”,“Condensate”and

“BlowerAssemblyInstallation”formoreinformation.

REPLACEMENT PARTS AND DELIMING PRODUCTS

Replacement parts and recommended delimer may be

orderedthroughauthorizedservicersordistributors.When

orderingparts,providecompletemodelandserialnumbers

(see rating plate), quantity and name of part desired.

Standardhardwareitemsmaybepurchasedlocally.

COMBO HEATING INLET AND OUTLET SIDE TAPS

Models equipped with Combo Heating capabilities are

shippedwiththetwosideplumbingtapsOPEN(items18

and20inFigure1andseealsoFigure8).Iftheheateris

tobeoperatedwithoutusingthesidetaps,theseopenings

must be closedwiththetwopipeplugssuppliedwiththe

heaters.

WATER PIPING - MIXING VALVE USAGE

Mixing Valves

Water temperature over

125°F can cause severe

burns instantly resulting in

severe injury or death.

Children, the elderly and the

disabled and are at highest

risk of scald injury.

Feel water before bathing or

showering.

Temperature limiting devices

such as mixing must be

installed when required by

codes and to ensure safe

temperatures at fixtures.

BURN

HOT

DANGER

Water heated to a temperature which satises space

heating, clothes washing, dish washing, and other

sanitizingneedscanscaldandcausepermanentinjury

uponcontact.Shortrepeatedheatingcyclescausedby

smallhot-waterusescancauseatemperatureincreaseof

thehotwaterby30F°higherthantheheater’stemperature

settings. If you choose a higher temperature setting,

ThermostaticMixingValveslocatedateachpoint-of-use

areparticularlyimportanttohelpavoidscalding.

MIXING VALVE

SHUT-OFF

VALVE

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

COLD-WATER

INLET

TEMPERED

POTABLE WATER

DISCHARGE

PIPE (DO NOT

CAPORPLUG)

GAS

SUPPLY

TEMPERATURE-

PRESSURE

RELIEF VALVE

DRAIN

VALVE

METAL DRAIN

PAN1.75”

MAX. DEPTH.

ATLEAST2”

GREATER THAN

THE DIAMETER

OF THE WATER

HEATER.

6”MAX.

AIR GAP*

CERTAIN

MODELS ARE

EQUIPPED WITH

SIDE PLUMBING

CONNECTIONS

FOR SPACE

HEATING. THE HOT

AND COLD FITTING

ASSEMBLIES

(PART#9001262)

CAN BE ORDERED

THROUGH THE

MANUFACTURER

*NOTE:THE

T&PVALVE

DISCHARGE

PIPE MUST

BE PIPED

DIRECTLY TO

THE DRAIN

OR EXTERNAL

TO THE

BUILDING

MASSACHUSETTS:INSTALLAVACUUMRELIEFINCOLDWATERLINE

PERSECTION19MGL142.

Figure 8.

his appliance has been design certied as complying

withAmericanNationalStandard/CSAStandardforwater

heatersandcertainmodelswithsideplumbingconnections

areconsideredsuitableforWater(Potable)Heatingand

SpaceHeating.Note:Donotuseinspaceheatingonly

applications.

Thewatersupplypressureshouldnotexceed80psi.Ifthis

occurs,apressurereducingvalvewithabypassshouldbe

installedinthecoldwaterinletline.Thisshouldbeplaced

onthesupplytotheentirehouseinordertomaintainequal

hotandcoldwaterpressures.

MIXING VALVE

SHUT-OFF

VALVE

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

COLD-WATER

INLET

TEMPERED

POTABLE WATER

DISCHARGE

PIPE (DO NOT

CAPORPLUG)

GAS

SUPPLY

TEMPERATURE-

PRESSURE

RELIEF VALVE

DRAIN

VALVE

METAL DRAIN

PAN1.75”MAX.

DEPTH. AT

LEAST

2”GREATER

THAN THE

DIAMETER OF

THE WATER

HEATER.

6”MAX.

AIR GAP*

*NOTE:THE

T&PVALVE

DISCHARGE PIPE

MUST BE PIPED

DIRECTLY TO

THE DRAIN OR

EXTERNAL TO

THE BUILDING

MASSACHUSETTS:

INSTALL A VACUUM

RELIEF IN COLD

WATER LINE PER

SECTION19MGL

142.

NON-TEMPERED

WATER SUPPLY

NON-TEMPERED

WATER RETURN

Figure 9.

  11

Somepeoplearemorelikelytobepermanentlyinjured

by hot water than others. These include the elderly,

children,theinrmandthephysically/mentallydisabled.

Table 1 (published by U.S. Government Memorandum,

1978) shows the approximate time-to-burn relationship

fornormaladultskin.Ifanyoneusinghotwaterprovided

bythewaterheaterbeinginstalled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.

Water

Temperature

°F

Time for 1st

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)

Table 1.

In addition to using lowest possible temperature

setting that satises demand of application, to reduce

the risk of scalding, install Thermostatic Mixing Valve

(temperaturelimitingvalves)ateachpoint-of-use.These

valvesautomaticallymixhotandcoldwater to limitthe

temperatureatthetap.

ThermostaticMixingValvesareavailablefromyourlocal

plumbingsupplier.ConsultaQualiedInstallerorService

Agency.Followmixingvalvemanufacturer’sinstructions

forinstallationofthevalves.Beforechangingthefactory

setting on the thermostat, read the “Operating The

TemperatureControlSystem”sectioninthismanual.

WATER HEATER OPERATION

Figure10showsthewaterheater’ssequenceofoperation

whenacallforheatisinitiated.Theignitioncontrolmodule

willattempttolighttheburnerthreetimes.Iftheignition

controldoesnotdetectignitionitwillenterlockoutmode

andashthecorrespondingerrorcode.

HEATER CONTROL

CHECKSTOENSURE

BLOWER PRESSURE

SWITCH IS OPEN

BLOWER IS

ENERGIZED

CONTROLCHECKS

TO ENSURE PRES-

SURE SWITCH CLOSES

INDICATING BLOWER

IS OPERATING AND

THERE ARE NO

VENTINGBLOCKAGES

(INLETOROUTLET)

IGNITERISENERGIZED

AND MAIN GAS VALVE

IS OPENED

MAIN BURNER COMES

ON AND THE FLAME IS

SENSED BY CONTROL

MAIN BURNER CONTIN-

UES TILL THE WATER

INTHETANKREACHES

THERMOSTAT SETTING

MAIN BURNER SHUTS

OFF. BLOWER

CONTINUES FOR A

POST PURGE TIME

HEATER

THERMOSTAT

CALLS FOR

HEAT

HEATER

REMAINS ON

STANDBY UNTIL

NEXT CALL FOR

HEAT

Figure 10.

Figure 12.

ELECTRICAL REQUIREMENTS & WIRING DIAGRAM

Failure to do so can result in

death or electrical shock.

Replace all parts and panels

before operating.

Disconnect power before

servicing.

Electric Shock Hazard

WARNING

Beforeplugginginthewaterheater,alwaysmakesure:

• The voltage and frequency correspond to that

speciedonthewaterheaterwiringdiagram.

• Theelectricaloutlethastheproperoverloadfuseor

breakerprotection.

1. The unit must be connected to a dedicated power

supply.

2. The unit must be connected to a 120VAC power

supply.

3. Thewaterheatermustbeproperlygrounded.

4. Thiswaterheaterisapolaritysensitiveapplianceand

willnotoperateifthepowersupplypolarityisreversed.

Note:Alwaysreferencethewiringdiagramforthecorrect

electricalconnections.

Aftermakingallelectricalconnections,completelyllthe

tankwithwaterandcheckallconnectionsforleaks.Open

thenearesthot-waterfaucetandletitrunfor3minutesto

purgethewaterlinesofairandsedimentandtoensure

completellingofthetank.Theelectricalpowermaythen

beturnedon.Verifyproperoperationafterservicing.See

also“InstallationChecklist”.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN

SERVICING CONTROLS. WIRING ERRORS CAN

CAUSE IMPROPER AND DANGEROUS OPERATION.

VERIFY PROPER OPERATION AFTER SERVICING.

POWER VENT WIRING SCHEMATIC.

NOTE: REFER TO THE “INSTALLATION CHECKLIST”

BEFORE OPERATING THIS HEATER.

HOT SURFACE IGNITER

HIGH LIMIT SWITCH

CAPACITOR

EARTH GND

PRESSURE SWITCH

BLOWER

FLAME SENSOR

FLAMMABLE VAPOUR SENSOR

Circled numbers indicate

sequence of operation.

Figure 11.

  13

Thiswaterheaterhasseverallockoutfeaturesdesigned

topreventtheheaterfromoperatinginunsafeconditions.

HIGH LIMIT CONTROLS (Energy Cut O󰀨)

Thermostat/Water Temperature

Thisfeatureisapartofthegascontrolvalve/thermostat

(see Figure 1, item 10) and limits the maximum water

temperature.Intheeventofthewateroverheating,this

safetyfeatureshutso󰀨thefuelsupplytotheburner.

Blower High Limit Switch

Thisdeviceislocatedontheblower(seeFigure6,item

5) and limits the maximum temperature of the blower.

If the blower temperature rises above the temperature

setting,theswitchopenscausingtheheatertoshutdown.

The switch will auto reset once the temperature drops

su󰀩ciently.

BLOWER AIR PRESSURE SWITCH

Thisdevice,locatedinthejunctionbox,monitorstheair

pressureproduced bythe blower. In theevent thatthe

exhaustventingbecomesblockedorsu󰀩cientlyrestricted,

theswitchwillshuttheheaterdown(seeFigure6,item22).

FLAMMABLE VAPOR SENSOR

When using a gas red water heater there is a risk of

ammablevaporsenteringthecombustionchamber,being

ignitedbytheburnerameandcausingaashback.In

ordertodetectsuchammablevaporsbeforetheyenter

thecombustionchamber, thiswaterheaterisequipped

witha ammable vaporsensor (FVS).Itis achemical-

absorption based sensor that is connected to the gas

control/thermostat (see Figure 13). When exposed to

ammable vapors it will trigger the control to stop the

owofgasandentertheFVSlockoutstate.Whileinthe

FVSlockout statethe LEDon the control will ash the

gaslockoutcode.(Refertothe“SystemStatusAndError

Codes”sectionofthismanualforanexplanationofthe

codes applicable to the control installed on your water

heater.)Ifthiserroroccurs,checkaroundthewaterheater

forsourcesofchemicalcontaminationsuchas:ammable

vaporsincludinggasvapors,solvents,paintandthinners

aswellassourcesofwateranddetergents.

Note:Resetting the heater will reset the FVIRcircuit if

allsourcesofcontaminationhavebeenremovedandthe

sensorclears.Ifallsourcesofcontaminationhavebeen

removedandthesystemwillnotreset,thesensorwillneed

tobereplaced(see“ResettingtheHeaterControl”).

If there is a problem with the wiring of the ammable

vaporsensorortheammablevaporinterface,theLED

willashthefailurestatuscode(see“SystemStatusAnd

ErrorCodes”).

MOUNTING

BRACKET

FLAMMABLE

VAPOR SENSOR

(PULLTOREMOVE)

COVER*

*ROTATELEFT(CCW)

TO REMOVE

Figure 13.

SAFETY LOCKOUTS

FACTS TO CONSIDER ABOUT THE LOCATION

Carefully choose an indoor location for the new water

heater because the placement is a very important

considerationforthesafetyoftheoccupantsinthebuilding

andforthemosteconomicaluseoftheappliance.This

waterheaterisnotforuseinmanufactured(mobile)homes

oroutdoorinstallation.

Whetherreplacinganoldwaterheaterorputtingthewater

heaterinanewlocation,thefollowingcriticalpointsmust

beobserved:

1. Select a location indoors as close as practical to

the vent termination or location to which the water

heaterventpipingisgoingtobeconnected,andas

centralizedwiththewaterpipingsystemaspossible.

2. Selectedlocationmustprovideadequateclearances

forservicingandproperoperationofthewaterheater.

3. Ensure the area hasa continuous supplyof air for

combustion,dilutionandventilation.

4. Avoidlocationsthatcouldcausethewaterheaterto

freezefromoutsideair.

5. Selectedlocationmustprovideaccesstoaproperly

groundedelectricalbranchcircuit.Adedicatedcircuit

ispreferred.DonotuseaGFIoutlet.

6. Avoidlocationsthatexposethewaterheatertodirect

sunlight.

7. Keep combustibles such as boxes, magazines,

clothes,etc.,awayfromthewaterheaterarea.

Important:Donotuseanextensioncordtoconnectthe

waterheatertoanelectricaloutlet.

Important:thisheaterhasspecialventingrequirements

wheninstalledinareaswheretheambienttemperatures

exceed 110°F (see “High Ambient Temperature

Installations”).

• All water heaters eventually leak.

• Do not install without adequate drainage.

Property Damage Hazard

CAUTION

Installationofthewaterheatermustbeaccomplishedin

suchamannerthatifthetankoranyconnectionsshould

leak, the ow of water will not cause damage to the

structure.Forthisreasonitisnotadvisabletoinstallthe

waterheaterinanatticorupperoor.Inallcases,ametal

drainpanshouldbeinstalledunderthewaterheater.Metal

drainpansareavailableatyourlocalhardwarestore.Such

ametaldrainpanmusthaveaclearanceofatleast1”

greaterthananypointonthewaterheater’souterjacket

andmustbepipedtoanadequatedrain.Thepanmust

haveamaximumdepthof1.75”.

Water heater life depends upon water quality, water

pressureandtheenvironmentinwhichthewaterheater

is installed. Water heaters are sometimes installed in

locationswhereleakagemayresultinpropertydamage,

evenwiththeuseofametaldrainpanpipedtoadrain.

However, unanticipated damage can be reduced or

preventedbyaleakdetectororwatershut-o󰀨deviceused

inconjunctionwithapipedmetaldrainpan.Thesedevices

are available from some plumbing supply wholesalers

andretailers,anddetectandreacttoleakageinvarious

ways:

• Sensorsmountedinthemetaldrainpanthattriggeran

alarmorturno󰀨theincomingwatertothewaterheater

whenleakageisdetected.

• Sensorsmountedinthemetaldrainpanthatturno󰀨

thewatersupplytotheentirebuildingwhenwateris

detectedinthemetaldrainpan.

• Watersupplyshut-o󰀨devicesthatactivatebasedon

thewaterpressuredi󰀨erentialbetweenthecold-water

andhot-waterpipesconnectedtothewaterheater.

• Devicesthatwillturno󰀨thegassupplytoagaswater

heater while at the same time shutting o󰀨 its water

supply.

STORAGE OF FLAMMABLE LIQUIDS

Flammableliquids(suchasgasoline,solvents,propane

(LP or butane, etc.) and other substances (such as

adhesives,paints,etc.)emitammablevaporswhichcan

beignitedbyagaswaterheater’shotsurfaceigniter(HSI)

ormainburner.Theresultingashbackandrecancause

deathorseriousburnstoanyoneinthearea.

ThiswaterheaterisequippedwithaFV(FlammableVapor)

sensorfordetectingthepresenceofammablevapors.

Whenthesensordetectsthosevapors,theunitwillshut

downandnotoperate.Shouldthishappen,pleaserefer

tothe“TroubleshootingGuidelines”sectionofthismanual.

Even though this water heater is a ammable vapors

ignitionresistant(FVIR)waterheaterandisdesignedto

reducethechancesofammablevaporsbeingignited,

gasolineandotherammablesubstancesshouldnever

bestoredorusedinthesamevicinityorareacontaininga

gaswaterheaterorotheropenameorsparkproducing

appliance. Examples of such locations are garages,

storageandutilityareas.

Thewaterheatermustbelocatedand/orprotectedsoitis

notsubjecttophysicaldamagebyamovingvehicle.

LOCATING THE NEW WATER HEATER

  15

Read instruction manual before

installing, using or servicing

water heater.

• Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

Fire or Explosion Hazard

WARNING

323546-000

1. Turn the thermostat counter-clockwise to the lowest setting.

2. Set the gas control switch to the “OFF” position.

3. Turn off electrical power to the appliance if service is to be performed.

TO TURN OFF GAS TO APPLIANCE

1. STOP! Read the safety

information above on this

label.

2. Turn off all electric power to the

appliance.

3. Turn the thermostat

counter-clockwise to the

lowest setting.

4. Set the switch on the control to

the “OFF” position.

5. Do not attempt to light manually.

6. Wait five (5) minutes to clear out

any gas. If you then smell gas, STOP!

Follow “B” in the safety information above on

this label. If you don't smell gas, go the next

step.

7. Turn on all electric power to

the appliance.

8. Set the switch on the control

to the “ON” position.

9. Turn thermostat to desired

setting.

DANGER Hotter water

increases the risk of

scald injury. Consult the

instruction manual before

changing temperature.

10. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance”

and call your service technician or gas

supplier.

OPERATING INSTRUCTIONS

DANGER

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 some gas is heavier

than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric switch; Do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas suppliers

instructions.

• If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to turn the gas control

buttons. Never use tools. If the control

buttons will not turn, don't try to repair them,

call a qualified service technician. Force or

attempted repair may result in a 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 unit. It must be

replaced!

BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.

FLAMMABLEFLAMMABLE

WARNING: If you do not follow these instructions exactly, a fire

or explosion may result causing property damage, personal

injury or loss of life.

FOR YOUR SAFETY READ BEFORE LIGHTING

Read and follow water heater warnings and instructions in furnished manual.

If manual is missing, you may obtain one free of charge by calling 1-800-821-2017.

Si Ud. no puede ni leer ni entender el inglés y si necesita manuales, etiquetas

o rótulos en español, Ud. los puede obtener si al llama 1-800-821-2017.

WARNING / ADVERTENCIA

HOT

BURN

Water temperature over 125°F can

cause severe burns instantly or

death from scalds.

Children, disabled and elderly are

at highest risk of being scalded.

See instruction manual before

setting temperature at water heater.

Feel water before bathing or

showering.

Temperature limiting valves are

available, see manual.

DANGER

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance. Storage or

use of gasoline or other flammable vapors or liquids in the

vicinity of this or any other appliance can result in serious injury

or death.

Can result in serious injury or death

FIRE AND EXPLOSION HAZARD

Flammable Vapors

FLAMMABLES

WARNING

For continued protection against

risk of fire:

• Do not install water heater on

carpeted floor.

• Do not operate water heater if

flood damaged.

Fire Hazard

WARNING

Clearances to combustibles

Minimum clearances between water heater and

combustiblesare0”atthesidesandrear,5.5”fromthe

frontand12”fromtop(standardclearance.)Ifclearances

statedontheheaterdi󰀨erfromstandardclearances,install

waterheateraccordingtoclearancesstatedontheheater

(seeFigure14).

Floors with carpeting

This water heater must not be installed directly on

carpeting. Carpeting must be protected by a metal or

wood panel beneath the appliance extending beyond

thefullwidthanddepthoftheappliancebyatleast3”in

everydirection,oriftheapplianceisinstalled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.

Clearance for servicing

Adequate clearance of 24” for servicing this appliance

shouldbeconsideredbeforeinstallation,suchaschanging

theanodes,etc.

Aminimumclearanceof5.5”mustbeallowedforaccess

toreplaceablepartssuchasthermostats,drainvalveand

reliefvalve.

Wheninstallingtheheater,considerationmustbegivento

properlocation.Locationselectedshouldbeascloseto

thewallaspracticableandascentralizedwiththewater

pipingsystemaspossible.

TOP VIEW

OF CLOSET

WITHOUT DOOR

AIR INTAKE*

TOP VIEW OF

CLOSET WITH

DOOR

0” MIN.

0” MIN. 0” MIN.

5.5” MIN.

* DO NOT BLOCK THE AIR INTAKES AT THE BACK OF THE WATER HEATER.

Figure 14.

Agaswaterheatercannotoperateproperlywithoutthe

correctamountofairforcombustionandventilation.Do

notinstallinaconnedareasuchasaclosetunlessyou

provide air as shown below and described in the “Air

Requirements”section(seeFigure15).Neverobstructthe

owofventilationairfordilutionandcombustion.Ifyou

haveanydoubtsorquestionsatall,callyourgassupplier.

Failureto provide theproper amount ofcombustion air

canresultinareorexplosionandcausedeath,serious

bodilyinjury,orpropertydamage.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

• Install water heater in accordance with the

instruction manual and NFPA54.

• To avoid injury, combustion and ventilation air

must be taken from outdoors.

• Do not place chemical vapor emitting products

near water heater.

Breathing Hazard - Carbon Monoxide Gas

WARNING

Figure 15.

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current

standards with respect to insulation and standby loss

requirements,makinganinsulationblanketunnecessary.

Should you choose to apply an insulation blanket to

this heater, you should follow these instructions (For

identicationofcomponentsmentionedbelow,seeFigure

1thruFigure7).Failuretofollowtheseinstructionswill

restrictthe air ow required forproper combustionand

dilution,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T&Prelief

valve,FVsensor,orAirIntakeSnorkel.

• Donotcoverthe“InstallationAndOperatingmanual”.

Keepitonthesideofthewaterheaterornearbyfor

futurereference.

• Doobtainnewwarningandinstructionlabelsfromthe

manufacturerforplacementontheblanketdirectlyover

theexistinglabels.

• Doinspecttheinsulationblanketfrequentlytomake

certainitdoesnotsag,therebyobstructingcombustion

airow.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

• Do not obstruct water heater air intake(s) with

insulating jacket.

• Gas and carbcn monoxide detectors are available.

• Install water heater in accordance with the

instruction manual and NFPA54.

Breathing Hazard - Carbon Monoxide Gas

WARNING

AIR REQUIREMENTS

For safe operation an adequate supply of fresh,

uncontaminatedairforcombustion,dilutionandventilation

mustbeprovided.

Note:Contaminatedordustyairmaycausebuild-upon

theblowerwheelresultinginnuisanceshutdowns.

An insu󰀩cient supply of air can cause recirculation of

combustionproductsresultingincontaminationthatmay

behazardoustolife.Suchaconditionoftenwillresultin

ayellow,luminousburnerame,causingsootingofthe

combustionchamber,burnersanduetubesandcreates

ariskofasphyxiation.

Donotinstallthewaterheaterinaconnedspaceunless

an adequate supply of air for combustion, dilution and

ventilationisbroughtintothatspaceusingthemethods

describedinthe“ConnedSpace”sectionthatfollows.

Never obstruct the ow of dilution/ventilation air. If you

haveanydoubtsorquestionsatall,callyourgassupplier.

Failuretoprovidetheproperamountsofaircanresultin

areorexplosionandcausepropertydamage,serious

bodily injury or death. The combustion and dilution air

inletsareshowninFigure2.

Important: Power Vented water heaters require air for

combustionanddilutionairfortheblower.

UNCONFINED SPACE

AnUnconnedSpaceisonewhosevolumeisnotlessthan

50cubicfeetper1,000Btu/hr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unconned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 unconned spaces in buildings, inltration may be

adequate toprovide air for combustion, ventilation and

dilutionofuegases.However,inbuildingsofunusually

tight construction (e.g., weather stripping, heavily

insulated,caulked,vaporbarrier,etc.)additionalairmust

beprovidedusingthemethodsdescribedinthe“Conned

Space”sectionthatfollows.

CONFINED SPACE

AConnedSpaceisonewhosevolumeislessthan50

cubicfeetper1,000Btu/hr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connedspaces.

Therequiredsizefortheopeningsisdependentonthe

methodusedtoprovidefreshairtotheconnedspace

  17

andthetotalBtu/hrinputratingofallappliancesinstalled

inthespace.

DIRECT VENT APPLIANCES

OtherappliancesinstalledinaDirectVentconguration

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conned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,

su󰀩cient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.

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connedspaces.

Theillustrationsshowninthissectionofthemanualare

a reference for the openings that provide fresh air into

connedspacesonly.Donotrefertotheseillustrations

for the purpose of vent installation. See “Installation of

Vent System” section for complete venting installation

instructions.

Chemicalvaporcorrosionoftheue,blowerassemblyand

ventsystemmayoccuriftheairsupplycontainscertain

chemicalvapors.Spraycanpropellants,cleaningsolvents,

refrigeratorandairconditionerrefrigerants,swimmingpool

chemicals,calciumandsodiumchloride(watersoftener

salt), waxes, bleach and process chemicals are typical

compoundswhicharepotentiallycorrosive.

A.ALLAIRFROMINSIDEBUILDINGS:(SeeFigure16)

 The confined space shall be provided with two

permanentopenings communicatingdirectly withan

additional room(s) of su󰀩cient volume so that the

combinedvolumeofallspacesmeetsthecriteriaforan

unconnedspace.Thetotalinputofallgasutilization

equipment installed in the combined space shall be

consideredinmakingthisdetermination.Eachopening

shallhaveaminimumfreeareaofonesquareinchper

1,000Btu/hrofthetotalinputratingofallgasutilization

equipmentintheconnedspace,butnotlessthan100

square inches.One opening shall commence within

12”ofthetopandonecommencingwithin12”ofthe

bottomoftheenclosures.

Figure 16.

B.ALLAIR FROM OUTDOORS: (See Figure 17 thru

Figure19)

 The confined space shall be provided with two

permanentopenings,onecommencingwithin12”ofthe

topandonecommencingwithin12“fromthebottom

of the enclosure. The openings shall communicate

directly,orbyducts,withtheoutdoorsorspaces(crawl

orattic)thatfreelycommunicatewiththeoutdoors.

 1. When directly communicating with the outdoors,

eachopeningshallhaveaminimumfreeareaof1

squareinchper4,000Btu/hroftotalinputratingof

allequipmentintheenclosure(seeFigure17).

Figure 17.

 2. When communicating with the outdoors through

verticalducts,eachopeningshallhaveaminimum

freeareaof1squareinchper4,000Btu/hroftotal

inputratingofallequipmentintheenclosure(see

Figure18).

 3. When communicating with the outdoors through

horizontal ducts, each opening shall have a

minimumfreeareaof1squareinchper2,000Btu/hr

oftotalinputratingofallequipmentintheenclosure

(seeFigure19).

Figure 18.

 4. When ducts are used, they shall be of the same

cross-sectionalareaasthefreeareaoftheopenings

to which they connect. The minimum short side

dimensionofrectangularairductsshallnotbeless

than3”(seeFigure19).

Figure 19.

 5. Alternatively a single permanent opening may

be used when communicating directly with the

outdoors,orwithspacesthatfreelycommunicate

with the outdoors. The opening shall have a

minimumfreeareaof1squareinchper3,000Btu/

hroftotalinputratingofallequipmentinenclosure

(seeFigure20).

Figure 20.

 6. Louvers and Grilles: In calculating free area,

considerationshallbegiventotheblockinge󰀨ect

oflouvers,grillesorscreensprotectingopenings.

Screensusedshallnotbesmallerthan1/4”mesh.

Ifthefreeareathroughadesignoflouverorgrille

isknown,itshouldbeusedincalculatingthesize

openingrequiredtoprovidethefreeareaspecied.

Ifthedesignandfreeareaisnotknown,itmaybe

assumedthatwoodlouverswillbe20-25percent

free area and metal louvers and grilles will have

60-75percentfreearea.Louversandgrillesshall

bexedintheopenpositionorinterlockedwiththe

equipmentso thattheyare openedautomatically

duringequipmentoperation.

 7. Special Conditions Created by Mechanical

ExhaustingorFireplaces:operationofexhaustfans,

ventilationsystems,clothesdryersorreplacesmay

createconditionsrequiringspecialattentiontoavoid

unsatisfactoryoperationofinstalledgasutilization

equipment.

CHEMICAL VAPOR CORROSION

CORROSION OF THE FLUEWAYS AND VENT SYSTEM

MAY OCCUR IF AIR FOR COMBUSTION CONTAINS

CERTAIN CHEMICAL VAPORS. SUCH CORROSION

MAYRESULTINFAILUREANDRISKOFASPHYXIATION.

Spraycanpropellants,cleaningsolvents,refrigeratorand

air conditioning refrigerants, swimming pool chemicals,

calciumandsodiumchloride(watersoftenersalt),waxes,

and process chemicals are typical compounds which

are potentially corrosive. Do not store products of this

sortneartheheater.Alsoairwhichisbroughtincontact

withtheheatershouldnotcontainanyofthechemicals.

If necessary, uncontaminated air should be obtained

fromremoteoroutsidesources.TheLimitedWarrantyis

voidedwhenfailureofwaterheaterisduetoacorrosive

atmosphere.See“LimitedWarranty”forcompleteterms

andconditions.

  19

WATER PIPING

To reduce the risk of unusually hot water reaching

the xtures in the house, install Thermostatic Mixing

Valves at each point-of-use.

Water temperature over

125°F can cause severe

burns instantly resulting in

severe injury or death.

Children, the elderly and the

disabled and are at highest

risk of scald injury.

Feel water before bathing or

showering.

Temperature limiting devices

such as mixing must be

installed when required by

codes and to ensure safe

temperatures at fixtures.

BURN

HOT

DANGER

Thewatersupplypressureshouldnotexceed80psi.Ifthis

occurs,apressurereducingvalvewithabypassshouldbe

installedinthecoldwaterinletline.Thisshouldbeplaced

onthesupplytotheentirehouseinordertomaintainequal

hotandcoldwaterpressures.

HOTWATERCANSCALD:

Water heaters are intended to produce hot water.

Waterheatedtoatemperaturewhichwillsatisfyspace

heating, clothes washing, dish washing, cleaning and

othersanitizingneedscanscaldandpermanentlyinjure

you upon contact. Some people are more likely to be

permanently injured by hot water than others. These

include the elderly, children, the inrm, 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certaintemperaturewateratthehot-

water tap, then you must take special precautions. In

additiontousinglowestpossibletemperaturesettingthat

satises that satses demand of application, to reduce

the risk of scalding, install Thermostatic Mixing Valves

(temperaturelimitingvalves)ateachpoint-of-use.These

valvesautomaticallymixhotandcoldwater to limitthe

temperatureatthetap.

SPACE HEATING AND POTABLE WATER SYSTEMS

This appliance has been design certied as complying

withAmericanNationalStandard/CSAStandardforwater

heatersandareconsideredsuitableforWater(Potable)

HeatingandSpaceHeating.Note:Waterheatersused

incombinationwater/spaceheatingshallnotbeusedin

spaceheatingonlyapplications.

Toxic Chemical Hazard

WARNING

• Do not connect to non-potable water system.

Consult a Qualied Installer or ServiceAgency. Follow

manufacturer’s instructions for installation of valves.

Beforechangingthefactorysettingonthermostat,read

“OperatingTheTemperatureControlSystem”sectionin

thismanual.

• This water heater should not be connected to any

heatingsystemsorcomponentspreviouslyusedwith

anon-potablewaterheatingappliance.

• Allpipingcomponentsconnectedtothisunitforspace

heating applications should be suitable for use with

potablewater.

• Toxicchemicals,suchasthoseusedforboilertreatment

shallnotbeintroducedintothepotablewaterusedfor

spaceheating.

• Ifthespaceheatingsystemrequireswatertemperatures

inexcessof120°F,installaThermostaticMixingValve

in the domestic (potable) hot water supply at each

point-of-usetolimittheriskofscaldinjury.

Note: Water piping and vent piping occupy the space

abovethewaterheater.Planthewaterpipingtoensure

itdoesnotcauseinterferencewiththeventpiping(see

“PlanningtheVentSystem”).

If this water heater is to be used to supply both space

heatingandpotablewater, theinstructionslistedbelow

mustbefollowed:

• Besuretofollowthemanual(s)shipped with the air

handlerorothertypeheatingsystem.

• Thiswaterheaterisnottobeusedasareplacement

foranexistingboilerinstallation.

• Do not use with piping that has been treated with

chromates,boilersealorotherchemicalsanddonot

addanychemicalstothewaterheaterpiping.

• Ifthespaceheatingsystemrequireswatertemperatures

inexcessof120°F,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ttingsmustbecompatible

withpotablewater.

• A properly installed ow control valve is required to

prevent thermosiphoning. Thermosiphoning is the

result of a continuous ow of water through the air

handlercircuitduringtheo󰀨cycle.Weeping(blowo󰀨)

ofthetemperature-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.

INSTALLING THE NEW WATER HEATER

• 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.

COMBO HEATING

Thissectionservesasaguidefortheinstallationanduse

of “Combo” heating systems utilizing a domestic water

heaterthathasbeenspecicallyapprovedforsuchuse.

Itiswrittenforthoseknowledgeableintherequiredtrades

andprofessionalsinvolvedinthedesignandinstallation

ofComboHeatingSystems.

Itistheresponsibilityoftheinstaller/designertofollowall

applicablecodestoensurethee󰀨ectivenessandsafety

oftheinstallation.

System Requirements

Thefollowingrequirementsmustbemetfortheinstallation

ofComboHeatingSystems:

1. Allcomponentsusedforthedistributionofwaterin

theheatingloopmustbesuitableforpotablewater.

These include all piping, ttings,solder and uxes,

pumpsforcirculationofwater,valves,etc.

2. Thewaterheatermustnotbeconnectedtoahydronic

heatingsystemthathasbeenusedpreviously.

3. No boiler treatment chemicals of any kind shall be

introducedintothesystem.

4. The Combo System components must be selected

andsizedtomeetandmaintainthetotalcalculated

demands for both domestic service hot water

and space heating requirement. The sizing and

installation must be performed in accordance with

good engineering practice such as “ASHRAE

Handbooks”, HRAI’s Unied Combo Guidelines,

“Hydronics Institute Manuals”, ANSI Z223.1, CSA

F280, National/Provincial Building Codes, ANSI

and/orcodeshavingjurisdiction.

5. Theairhandler(fancoil)and/orthecirculatingpump

inabaseboardhydronicloopwillrequireadedicated

120Vcircuit.Thismustbeprovidedandidentiedfor

thispurpose.

6. Allpipingbetweenthewaterheaterandtheairhandler

or hydronic baseboard loop must be adequately

insulatedtoreduceheatloss.

7. Ifthelocaljurisdictionrequiresaback-owpreventer

inthecoldwaterline,anexpansiontankofadequate

sizemustbeinstalled.

8. “Combo” Heating Systems require higher water

temperatures than other applications. When the

systemisused to supplywaterfor Combo Heating

applications,ameans,suchasmixingvalve,mustbe

installedtotemperthewaterinordertoreducescald

hazardpotential(seeFigure21&Figure22).

Installation

Theheatingmodemaybeoneofthefollowingoptions:

A. Afancoil/airhandler(Figure21).

B. Ahydronicbaseboard(nnedtube)loop/Inoorheating

(Figure22).

Thefollowingisalistofrequirementsfortheinstallation

ofoptionAorB.

1. Install shut-o󰀨 valves and unions so that the water

heatercanbeisolatedfromtheheatingmoduleshould

servicing of the water heater become necessary.

2. Installadrainvalveatthelowestpointoftheheating

loopsothatwatercanbedrainedfromtheheating

modulewithouta󰀨ectingthewaterheater.

3. Iftheairhandlerdoesnothaveaventingmeansat

the highest point of the piping arrangement, install

an air bleed at the highest point of the plumbing

arrangement.

WATER

HEATER

8 in TO

12 in MAX.

HOT

OUTLET

EXPANSION TANK

(OPTIONAL)

MIXING

VALVE

COLD INLET

CHECK VALVE (IF USED

REQUIRES EXPANSION TANK)

COLD SUPPLY

HOSE BIB

(OPTIONAL)

FLOW

CONTROL

SUPPLY

RETURN

CHECK

VALVE

EXTERNAL

CIRCULATOR

AIR

HANDLER

HOT WATER

TO HOUSE

FIXTURE

INTERNAL

CIRCULATOR

DRAIN/

PURGE

VALVE

(seealso

Massachusetts

coderequirements

onpg8)

Figure 21.

(seealso

Massachusetts

coderequirements

onpg8)

WATER

HEATER

8 in TO

12 in MAX.

HOT

OUTLET

EXPANSION TANK

(OPTIONAL)

MIXING

VALVE

COLD INLET

CHECK VALVE (IF USED

REQUIRES EXPANSION TANK)

COLD SUPPLY

HOSE BIB

(OPTIONAL)

FLOW

CONTROL

SUPPLY

RETURN

CHECK

VALVE

EXTERNAL

CIRCULATOR

HOT WATER

TO HOUSE

FIXTURE

HYDRONIC

BASEBOARDS

(SERIES

CONNECTED

SHOWN)

Figure 22.

  21

CLOSED WATER SYSTEMS

Watersupplysystemsmay,becauseofcoderequirements

orsuchconditionsashighlinepressure,amongothers,

haveinstalleddevicessuchaspressure-reducingvalves,

check valves, and back ow preventers. Devices such

asthesecausethewatersystemtobeaclosedsystem.

THERMAL EXPANSION

Aswaterisheated,itexpands(thermalexpansion).Ina

closedsystem,thevolumeofwaterwillincrease.Asthe

volumeofwaterincreases,therewillbeacorresponding

increase in water pressure due to thermal expansion.

Thermal expansion can cause premature tank failure

(leakage).This type of failureis notcovered under the

limited warranty. Thermal expansion can also cause

intermittenttemperature-pressurereliefvalveoperation:

waterdischargedfromthevalveduetoexcessivepressure

build up. The temperature-pressure relief valve is not

intendedfortheconstantreliefofthermalexpansion.This

conditionisnotcoveredunderthelimitedwarranty.

A properly-sized thermal expansion tank should be

installed on all closed systems to control the harmful

e󰀨ectsofthermalexpansion.Contactaplumbingservice

agencyoryourretailsupplierregardingtheinstallationof

athermalexpansiontank.

Note:Toprotectagainstuntimelycorrosionofhotandcold

waterttings,itisrecommendedthatdi-electricunionsor

couplingsbeinstalledonthiswaterheaterwhenconnected

tocopperpipe.

• Avoid water heater damage.

• Install thermal expansion tank if necessary.

• Do not apply heat to cold water inlet.

• Contact qualified installer or service agency.

Property Damage Hazard

CAUTION

METAL

DRAIN

PAN

FLOOR

DRAIN

HOT-WATER

OUTLET

COLD-

WATER

INLET

UNION

3/4”SWEAT

FITTING

3/4”SWEAT

FITTING

TEMPERATURE-

PRESSURE

RELIEF VALVE

DISCHARGE PIPE

(DO NOT CAP

ORPLUG)

6”MAX.

AIR GAP

DRAIN

VALVE

SHUT-OFFVALVE

SOME

COMPONENTS

NOT SHOWN

FOR CLARITY.

Figure 23.

Figure21showstypicalattachmentofwaterpipingtothe

waterheater.Thewaterheaterisequippedwith3/4”NPT

waterconnections.

Note: If using copper tubing, solder tubing to an

adapterbeforeattachingtheadaptertothewaterheater

connections.Donotsolderthewaterlinesdirectlytothe

waterheaterconnections-itwillharmthediptubeand

heattrapsanddamagethetank.

TEMPERATURE-PRESSURE RELIEF VALVE

• Temperature-pressure relief

valve must comply with ANSI

Z21.22-CSA4.4 and ASME

code.

• Properly sized temperature-

pressure relief valve must be

installed in opening provided.

• Do not plug, block, or cap the

discharge line.

• Failure to follow this warning

can result in excessive tank

pressure, serious injury or

death.

Explosion Hazard

WARNING

Thiswaterheaterisprovidedwithaproperlyrated/sized

and certied combination Temperature-Pressure Relief

Valve (T&P valve) by the manufacturer. The valve is

certied 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certied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)

andadischargecapacitynotlessthanthewaterheater

Btu/hrinputrateasshownonthewaterheater’smodel

ratingplate.

Forsafeoperationofthewaterheater,thetemperature-

pressure relief valve must not be removed from its

designatedopeningnorplugged.TheT&P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”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dischargeopeningmustnotbeblockedorreducedin

sizeunderanycircumstances.Excessivelength(over30

feet),oruseofmorethanfourelbowscancauserestriction

andreducethedischargecapacityofthevalve.

Novalveorotherobstructionistobeplacedbetweenthe

T&Pvalveandthetank.Donotconnectdischargepiping

directlyto thedrain unlessa maximum of 6” 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.

• Temperature-pressure relief valve discharge pipe

must terminate at an adequate drain.

Water Damage Hazard

CAUTION

T&P valve discharge pipe requirements:

• Shallnotbesmallerinsizethantheoutletpipesize

ofthevalve,orhaveanyreducingcouplingsorother

restrictions.

• Shallnotbepluggedorblocked.

• Shallnotbeexposedtofreezingtemperatures.

• Shallbeofmateriallistedforhotwaterdistribution.

• Shall be installed so as to allow complete drainage

ofboththetemperature-pressurereliefvalveandthe

dischargepipe.

• Mustterminateamaximumofsixinchesabovea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

• Shallnothaveanyvalveorotherobstructionbetween

thereliefvalveandthedrain.

• Burn hazard.

• Hot water discharge.

• Keep clear of

temperature-pressure

relief valve discharge.

BURN

HOT

DANGER

TheT&Pvalvemustbemanuallyoperatedatleastonce

ayear.Cautionshouldbetakentoensure(1)nooneis

infrontoforaroundtheoutletofthedischargeline,and

(2) the water manually discharged will not cause any

bodilyinjuryorpropertydamagebecausethewatermay

beextremelyhot.Ifaftermanuallyoperatingthevalve,it

failstocompletelyresetandcontinuestoreleasewater,

immediatelyclosethecold-waterinlettothewaterheater,

followthedraininginstructionsinthismanual,andreplace

thetemperature-pressurereliefvalvewithaproperlyrated/

sizednewone.

Note:Thepurposeofatemperature-pressurereliefvalve

is to prevent excessive temperatures and pressures in

thestoragetank.TheT&Pvalveisnotintendedforthe

constant relief of thermal expansion.A properly sized

thermal expansion tank must be installedon all closed

systemstocontrolthermalexpansion,see“ClosedWater

Systems”and“ThermalExpansion”section.

Temperature-Pressure Relief Valve and Pipe

Insulation

TheT&Pvalveinstalledonthiswaterheateriscoveredby

insulationtominimizeheatloss.Theinsulationhasahole

onthebottomsidetoaccommodatethevalveoutletand

allowforthepipingconnection.Donotrestricttheoutlet

openingoftheT&Pvalve.

T&P Relief Valve

Drain Line

Manual Relief Lever

T&P Relief Valve Insulation

(Outlet opening on underside)

Figure 24.

Locatethetemperatureandpressurereliefvalveonthe

water heater (also known as a T&P relief valve). See

Figure24.

1. Locate the slit running the length of the T&P relief

valveinsulation.

2. SpreadtheslitopenandttheinsulationovertheT&P

reliefvalve.SeeFigure24.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24).Ensureadischargepipeisinstalledinto

theT&Pvalvedischargeopeningpertheinstructions

inthismanual.

3. Locatethehotwater(outlet)&coldwater(inlet)pipes

tothewaterheater.

4. Locatetheslitrunningthelengthofasectionofpipe

insulation.

5. Spreadtheslitopenandsliptheinsulationoverthe

coldwater(inlet)pipe.Applygentlepressure along

the lengthof the insulation to ensure that it is fully

seatedaroundthepipe.Also,ensurethatthebase

oftheinsulationisushwiththewaterheater.Once

seated,securetheinsulationwithducttape,electrical

tape,orequivalent.

6. Repeatsteps5and6forthehotwater(outlet)pipe.

7. Addadditionalsectionsofpipeinsulationasneeded.

HIGH ALTITUDE INSTALLATION

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

• For operation above 10,100 ft.

(3,079 metres) a high altitude

orifice must be installed.

• Contact a qualified installer or

service agency.

Breathing Hazard - Carbon Monoxide Gas

WARNING

Thisheaterisapprovedforoperationupto10,100feet

withoutalteration.

Failure to replace standard orice with a high altitude

orice when installed above 10,100 feet could result

in improper and ine󰀩cient 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specicchangeswhichmaybe

requiredinyourarea.

GAS PIPING

• 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.

Fire and Explosion Hazard

WARNING

Explosion Hazard

Have a qualified technician make sure that the L.P.

gas operating pressure does not exceed 13" water

column.

Failure to do so can result in death, explosion, or

fire.

WARNING

Makesure thegas supplied is the same type listed on

themodelratingplate.Theinletgaspressuremustnot

exceed14inchw.c.fornaturalgasandpropanegas.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/thermostat is subjected to

pressures exceeding 1/2 psi, the damage to the gas

controlvalve/thermostatcouldresultinareorexplosion

fromleakinggas.

Ifthemaingaslineshut-o󰀨servingallgasappliancesis

used,alsoturn“OFF”thegasateachappliance.Leave

all gas appliances shut “OFF” until the water heater

installationiscomplete.

Agaslineofsu󰀩cient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shut-o󰀨valveinthegas

supplylineservingthewaterheater,and

• Asedimenttrap(dirtleg)aheadofgascontrolvalve/

thermostattohelppreventdirtandforeignmaterials

fromenteringthegascontrolvalve/thermostat.

• Aexiblegasconnectororagroundjointunionbetween

theshut-o󰀨valveandgascontrolvalve/thermostatto

permitservicingoftheunit.

Besuretocheckallthegaspipingforleaksbeforelighting

thewaterheater.Useasoapywatersolution,notamatch

or open ame. Repair and retest as required. When

nished,rinseo󰀨soapysolutionandwipedry.

• Use joint compound or tape

compatible with propane.

• Leak test before operating

heater.

• Disconnect gas piping and

shut-off valve before pressure

testing system.

Fire and Explosion Hazard

WARNING

UsepipejointcompoundorTeontapemarkedasbeing

resistanttotheactionofgases.

Theapplianceanditsgasconnectionmustbeleaktested

beforeplacingtheapplianceinoperation.

Theapplianceanditsindividualshut-o󰀨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psi.Itshouldbeisolatedfromthegassupply

piping system by closing its individual manual shut-o󰀨

valveduringanypressuretestingofthegassupplypiping

systemattestpressuresequaltoorlessthan1/2psi.

Connectinggaspipingtothegascontrolvalve/thermostat

of water heater can be accomplished by either of two

methodsshowninFigure25&Figure26.

Figure 25.

Figure 26.

SEDIMENT TRAPS/DIRT LEG

• Contaminants in gas lines can

cause fire or explosion.

• Clean all gas piping before

installation.

• Install sediment trap in accor-

dance with NFPA54.

Fire and Explosion Hazard

WARNING

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tting

withacappednippleinthebottomoutletorotherdevice

recognizedasane󰀨ectivesedimenttrap.Ifateettingis

used,itshouldbeinstalledinconformancewithoneofthe

methodsofinstallationshowninFigure25&Figure26.

Contaminants in the gas lines may cause improper

operation of the gas control valve/thermostat that may

resultinre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

  25

trap(sometimescalledadirtleg)mustbeincorporatedin

thepiping.Thesedimenttrapmustbereadilyaccessible.

Installinaccordancewiththe“GasPiping”section.Referto

thecurrenteditionoftheNational Fuel Gas Code (ANSI

Z223.1/NFPA 5 4).

HOT-WATER

OUTLET

COLD-

WATER

INLET

UNION

TEMPERATURE-

PRESSURE

RELIEF VALVE

DISCHARGE PIPE

(DO NOT CAP

ORPLUG)

6”MAX.AIRGAP

BELOW DISCHARGE

PIPE

METAL

DRAIN

PAN

FLOOR

DRAIN

VALVE

SHUT-OFFVALVE

SOME

COMPONENTS

NOT SHOWN

FOR CLARITY.

SIDE TAP

(OUTLET)

SIDE TAP

(INLET)

Figure 27.

FILLING THE WATER HEATER

• Avoid water heater damage.

• Fill tank with water before operating.

Property Damage Hazard

CAUTION

• Do not insert the power cord into the electrical

receptacleuntiltheheaterhasbeenfullyinstalled.

• Neverusethiswaterheaterunlessitiscompletelyfull

ofwater.Topreventdamagetothetank,thetankmust

be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(seeFigure27).

2. Iftheheaterisequippedwithplumbingsidetapsand

theyarenotconnectedtopiping,ensurethattheside

tapshavebeenclosedwithpipeplugs.

3. Openallhot-waterfaucetsservedbythewaterheater

to allow air to escape from the tank and the water

piping.Ensureanyshut-o󰀨valvesbetweentheheater

andthefaucetsaretheopenposition.

4. Openthecold-watersupplyvalvetothewaterheater.

Notes:

 • Thecold-watersupplyvalvemustbeleftopenwhen

thewaterheaterisinuse.

 • Avoidwaterleakagewhenllingthetank.Donot

allowtheinsulationofthewaterheatertogetwetas

watercanreducethee󰀨ectivenessoftheinsulation.

5. Toensure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.

6. Check all water piping and connections for leaks.

Repairasneeded.

VENTING

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

• Install vent system In accordance with codes.

• Do not operate water heater if flood damaged.

• Install water heater in accordance with the

instruction manual.

• Do not operate if soot buildup is present.

• Do not obstruct water heater air intake(s) with

insulating blanket.

• Do not place chemical vapor emitting products near

water heater.

• Gas and carbon monoxide detectors are available.

• Never operate the heater unless it is vented to the

outdoors and has adequate air supply to avoid risks

of improper operation, fire, explosion or asphyxia-

tion.

• 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 Hazard - Carbon Monoxide Gas

WARNING

Important:DONOTcommonventthiswaterheaterwith

anypowerventedappliance.DONOTventintoacommon

chimney.

TERMINATION CLEARANCES SIDEWALL POWER VENT

INSIDE CORNER

DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

OPERABLE

Vent terminal

Air supply inlet

Area where is not permitted

Gas meter / regulator

Figure 28.

Ventterminalclearancesfor“PowerVent”installations.PowerVentcongurationsuseroomairforcombustion.

Clearanceabovegrade,

veranda,porch,deckor

balcony

12in. H

Clearancetoeachsideof

centerlineextendedabove

meter/regulatorassembly

N/A

Clearancetowindowordoor

thatmaybeopened

4ft.belowortoside

ofopening;1ft.

aboveopening

Clearancetoserviceregulator

ventoutlet

3ft.*

Clearancetopermanently

closedwindow

12in.* J

Clearancetoanon

mechanicalairsupplyinletinto

buildingorcombustionairinlet

toanyotherappliance

4ft.belowortoside

ofopening;1foot

aboveopening.

Verticalclearancetoventilated

so󰀩tlocatedabovethe

terminalwithinahorizontal

distanceof2ft.fromthe

centerlineoftheterminal

12in.* K

Clearancetoamechanicalair

supplyinlet

3ft.aboveifwithin

10ft.horizontally

Clearancetounventilated

so󰀩t

12in.* L

Clearanceabovepaved

sidewalkorpaveddriveway

locatedonpublicproperty

7ft.†

F Clearancetooutsidecorner 2ft.* M

Clearanceunderveranda,

porch,deck,orbalcony

12in.‡

G Clearancetoinsidecorner 18in.*

InaccordancewiththecurrentANSIZ223.1/NFPA54,NationalFuelGasCode.

†Aventshallnotterminatedirectlyaboveasidewalkorpaveddrivewaythatislocatedbetweentwosinglefamily

dwellingsandservesbothdwellings.

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

*Clearanceinaccordancewithlocalinstallationcodesandtherequirementsofthegassupplierandthe

manufacturer’sinstallationinstructions.

BLOWER ASSEMBLY INSTALLATION

1. Thispowerventedwaterheatercomeswithblower

assemblyinstalled(seeFigure29).

2. Afterunitissetinplace,makesureblowerassemblyis

stillmountedsecurely.Makesurethereisnodamage

toblower.

HOSE

CONNECTION

PORT FOR

CONDENSATE

DRAIN

DILUTION

AIR

INLETS

8in.

LOOP

DRAIN

BLOWER

ASSEMBLY

Figure 29.

3. Makesurethereisnopackingmaterialintheinletor

dischargeoftheblower.

4. Make sure that the plastic tubing is still attached

fromtheairpressureswitchtotheportontheblower

housing. Make sure the plastic tubing is not folded

anywherebetweenthepressureswitchandtheblower

housing(seeFigure37thruFigure41).

5. Thiswaterheaterisapolaritysensitiveapplianceand

willnotoperateifthepowersupplypolarityisreversed.

Power to this water heater must be wired properly

(correctpolarity).

6. Do not plug in power cord until vent system is

completelyinstalled.ThePowerVentoperateson110

-120VAC.thereforeagroundedoutletmustbewithin

reachofthe6footexiblepowercordsuppliedwith

theheater.Thepowercordsuppliedmaybeusedon

aunitonlywherelocalcodespermit.Iflocalcodesdo

notpermituseofexiblepowersupplycord:

a. Make sure the unit is unplugged from the wall

outlet.Removethescrewandopenpanelonthe

frontofthejunctionboxontheblower.

b. Cutthe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 the neutral and line connections

arenotreversedwhenmakingtheseconnections.

f. Groundheaterproperly.Thiswaterheatermustbe

groundedinaccordancewiththeNationalElectrical

CodeNFPA70and/orlocalcodes.Thesemustbe

followed in all cases.The waterheater must be

connectedtoagroundedmetal,permanentwiring

systemoranequipmentgroundingconductormust

berunwiththecircuitconductorsandconnected

totheequipmentgroundingterminalorleadonthe

waterheater(seeFigure12;thewiringdiagram).

g. Closethe panel onthe junction box. Make sure

thattheaccesspanelissecuredshut.

7. The blower discharge boot is made to accept only

straightsectionsof2”or3”pipe.Tostarto󰀨withan

elbow,ashortsectionofthestraightpipemustbecut

andgluedintotheendoftheelbowthatwillmounton

thedischargeboot.

INSTALLATION OF VENT SYSTEM

Beforebeginninginstallationofpipingsystem,thoroughly

readthe“VentPipePreparation”sectionofthismanual.

PLANNING THE VENT SYSTEM

Planthelayoutoftheventsystemfromtheventtermination

tothewaterheaterconsideringallofthe90degreeand45

degreeelbowsplusthenumberoffeetofpipethatwould

beneededtoinstallthetotalventsystem.Thewaterheater

must be vented to the outdoors as described in these

instructions.Thiswaterheatermustbeventedseparately

fromallotherappliances.

The unit may be vented horizontally through a wall or

verticallythroughtheroof.Piperunsmustbeadequately

supportedalongbothverticalandhorizontalruns.

Note:Donotuseanelbowasasupportpoint.Elbowsare

notdesignedtocarrytheloadorstressesoftheventing

systemiftheyarerigidlyheld.

Itisimperativethatthersthanger(orsupport)belocated

on the horizontal run immediately adjacent to the rst

90-degreeelbowfromtheverticalrise.Supportmethod

usedshouldisolatetheventpipefromtheoorjoistsor

otherstructuralmemberstopreventthetransmissionof

noise and vibration. Do not support, pin, or otherwise

secure the venting system in a way that restricts the

normalthermalexpansionandcontractionofthechosen

ventingmaterial.

Ifthewaterheaterisbeinginstalledasareplacementfor

anexistingpowerventedheaterinpre-existingventing,

athoroughinspectionofexistingventingsystemmustbe

performedpriortoanyinstallationwork.Verifythatcorrect

material,asdetailedinbelow,hasbeenused,andthatthe

minimumormaximumventlengthsandterminallocation

asdetailedinthismanualhavebeenmet.

HIGH AMBIENT TEMPERATURE INSTALLATIONS

This heater requires room air to lower the flue gas

temperatures before the gases pass through the vent

system.Thedilutionairinletsarelocatedontherearof

theblowerassembly(seeFigure2&Figure29).

Astheroomtemperaturerises,theabilitytolowertheue

gaseslessenssospecialattentiontothechoiceofventing

materialisrequired.Establishingtheambienttemperatures

where the heater and the venting is installed is very

important, especially in regions with warmer climates

or any region that experiences hot summers.Ambient

conditions hotter than 110°F require that the venting

materialbeeitherCPVCorpolypropylene.Areasthatcan

experience high ambient environments include closets,

alcoves,areasunderstaircases,attics-especiallyinmetal

roofed buildings, areas with restricted air movement,

roomswithlargesolargains,metal sheds, industrialor

commercialenterprisesandventingsystemsexposedto

directsunlight.Forhightemperatureenvironments,obtain

highlimitswitchupgradeKit#9008306015andusethe

higherratedventpiping.

Note:Thisunitcanbeventedwiththefollowingpiping:

PVCpipe

materials

(solidpipe)

DWVASTM-D2665

Schedule40,80*&120*ASTM-D1785,

SDRSeriesASTM-D2241

PVCpipe

materials

(cellularcore)

ASTM-D4396

CPVCpipe

materials

CPVC41ASTM-D2846

Schedule40,80*&120*ASTM-F441

SDRSeriesASTM-F442,

ABSpipe

materials

DWVASTM-D2661

Schedule40

ABSpipe

materials

(cellularcore)

ASTMF-628

Polypropylene

ventsystem

UL-1738

* NOTE: USINGSCHEDULE80OR120

SIGNIFICANTLY REDUCES THE VENT LENGTH.

Note:Iflocalcodesrequireventingtobemarkedsuitable

foruseasgasventing,typeBHventingmaybeused.

The fittings, other than the Termination should be

equivalentto:

PVCpipe

PVCDWVASTMD-2665

CPVCpipe CPVCASTMF-438

ABSpipe ABSASTMD-2661/3311

Polypropylene

ventsystem

UL-1738

If CPVC orABS pipe and ttings are used, the proper

cementmustbeusedforalljoints,includingjoiningthe

pipetoTermination(PVCMaterial).Iflocalcodesdonot

allow the use of the PVC termination when a material

otherthanPVCisusedforventing,anequivalentttingof

thatmaterialmaybesubstitutedifthescreeninthePVC

terminalisremovedandinsertedintothenewtting.

This water heater is supplied with a 45 degree PVC

terminationelbowandtheapplicableventscreens.A90

degreeterminationelbowisoptional.

ASTM D-2564 Grade Cement should beused on PVC

Materials andASTM F-493 Grade Cement on CPVC

Materials.

POLYPROPYLENE VENT SYSTEMS

Polypropyleneventsystemsdonotusecementtoconnect

thepipeandelbowsectionsbutuseapushtogethergasket

seal method. Do not attempt to connect polypropylene

withsealantcement.

Polypropyleneventsystemsaredesignedtousespecic

adaptorstoconnectintotherubbercouplingonthetop

oftheblower.Theseareavailablethroughyourventing

supplier.

ThePVCventterminationelbowsuppliedwiththisheater

has been certied to be used with polypropylene vent

systems.A polypropylene to PVC end connection is

requiredandisavailablethroughyoursupplier.

Optionalwallplatesthattthepolypropyleneventingare

alsoavailablethroughyoursupplier.

Carefullyinspecttheentireventingsystemforanysignsof

cracksorfractures,particularlyatjointsbetweenelbows

andother 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inthesystem.

Ifanyoftheseconditionsarefound,theymustbecorrected

inaccordancewiththeventinginstructionsinthismanual

beforecompletinginstallationandputtingthewaterheater

intoservice.

The vent piping shall be connected to the blower with

therubbercouplingandsecuredwithgearclamps.The

couplingandclampsareprovidedwiththeheater.

Eventhoughtheuegastemperatureleavingtheblower

is hot, some installations will have water condense in

theventpiping.Ifthis occurs, thenadequatemeansof

draininganddisposingofthecondensateshallbemade

bytheinstaller.

CONDENSATE

Condensateformationdoesnotoccurinallinstallations

of power vented water heaters, but should be drained

oninstallationswhereitcanformintheventingsystem.

Condensation in the venting system of power vented

waterheatersisdependentuponinstallationconditions

including, but not limited to, ambient temperature and

humidity of installation location, ambient temperature

andhumidityofventingspace,ventdischargeandslope,

andproductusage.Incertainconditions,installationsin

unconditionedspaceorhavinglonghorizontalorvertical

ventrunscanaccumulatecondensate.Longlengthsof

ventingthatpassthroughcool/coldareaswillexperience

condensation.Theventpipeshouldbeslopedupwards

awayfrom theblowerassembly, thenadequate means

for draining and disposing of the condensate needs to

bemadebytheinstaller.Ifinstallationconditionscause

condensation,installacondensatetraploopapproximately

8in.indiameterusing3/8”plastichose.Connectthehose

tothebuilt-indrainportoftherubbercouplingoftheblower

assembly (see Figure 29). Loop the hose in a vertical

positionasshown.Thetubeloopmustbelledwithwater

atleasthalfwaypriortooperatingtheheater.Ensurethe

endofthetubehasaccesstoadrainascondensatewill

owfrom the end.Secure the tubingto thesideof the

heater. Prior to operating the water heater, make sure

theremovablecapisinstalledonthedrainport(ifadrain

hoseisnotneeded).

Note:Thiscapmustremaininplaceifadrainhoseisnot

installed.

EXHAUST VENTING

This heater is designed to exhaust the products of

combustion(uegases)totheoutdoorsusingasealed

pipingsystem.Table2liststheallowableventmaterials

and sizing information. Figure 33 shows the general

ventinglayoutwhileFigure37thruFigure41showvarious

endterminationdetailsandclearances.Connectionofthe

ventingpipingtothe blower isshowninFigure37 thru

Figure41.

Correctinstallationoftheventingsystemisessentialto

thesafeande󰀩cientoperationofthiswaterheater.Vent

pipingmustbeinstalledinaccordancewithallapplicable

codes.All installations shall meet the requirements as

statedinthecurrenteditionofthe “National Fuel Gas

Code, ANSI Z223.1/NFPA 54”.

Note:TheinformationprovidedinFigure28isintended

as a guideline for good vent installation practices only

and is not intended to restrict venting options beyond

thoserestrictionsestablishedbythecurrenteditionofthe

“National Fuel Gas Code, ANSI Z223.1/NFPA 54”orany

applicablelocalandstatecodes.

6in.

min.

BACKTOBACKELBOWS

NORMAL ELBOW

90°LONGSWEEPELBOW

(LESSRESTRICTIVE)

90°SHORTSWEEPELBOW

(MORERESTRICTIVE)

STREET ELBOW

PREFERRED PRACTICE

Figure 30.

Important Notes and Warnings

• ThisheateriscertiedtobeinstalledusingPVC,CPVC,

ABSorpolypropyleneplasticventmaterial.Onlyuse

approvedmaterial.Allventingmaterialandcomponents

mustbejoinedwiththeapprovedprimer/cleanerand

solventcement.

• Do not common vent this heater with any other

appliance.

• During operation the plastic piping will expand as it

heatsupandcontractasitcoolsdown.Thisisnormal

forthistypeofventing.Rigidlyfasteningtheventpiping

cancauseunduestressthatmayresultinthecracking

orfracturingtheventpipingmaterial.Afractureofthe

venting pipe may pose a serious safety hazard. To

preventstressingoftheventsystem,allhangersand

supportsmustallowtheventpipingfreedomtomove.

• Uselongsweepelbows wherever possible.Closely-

coupledelbowsandshortradiuselbowscanreduce

theventingcapacity.

• All power vented water heaters generate a certain

amountofoperationalnoise.Inordertominimizenoise

transmissiontothesupportstructure,useisolationpads

betweenthepipehangersandtheventpipe.

• Most power vent installations develop some

condensationintheventpiping.Whenusinglongruns

ofventingorwhentheventingpassesthroughcoldor

unheatedareas,considerableamountsofcondensate

fromthe uegases candevelop. Provisionmust be

made for the condensate to drain freely from the

systemortobecollectedinacondensatetrap(s)that

canbedrained.Damageorfractureoftheventpiping

mayoccurifthecondensateisallowedtocollectand

freeze.Poolingofcondensatecanrestrictairowand

cancausenuisancefailuresofthesystem.

Venting terminations and sizing

• RefertoFigure33andTable2forventpipematerials

and sizing. Examples of the vent terminations are

shown in Figure 34 & Figure 35. If the installation

requires a vent riser, suitable drainage must be

providedtoensurecondensationdoesnotaccumulate.

TerminationthrougharoofisshownFigure36.

• 40,50and60gallonheaterswithratedinputsof50k

Btu/hrorlessaresuppliedwitha2”-3”rubbercoupling

toattachtheventingtothebloweranda2”,45°vent

terminationelbow.

with2in.venting(short) with2in.venting(long)

For heaters with rated inputs of 50k Btu/hr or less:

VENT LENGTH LESS THAN OR

EQUALTO20EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

VENT LENGTH GREATER THAN

20EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

with4in.venting

VENT LENGTH GREATER THAN

125EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

with3in.venting

VENT LENGTH GREATER THAN

50EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

with3in.venting

VENT LENGTH LESS THAN OR

EQUALTO50EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

Figure 31.

• 50and75gallonheaterswitharatedinputof60kBtu/

hrormorearesuppliedwitha3”-3”rubbercoupling

toattachtheventingtothebloweranda3”,45°vent

terminationelbow.

• Suppliedwiththisheaterareseveralventtermination

screens(seeFigure31&Figure32).

Installedin the ventterminationelbow,the vent screen

is required to keep foreign objects, rodents and small

birds from entering the venting system. These screens

havebeensizedtoensuremaximumenergye󰀩ciencyof

theventsystembasedonthe“equivalentlength”ofthe

vent piping. CHOOSE ONLY the ONE SCREEN THAT

MATCHES YOUR VENTING CONFIGURATION (see

Figure31&Figure32).Howtodeterminethe“equivalent

length”isshowninFigure33andinTable2.

Vent screen installation

• Install the appropriate vent screen into the vent

terminationelbow.

• Gentlypushthescreenintotheterminationelbowuntil

itsitsagainsttheinsideshoulder.

• Themetalwirescreensareself-securing.

• Plastic screens must be secured with (2) drops of

silicone sealant.This willallow for easy removal for

inspectionandcleaning.

with4in.venting

VENT LENGTH GREATER THAN

50EQUIVALENTFT.

USE THIS SCREEN

(SUPPLIED).

with3in.venting(short) with3in.venting(long)

For heaters with rated inputs of 60k Btu/hr or more:

VENT LENGTH LESS THAN OR

EQUALTO20EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

VENT LENGTH GREATER THAN

20EQUIVALENTFT.

USETHISSCREEN(SUPPLIED).

Figure 32.

  31

Calculating Equivalent Feet

WATER

HEATER

MODEL

HEATER

INPUT

(Btu/hr)

VENT SIZE

(Inside

Diam.)

PRESSURE

SWITCH

SETTING

MAXIMUM EQUIVALENT

VENT LENGTH

MINIMUM EQUIVALENT

VENT LENGTH

40&50gal. 40,000

2”

-0.27in.w.c.

50ft.+terminationelbow 7ft.terminationelbow

60gal. 42,000 -0.27in.w.c.

40&50gal. 50,000 -0.37in.w.c

40&50gal. 40,000

3”

-0.27in.w.c.

125ft.+terminationelbow 7ft.terminationelbow60gal. 42,000 -0.27in.w.c.

40&50gal. 50,000 -0.37in.w.c.

50gal.(short) 62,000

3”

-0.99in.w.c.

50ft.+terminationelbow 7ft.+terminationelbow50gal.(tall) 65,000 -0.99in.w.c.

75gal. 72,000 -0.99in.w.c.

40&50gal. 40,000

4”

-0.27in.w.c.

180ft.+terminationelbow 125ft.+terminationelbow60gal. 42,000 -0.27in.w.c.

40&50gal. 50,000 -0.37in.w.c.

50gal.(short) 62,000

4”

-0.99in.w.c.

125ft.+terminationelbow 50ft.+terminationelbow

50gal.(tall) 65,000 -0.99in.w.c.

75gal. 72,000 -0.99in.w.c.

EquivalentlengthsofstraightpipeforvariouselbowsusingSchedule40PVC,CPVCandpolypropylene.

Size Type

Short Sweep/

Short Radius

Long Sweep/

Long Radius

Notes:

1. Uselongradiuselbowswhere

possible.Minimumdistancebetween

90ºelbowsshouldbe6”wherever

possible.

2. Ventingsystemsmayuseamaximum

ofve(5)90°elbows.

3. Useproperscreentermination(see

Figure31&Figure32).

2”

90°elbow 8ft. 5ft.

2”

45°elbow 4ft. 2.5ft.

Table 2.

Exampleforcalculatingequivalentfeet.

Section“A” 0.5ft.

90°elbow 8.0ft.

SectionB 1.0ft.

45°elbow 4.0ft.

SectionC 1.5ft.

45°elbow 4.0ft.

SectionD 15.0ft.

TotalEquivalent 34.0ft.

Basedonthisexampleusethe(fullyopen)rodent

screenforventlengthgreaterthan20equivalentft.

(seeFigure31&Figure32).

Note:Theventpipemustbesupportedevery4ft..Topreventvibrationandsagging,itisrecommendedtouse

isolationpadswhenattachingstrapstooorjoists,wallsorceilings.PVCandCPVCventpipeshouldbesloped

upwardsawayfromtheblowerassemblyatapitchof1/8in.riseper4ft..Polypropyleneventsystemsrequirea

1/4”per1ft.upwardslopetoensureproperdrainage.

STRAP

45°SHORT

ELBOW

90°SHORT

ELBOW

RODENT

SCREEN

(INSTALL INTO

ELBOW)

TERMINATION

ELBOW

GROUND LEVEL

12”MIN.ORABOVE

ANTICIPATED SNOW

LEVEL.

COVER PLATE

(OPTIONAL)

Figure 33.

Venting instructions

1. Plantheventinglayoutstartingattheventtermination

andworkbacktowardtheheater.Takeintoconsideration

thestyleandpositionoftheventtermination,thevent

piperouting,elbowsandconnectorsrequiredandthe

necessarysupporthangers.

2. Ventingshouldbeasdirectaspossiblewiththefewest

numberofttings.Uselongradius45degreeandlong

radius90degreeelbowswhereverpossible.

3. Avoidusing90degreeelbows“backtoback”anddo

notusestreetelbows.Maintainaminimum6”straight

sectionbetweenelbows.Closelycoupledandshort

radiuselbowsreducetheventingcapacity.Figure30

showsexamplesofventpipeconnections.

4. DO NOT USE AN ELBOW AS A SUPPORT POINT.

Elbowsarenot designedtocarrythe weightofthe

ventingsystem.

5. Calculate“EquivalentVentLength”beforestarting.Do

notexceedthevaluesshowninTable2.Anexample

ofhowthislengthisdeterminedisshowninFigure

33.Thevaluefromyourcalculationsshouldalsobe

usedtodeterminewhichrodentscreentoinstallinto

theventterminationelbow.

6. Measuretheventpipingandcuttorequiredlengths.

Pipes must be cut at right angles and deburred to

ensurea good smootht with su󰀩cientoverlap for

thegluejoints.Correctanyinterferenceconditions.

7. Provide support hangers for horizontal vent piping

every 4 ft. to prevent sagging and stress. Provide

a minimum of 1/8” rise per 4 ft. of vent piping to

ensure adequate drainage (polypropylene vent

systemsrequirea1/4in.riseper1ft.ofventpipe).

Horizontalventpipingmustnotsagtoformvalleys

wherecondensatecancollect.Verticalventingshall

be supported every 5 ft.. Use appropriate support

strapsandvibrationisolators(foampads)onstraight

sectionsonly.Allowsu󰀩cientclearanceforexpansion

andcontractionoftheventingsystem.

8. Atthepointwheretheventingexitsthebuilding,cuta

2-1/2”holefor2”venting,a3-1/2”holefor3”ventingor

a4-1/2”holefor4”venting.Forsidewallapplications,

usetheappropriatemetalcoverplateasatemplate

to mark the hole for the vent pipe to pass through

thewall.BEWAREOFCONCEALEDWIRINGAND

PIPING INSIDE THE WALL.

9. Inserttheventpipingthroughthisholeandsecureinto

position.Connecttheventpipetotheendtermination

elbowasshowninFigure34thruFigure36.

10. Drytallventpipes,elbows,connectorsandttings

beforejoininganypartswithsolventcement.PARTS

MUST FIT WITHOUT STRESS OR BENDING OF

ANY SECTION and each connection must overlap

a minimum of 1/2”. Do not force fit any of the

connections.Useonlytheappropriatesolventcement.

Caution: Solvent cements may produce

flammable vapors. Use only in well-ventilated

areas and keep away from all sources of ignition.

Note:DONOTusesolventcementonpolypropylene

ventsystems.

11. Installtheproperlysizedrodentscreenintotheoutlet

elbow and secure with a small quantity of silicone

sealant.RefertoFigure31&Figure32todetermine

theproperscreen.

12. Donotsealtheventpipingtothewalluntiltheventing

isproperlyconnectedtotheblowerassembly.

13. Completetheventinginstallationbysealingaround

the termination assembly where it passes through

theoutsidewall,insideandout,withsiliconeorother

suitablesealant.Applyenoughsealanttosecurethe

(optional)coverplatetothewall.

• Use only in well-ventilated areas.

• Do not use near flame or open fire.

• Use only the Solvent Cement and Primer appropriate for

the venting material being used.

• Solvent cements for plastic pipe are flammable liquids and

must be kept away from all sources of ignition.

Use of Solvent Cement and Primer

CAUTION

SEALANT

(UNDER

PLATE)

GROUND

LEVEL*

RODENT

SCREEN

(INSTALL

INTO

ELBOW)

* WHERE SNOW COVER IS NORMAL DURING

WINTER, ENSURE OUTLET IS INSTALLED

ABOVE ANTICIPATED SNOW LEVEL.

12”

MIN.*

ATTACH

TERMINATION

ELBOW (MAY

ALSOBE90°)

6”

VENT PIPING MAY

BE SLOPED IN ANY

DIRECTION, AS

LONG AS A WATER

TRAP IS NOT

CREATED IN THE

VENTING SYSTEM.

THE SLOPE

SHOULDBEKEPT

TO A MINIMUM

SO AS NOT TO

EXERT ANY UNDUE

STRESS ON THE

PIPE.

COVER PLATE

(OPTIONAL)

Figure 34.

BRACKET

VENT

RISER

SEALANT

(UNDER

PLATE)

ATTACH

TERMINATION

ELBOW (MAY

ALSOBE90°)

GROUND

LEVEL*

RODENT

SCREEN

(INSTALL

INTO

ELBOW)

VENT PIPING TO BE

SLOPED(DOWN)

TOWARD HEATER

TO PREVENT

WATER FROM

COLLECTING

(MAY REQUIRE

A CONDENSATE

TEE).

EQUIVALENT

VENT LENGTH

MEASURED

FROM THIS

POSITION

* WHERE SNOW COVER IS NORMAL DURING

WINTER, ENSURE OUTLET IS INSTALLED ABOVE

ANTICIPATED SNOW LEVEL.

12”MIN.*

COVER PLATE

(OPTIONAL)

Figure 35.

TERMINATION

MAYBE90°

ELBOW

3”MIN.

LENGTH

ROOF

LINE

A VENT USED IN A

SPECIAL VENTING

SYSTEM WITH POSITIVE

VENT PRESSURE AND

PASSING THROUGH A

ROOF SHALL EXTEND AT

LEAST18”ABOVETHE

HIGHEST POINT WHERE

IT PASSES THROUGH THE

ROOF SURFACE AND ANY

OTHER OBSTRUCTION

WITHINAHORIZONTAL

DISTANCEOF18”.A

VERTICAL VENTING

SYSTEM MUST BE

SUPPORTEDEVERY5ft..

18”OR

ABOVE

ANTICIPATED

SNOW LEVEL

RODENT

SCREEN

(INSTALL

INTO

ELBOW)

Figure 36.

Vent pipe connection to blower

1. The plastic vent piping connects into the rubber

couplinglocatedonthetopoftheblowerassembly.

This coupling includes gear clamps to connect the

venting to the blower. These connections must be

properlyseatedandtightenedtopreventtheleakage

ofuegasesintothearea.SeeFigure37thruFigure

41.

2. The40,50and60-gallonheaterswithratedinputsof

50kBtu/hrorlessaredesignedandsuppliedwitha

2”rubbercouplingtoaccepttheventpipe.

3. The50and75-gallonmodelswithratedinputsof60k

Btu/hrormorearesuppliedwitha3”rubbercoupling

to accept the vent pipe. Note: Polypropylene vent

systemsrequireseparateadaptor.

4. Beforeinstallingcleanandlightlysandtheendofthe

PVC/CPVCplasticventpipingthatwillconnectinto

therubbercoupling.Forpolypropyleneventsystems

followmanufacturer’sinstructions.

5. Loosentheupperclampontherubbercouplingand

insertthesandedendoftheventpipingafull1-1/4”.

Do not use glue or sealant in the rubber coupling.

Checkthatthereisnostressontheconnectionorthe

ventpipingthatmaybecausedbytwistingorbending.

6. Tighten the upper clamp so that the vent piping is

rmlysecuredinthecouplingandisgastight.Donot

overtightenorcausedistortionofanyoftheparts.

Ensure the bottom of the rubber coupling is rmly

seatedonthebloweroutletandthatthelowergear

clamp is also secure. Check to ensure there is no

distortionormovementoftheclampedassemblyonce

itiscompleted.

• Do not overtighten the top and bottom gear clamps of the

rubber coupling.

• Do not apply solvent cement or silicone to the rubber

coupling connection.

Property Damage Hazard

CAUTION

Di󰀨erent coupling installations according to vent

sizes

BLOWER

2”VENT

PIPE

2”RUBBER

COUPLING

(SUPPLIED)

CONFIGURATION

FOR40,50AND

60-GALLON(LO-

INPUT)HEATERS

CONNECTED TO

2" VENTING.

Figure 37.

2”RUBBER

COUPLING

(SUPPLIED)

BLOWER

3”VENT

PIPE

2”-3”

ADAPTER*

(FIELD

SUPPLIED)

2”VENTPIPE,

75mm(3in.)

MAX LENGTH

CONFIGURATION

FOR40,50AND

60-GALLON(LO-

INPUT)HEATERS

CONNECTED TO

3”VENTING.

*FOR3”DIRECT

CONNECTION TO

THE BLOWER,

ORDER

COUPLINGKit#

9008311005

(SEEALSOFigure

41).

Figure 38.

4”VENT

PIPE

3”RUBBER

COUPLING

(ORDER COUPLING

Kit#9008311005

TOREPLACE2”

RUBBER COUPLING

SUPPLIED.)

3”VENTPIPE,

3in.MAX

LENGTH

3”-4”

ADAPTER

(FIELD

SUPPLIED)

BLOWER

CONFIGURATION

FORLO-INPUT

HEATERS

CONNECTED TO

4”VENTING.

LOW-INPUT

HEATERS ARE

SUPPLIED WITH

A2”RUBBER

COUPLING.

Figure 39.

3”VENT

PIPE

3”RUBBER

COUPLING

(SUPPLIED)

BLOWER

CONFIGURATION

FORHI-INPUT

HEATERS

CONNECTED TO

3”VENTING.

(OPTIONAL

CONFIGURATION

FORLO-INPUT

HEATERS

CONNECTED TO

3”VENTING.)

Figure 40.

4”VENT

PIPE

3”RUBBER

COUPLING

(SUPPLIED)

3”VENTPIPE,

3in.MAX

LENGTH

3”-4”

ADAPTER

(FIELD

SUPPLIED)

BLOWER

CONFIGURATION

FORHI-INPUT

HEATER

CONNECTED TO

4”VENTING.

Figure 41.

BLOWER EXHAUST DIRECTION

Theblowerassemblymayberotated90degreeclockwise

orcounterclockwisetoallowhorizontalventinginareas

havingrestrictedspaceabovethewaterheater.Torotate

thebloweroutlet,removethefournuts(with11/32”nut

driver)(seeFigure42),securingtheuecollectortothe

blowerhousing.Pulltheblowerassemblyforwardtofree

it from the mounting studs. Rotate the blower housing

clockwiseorcounter-clockwiseandalignthefourholes

andscrewstogether.Reattachtheblowerhousingtothe

uecollector.

11/32”nut

Note:Couplingtoventsystem

notshownforclarity.

Figure 42.

VENT PIPE PREPARATION

1. INITIALPREPARATION

 • Makesurethesolventcementyouareplanningto

useisdesignedforthespecicapplicationyouare

attempting.

• Knowthephysicalandchemicalcharacteristicsand

limitationsofthePVCandCPVCpipingmaterials

thatyouareabouttouse.

• Knowthereputationofyourmanufacturerandtheir

products.

• Know your own qualifications 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.

• Closely supervisethe installation andinspect the

nishedjobbeforestart-up.

• Contact the manufacturer, supplier,or competent

consultingagencyifyouhaveanyquestionsabout

the application or installation of PVC and CPVC

pipe.

• Take thetimeande󰀨orttodoaprofessional job.

Shortcutswillonlycauseyouproblemsanddelays

instart-up.Byfar,themajorityoffailuresinPVCand

CPVC systems are the result of shortcuts and/or

improperjoiningtechniques.

2. SELECTION OF MATERIALS (PCV and CPVC

VENTING)

• CuttingDevice-SaworPipeCutter

• DeburringTool,Knife,File,orBevelingMachine(2”

andabove)

• Brush-PureBristle

• Rag-Cotton(NotSynthetic)

• PrimerandCleaner

• SolventCement-PVCforPVCComponentsand

CPVCforCPVCComponentsonly

• Containers - Metal or Glass to hold Primer and

Cement.SelectthetypeofPVCorCPVCmaterials

to be used on the basis of their application with

respect to chemical resistance, pressure rating,

temperaturecharacteristics,etc.

• InsertionTool-Helpfulforlargerdiameterpipeand

ttings6”andabove.

Read instruction manual before

installing, using or servicing

water heater.

• Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

Fire or Explosion Hazard

WARNING

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.

  35

Cement:

  The cement should be a bodied cement of

approximately 500 to 1600 centipoise viscosity

containing10-20%(byweight)virginPVCmaterial

solvated with Tetrahydrofuran (THF). Small

quantities of Dimethyl Formamide (DMF) may

beincludedtoactasaretardingagenttoextend

curing time. Select the proper cement; Schedule

40cementshouldbeusedforSchedule40 pipe.

Neveruseall-purposecements,commercialglues

andadhesivesorABScementtojoinPVCorCPVC

pipeandttings.

• Primers and cements are

extremely flammable, and must

not be stored or used near heat

or open flame.

• Also, use only in a well venti-

lated area.

Fire Hazard

WARNING

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.

RECOMMENDEDBRUSH*SIZEFOR

PRIMER AND CEMENT APPLICATIONS

Nominal

Pipe(IPS)

BrushSize

2 1.5”

3 1.5”-2.5”

*USE ONLY NATURAL BRISTLE

Table 3.

3. MAKINGTHEJOINT

A. Cutting

  Pipemustbesquarelycuttoallowfortheproper

interfacing of the pipe end and the 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,ifused,shouldbespecically

designedtocutplasticpipe.

Figure 43.

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.

Figure 44.

C. Test dry t of the joint

  Tapered fitting 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su󰀩cient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.

• Cans of cement and primer should

be closed at all times when not in

use to prevent evaporation of

chemicals and hardening of cement.

• They are also very flammable and

should be kept away from heat or

flame.

Fire Hazard

WARNING

Figure 45.

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su󰀩cient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.

Figure 46.

G. Cleanup and joint movement

  Remove allexcess cement fromaround thepipe

andtting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su󰀩cienttimeshould

beallowedforpropercuringofthejoint.Exactdrying

time is di󰀩cult to predict because it depends on

variablessuchastemperature,humidityandcement

integrity.Formorespecicinformation,youshould

contactyoursolventcementmanufacturer.

Figure 47.

INSTALLATION CHECKLIST

Note:Useandcompletethischecklistbeforelightingthe

heater. Correct any conditions that do not meet these

instructions.

Vent Termination

Horizontal

1. 12in.min.abovegrade/snowlevel.

2. Awayfromcorners,othervents,windowsetc.

Vertical

1. Exhaust vent termination 18 in. min. above

roof/snowlevel.

Water System Piping

1. TemperatureandPressurereliefvalveproperly

installedwithadischargelineruntoanopen

drainandprotectedfromfreezing.

2. Allpipingproperlyinstalledandfreeofleaks.

3. Heatercompletelylledwithwater.

4. Closedsystempressurebuild-upprecautions

installed.

5. All components used in combo heating

systemsorrecirculationloopsystemssuitable

forpotablewater.

6. Checkvalvesinstalledincomboheatingand

recirculationloopsystems.

7. ThermostaticMixingValvesateachpoint-of-

use.

Electrical Connections

1. Unitconnectedtoadedicated120Velectrical

supply.

2. Properpolarity.

3. Waterheaterproperlygrounded.

4. Installed in accordance with prevailing

provisionsoflocalcodes,orintheabsenceof

such,thelatesteditionof“National Electrical

Code” (NFPA 70)”.

After all actions on checklist are checked/

completed, read the Lighting Instructions and

proceed with lighting the heater.

CheckHere

Water Heater Location

1. Centrallylocatedwiththewaterpipingsystem.

Locatedasclosetogaspipingandventpipe

systemaspossible.

2. Located indoors and in a vertical position.

Protectedfromfreezingtemperatures.

3. Properclearancesfromcombustiblesurfaces

maintained and not installed directly on a

carpetedoor.

4. Provisionsmadetoprotecttheareafromwater

damage.Metaldrainpaninstalledandpiped

toanadequatedrain.

5. Installationareafreeofcorrosiveelementsand

ammablematerial.

6. Su󰀩cientroomtoservicethewaterheater.

Gas Supply and Piping

1. Gassupplyisthesametypeaslistedonthe

waterheaterdataplate.

2. Gas line equipped with shut-o󰀨 valve, union

anddirtleg

3. Approvedpipejointcompoundused.

4. Adequatepipesizeandofapprovedmaterial.

5. Chloride-freesoapandwatersolutionorother

approvedmeansusedtocheckallconnections

andttingsforpossiblegasleaks.

Vent Pipe System

1. Ventpipeandttingsofapprovedmaterial.

2. Acceptablesize,lengthandnumberofelbows

onexhaustventsystem.

3. Installed in accordance with prevailing

provisionsoflocalcodes,orintheabsenceof

such,thelatesteditionof“National Fuel Gas

Code” ANSI Z223.1 (NFPA 54).

4. Horizontalpipingslopesatanupwardpitchof

1/8in.riseper4ft.awayfromthewaterheater.

5. Notobstructedinanyway.

CheckHere

Readandunderstandthesedirectionsthoroughlybeforeattemptingtooperatethewaterheater.Makesuretheburner

viewportisnotmissingordamaged.Makesurethetankiscompletelylledwithwaterbeforeoperatingthewaterheater.

Thegascontrolvalve/thermostathasan“On/O󰀨Switch”andmustbeturnedonbeforethewaterheaterisoperational.

Checkthelabelonthefrontofthewaterheaternearthegascontrolvalve/thermostatforthecorrectgas.Donotstart

thiswaterheaterwithanygasotherthantheonelistedonthelabel.Ifyouhaveanyquestionsordoubts,consultthe

gassupplierorgasutilitycompany.ThefollowingLightingInstructionlabelappearsonthefrontofthewaterheater.

ThisheaterisequippedwithaHoneywell/Resideogascontrol/thermostatandahot-surfaceigniter.Thiscontrolisa

combinationgasvalve,thermostatandignitioncontrollerforuseonthispowerventedwaterheater.Thevalvecontains

amicro-controllerthatsupervisestheignitionsequenceandmonitorsthetemperaturesettingsandoperationofthe

heater.Thecontrolleralsomonitorstheammablevaporsafetyfeaturesofthisheater.

This heater is equipped with a hot-surface ignition system that automatically ignites the burner. Do not attempt

to light this heater manually with a match or ame-producing device.

323546-000

1. Turn the thermostat counter-clockwise to the lowest setting.

2. Set the gas control switch to the “OFF” position.

3. Turn off electrical power to the appliance if service is to be performed.

TO TURN OFF GAS TO APPLIANCE

1. STOP! Read the safety

information above on this

label.

2. Turn off all electric power to the

appliance.

3. Turn the thermostat

counter-clockwise to the

lowest setting.

4. Set the switch on the control to

the “OFF” position.

5. Do not attempt to light manually.

6. Wait five (5) minutes to clear out

any gas. If you then smell gas, STOP!

Follow “B” in the safety information above on

this label. If you don't smell gas, go the next

step.

7. Turn on all electric power to

the appliance.

8. Set the switch on the control

to the “ON” position.

9. Turn thermostat to desired

setting.

DANGER Hotter water

increases the risk of

scald injury. Consult the

instruction manual before

changing temperature.

10. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance”

and call your service technician or gas

supplier.

OPERATING INSTRUCTIONS

DANGER

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 some gas is heavier

than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric switch; Do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas suppliers

instructions.

• If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to turn the gas control

buttons. Never use tools. If the control

buttons will not turn, don't try to repair them,

call a qualified service technician. Force or

attempted repair may result in a 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 unit. It must be

replaced!

BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.

FLAMMABLE

WARNING: If you do not follow these instructions exactly, a fire

or explosion may result causing property damage, personal

injury or loss of life.

FOR YOUR SAFETY READ BEFORE LIGHTING

Read and follow water heater warnings and instructions in furnished manual.

If manual is missing, you may obtain one free of charge by calling 1-800-821-2017.

Si Ud. no puede ni leer ni entender el inglés y si necesita manuales, etiquetas

o rótulos en español, Ud. los puede obtener si al llama 1-800-821-2017.

WARNING / ADVERTENCIA

HOT

BURN

Water temperature over 125°F can

cause severe burns instantly or

death from scalds.

Children, disabled and elderly are

at highest risk of being scalded.

See instruction manual before

setting temperature at water heater.

Feel water before bathing or

showering.

Temperature limiting valves are

available, see manual.

DANGER

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance. Storage or

use of gasoline or other flammable vapors or liquids in the

vicinity of this or any other appliance can result in serious injury

or death.

Can result in serious injury or death

FIRE AND EXPLOSION HAZARD

Flammable Vapors

FLAMMABLES

WARNING

LIGHTING INSTRUCTIONS

Install Thermostatic Mixing Valves to regulate the

temperature of the water supplied to each point-of-use

(for example, kitchen sink, bathroom sink, bath and

shower).Installandadjustthemixingvalveaccordingto

itsmanufacturer’sinstructions.

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satisesyourhot-waterneeds.

Thiswillalsoprovidethemostenergye󰀩cientoperation

ofthewaterheater.

Shortrepeatedheatingcyclescausedbysmallhot-water

usescancauseatemperatureincreaseofthehotwater

by30F°higherthantheheater’stemperaturesettings.If

youexperiencethistypeofuseyoushouldconsiderusing

lowertemperaturesettingstoreducescaldhazards.

WARNING! Even if the water heater’s thermostat is set

to a relatively low temoerature, hot water can scald.

Install Thermostatic Mixing Valves at each point-of-use

to reduce the risk of scalding.

Shouldoverheatingoccurorthegassupplyfailstoshut

o󰀨, turn o󰀨 the main manual gas shut o󰀨 valve to the

appliance(seeFigure1).

Water temperature over

125°F can cause severe

burns instantly resulting in

severe injury or death.

Children, the elderly and the

disabled and are at highest

risk of scald injury.

Feel water before bathing or

showering.

Temperature limiting devices

such as mixing must be

installed when required by

codes and to ensure safe

temperatures at fixtures.

BURN

HOT

DANGER

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

inrm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 certain

temperature water at the hot-water tap, then you must

takespecialprecautions.Inadditiontousingthelowest

possibletemperaturesettingthatsatisesyourhot-water

needs,ameanssuchasamixingvalve,shouldbeused

atthehot-watertapsusedbythesepeopleoratthewater

heater. Mixing valves are available at plumbing supply

or hardware stores (see Figure 8 & Figure 9). Follow

manufacturer’sinstructionsforinstallationofthevalves.

Beforechangingthefactorysettingonthethermostat,in

thismanual,seeTable4.

The water heater should be located in an area where

the general public does not have access. If a suitable

areaisnotavailable,acovershouldbeinstalledoverthe

thermostattopreventtampering.

This water heater is equipped with an adjustable

thermostattocontrolwatertemperature(seeFigure48).

Hotwatertemperaturesrequiredforautomaticdishwasher

andlaundryusecancausescaldburnsresultinginserious

personalinjuryand/ordeath.Thetemperatureatwhich

injuryoccursvarieswiththeperson’sageandtimeofthe

exposure.Theslowerresponsetimeofchildren,agedor

disabledpersonsincreasesthehazardstothem.Never

allowsmallchildrentouseahot-watertap,ortodrawtheir

ownbathwater.Neverleaveachildordisabledperson

unattendedinabathtuborshower.

Thehotsettingshownonthedialisapproximately120°F.

Thisisagoodstartingpointtosetthetemperature.

Settingthewaterheatertemperatureat120°Fwillreduce

theriskofscalds.Somestatesrequiresettingsatspecic

lowertemperatures.

Thethermostatsettingsonthegascontrolvalveareshown

inFigure48.

Thewatertemperaturesettingwasfactorysetatthelowest

(VAC)temperaturesetting.

OPERATING THE TEMPERATURE CONTROL SYSTEM

GAS CONTROL VALVE/THERMOSTAT

ON/OFF

SWITCH

TEMPERATURE

SETTING DIAL

155°F

70°F

130°F 140°F 150°F

120°F

110°F

Figure 48.

Temperature

Dial Setting

Approximate

Temperature

°F

Time to induce a 2nd

and 3rd Degree burn

to adult skin

VERY HOT 155 Lessthan1second

C 150 About1.5seconds

B 140 Lessthan5seconds

A 130 Morethan30seconds

HOT 120 Morethan5minutes

LOW 110 Normalshowertemp

VAC 70 N/A

Table 4.

WARNING! Higher temperatures increase the risk os

scalding, but even at 120°F, hot water can scald, (see

table 4). Install Thermostatic Mixing Valve(s) at each

point-of-use to reduce the risk of scalding.

Note:Thetemperaturesindicatedareapproximates.The

actualtemperatureoftheheatedwatermayvary.

The Vacation Setting (VAC) sets the controller at

approximately70°F.Thissettingisrecommendedwhen

thewaterheaterisnotinuseforalongperiodoftime.This

e󰀨ectivelyturnsthecontrollertemperaturesettingdownto

atemperaturethatpreventsthewaterinthewaterheater

fromfreezingwhilestillconservingenergy.

  41

START UP CONDITIONS

Condensate

Wheneverthewaterheaterislledwithcoldwater,some

condensate will form while the burner is ON.A water

heatermayappeartobeleakingwheninfactthewateris

condensate.Thisusuallyhappenswhen:

a. Anewwaterheaterislledwithcoldwaterfortherst

time.

b. Burninggasproduceswatervaporinwaterheaters,

particularly high efficiency models where flue

temperaturesarelower.

c. Largeamountsofhotwaterareusedinashorttime

andtherellwaterinthetankisverycold.

Moisturefromtheproductsofcombustioncondenseon

thecoolertanksurfacesandformdropsofwaterwhich

mayfallontotheburnerorotherhotsurfacestoproduce

a“sizzling”or“frying”noise.

Because of the suddenness and amount of water,

condensate water maybe diagnosed as a “tank leak”.

Afterthewaterinthetankwarmsup(about1-2hours),

theconditionshoulddisappear.

Donotassumethewaterheaterisleakinguntiltherehas

beenenoughtimeforthewaterinthetanktowarmup.

Anundersizedwaterheaterwillcausemorecondensation.

The water heater must be sized properly to meet the

family’s demands for hot water including dishwashers,

washingmachinesandshowerheads.

Excessive condensate maybe noticed during the

winter and early spring months when incoming water

temperaturesareattheirlowest.

Good venting is essential for a gas red water heater

to operate properly as well as to carry away products

ofcombustionandwatervapor(seealso“Condensate”

section).

Thermal expansion

See “Thermal Expansion” section elsewhere in this

manual.

• Avoid water heater damage.

• Install thermal expansion tank if necessary.

• Do not apply heat to cold water inlet.

• Contact qualified installer or service agency.

Property Damage Hazard

CAUTION

A properly-sized thermal expansion tank should be

installed on all closed systems to control the harmful

e󰀨ects of thermal expansion. Contact a plumbing

service agency or your retail supplier regarding the

installation of a thermal expansion tank.

Closed water systems

See “Closed Water Systems” section elsewhere in this

manual.

Smoke/odor

Itisnotuncommontoexperienceasmallamountofsmoke

andodorduringtheinitialstart-up.Thisisduetoburningo󰀨

ofoilfrommetalparts,andwilldisappearinashortwhile.

Strange sounds

Possiblenoisesduetoexpansionandcontractionofsome

metalpartsduringperiodsofheat-upandcool-downdo

notnecessarilyrepresentharmfulordangerousconditions.

Condensation causes sizzling and popping within the

burnerareaduringheatingandcoolingperiodsandshould

beconsiderednormal.See“Condensate”sectioninthis

manual.

OPERATIONAL CONDITIONS

Smelly water

Each water heater contains at least one anode rod for

corrosionprotectionofthetank.Certainwaterconditions

willcauseareactionbetweenthisrodandthewater.The

mostcommoncomplaintassociatedwiththeanoderod

isoneofa“rotteneggsmell”inthehotwater.Thesmell

isaresultoffourfactorswhichmustallbepresentforthe

odortodevelop:

a. Aconcentrationofsulfateinthesupplywater.

b. Littleornodissolvedoxygeninthewater.

c. A sulfate reducing bacteria which has accumulated

within the water heater (this harmless bacteria is

nontoxictohumans).

d. Anexcessofactivehydrogeninthetank.Thisiscaused

bythecorrosionprotectiveactionoftheanode.

Smellywatermaybeeliminatedorreducedinsomewater

heatermodelsbyreplacingtheanode(s)withoneofless

activematerial,andthenchlorinatingthewaterheatertank

andallwaterlines.Contactthelocalwaterheatersupplier

orserviceagencyforfurtherinformationconcerningan

AnodeReplacementKitandthischlorinationtreatment.

Ifthesmellywaterpersistsaftertheanodereplacement

and chlorination treatment, we can only suggest that

chlorinationoraerationofthewatersupplybeconsidered

toeliminatethewaterproblem.

Do not remove the anode leaving the tank unprotected.

By doing so, all warranty on the water heater tank is

voided.

FOR YOUR INFORMATION

“AIR” IN HOT-WATER FAUCETS

• Flammable hydrogen gases may

be present.

• Keep all ignition sources away

from faucet when turning on hot

water.

Explosion Hazard

WARNING

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 ammable and explosive. To prevent

the possibility of injury under these conditions, it is

recommendedthatthehot-waterfaucet,locatedfarthest

away,beopenedforseveralminutesbeforeanyelectrical

applianceswhichareconnectedtothehot-watersystem

areused(suchasadishwasherorwashingmachine).If

hydrogengasispresent,therewillprobablybeanunusual

soundsimilartoairescapingthroughthepipeasthehot-

waterfaucetisopened.Theremustbenosmokingoropen

amenearthefaucetatthetimeitisopen.

GENERAL UPKEEP

Makeitahabittolookaroundtheheater,theventpiping,

andthehotandcoldwaterpipes.Donotallowanymaterial

tobepiledupagainsttheheater.Donotplaceanyobject

ontopoftheventpipes.

Every3-6monthsorasnecessary:

• Cleanlintfromblower,topofheater.

Onceperyear:

• InspecttheVentSystem.

• BurnerOperationandInspection.

• CombustionChamberforscalingorsooting.

• Temperature-PressureReliefValveTest.

• AnodeRodInspection.

• Flushapailofwaterfromtheheaterdrainvalve,once

peryear.

Ifanydecienciesorabnormalitiesareencounteredduring

theseinspectionscallaqualiedservicetechnician.

VENTING SYSTEM INSPECTION

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

• Flue gases may escape if vent pipe is not properly

connected.

• Be alert for obstructed, sooted or deteriorated vent

system to avoid serious injury or death.

• Do not store corrosive chemicals in vicinity of water

heater.

• Chemical corrosion of flue and vent system can

cause serious injury or death.

• Analyze the entire vent system to make sure that

condensate will not become trapped in a section of

vent pipe and therefore reduce the open cross

sectional area of the vent.

Breathing Hazard - Carbon Monoxide Gas

WARNING

Atleastonceayearavisualinspectionshouldbemade

oftheventingsystem.Youshouldlookfor:

• Obstructionswhichcouldcauseimproperventing.The

combustion,dilutionandventilationairowmustnot

beobstructed.

• Damageordeteriorationwhichcouldcauseimproper

ventingorleakageofcombustionproducts.

Besuretheventpipingisproperlyconnectedtoprevent

escape of dangerous 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.

BLOWER MAINTENANCE

Inspectthetopoftheheaterandaroundtheventilation

openingsoftheblowermotorandtherearblowerdilution

airintakesforanylintanddustthatmayhaveaccumulated.

Depending on the location of the heater, significant

quantitiesoflintmayaccumulate.Thelintmayobstruct

thefreeowofairtothemotor,andcausethemotorand

blowertorunhotterthannormal(seeFigure49).

Tocleananydustandlint,proceedasfollows:

1. Unplugthewaterheater.

2. Usinganylonbristledpaintortoothbrush,brushaway

anylint.Pickupthelintwithacloth.

Betterresultscanbeachievedbyusingthesmallbrush

ona vacuumcleaner to remove all lint and dust which

haveaccumulatedontopoftheheater,thelouvresofthe

airintakesnorkel,themotorventilationopeningsandthe

rearblowerdilutionairintakes.

Important: Do not insert any foreign object into the

ventilationopeningsofthemotor.

CLEANING THE BLOWER.

Industyandcontaminatedairconditions,theinteriorof

the blower and the blower wheel may require periodic

cleaning.Thisisoftenindicatedbynuisancefailuresofthe

airpressureswitchorthehighlimittemperaturecontrol.

Acollectionofdustordebrisontherearblowerdilution

airintakescanalsoindicatereducedblowercapacity.To

cleantheinsideoftheblowerassemblyandtheblower

wheelrequirestheremovaloftheblower/motorfromthe

mounting plate located on the top of the heater.Tools

requiredincludean11/32”nutdriver,small(1”)paintbrush,

toothbrushandvacuumcleaner.

1. Turnthethermostatonthegascontroltothelowest

setting.Iftheheaterisrunning,waitforittoshutdown

(seeFigure48).

2. Turnthegascontrolswitchtothe“OFF”position.

3. Disconnecttheelectricalpowertothewaterheater

fromthewalloutlet.

4. Disconnecttheventpipingfromthetopoftheblower.

Loosenthelower gear clampthatholds the rubber

couplingtotheblower(seeFigure49).

5. Removeandretainthe(4)11/32”nutslocatedonthe

backoftheblowerwiththenutdriver(seeFigure42

&Figure49).

6. Holding the blower motor and the blower housing,

pull the assembly forward to disengage it from the

mountingplate.Theblowerwillstillbeconnectedtothe

junctionboxsoexercisecarenottostressthewiring.

PERIODIC MAINTENANCE

7. Accessingtheblowerwheelthroughtheoutlet,use

the paint brush to brush o󰀨 the outer edge of the

blowerwheeltodislodgethedirtstuckontheblades

andtheinsideofthehousing.Rotatethewheeluntil

allbladesareclear.Note:Thewheelisabalanced

component.Donotbend,dentordistortthebladesas

thiscanupsetthewheelbalanceanda󰀨ecttheblower

operation.Vacuumoutthelooseneddirt.

8. Accessingtheinsideoftheblowerwheelthroughthe

rearofthehousing,gentlybrusho󰀨theinsideofthe

bladesusingthetoothbrush.Again,takecarenotto

distorttheblades.Rotatethewheeluntilallbladesare

cleanedandvacuumthedebris.Donotremoveany

ofthebalancingchipsattachedtotheblades.

9. Inspectthe uecollector hood(still attached to the

heater)andvacuumoutthedustanddebristhatmay

haveaccumulated.

10. Withallpartscleanedandtheblowerwheelturning

freely, reinstall the blower to the mounting plate

aligningthe(4)studsandpushingtightagainstthe

mountingplate.

11. Reinstallthe(4)11/32”nutsandtightensecurely.All

(4)nutsmustbeinplaceandsecuretosafelyoperate

theblower.

12. Reattachtheventpipingandcouplingtothetopofthe

blower,tightenthebottomgearclampandensurethe

pipingissecure.

13. Withallcomponentscleanandsecure,reconnectthe

electricalpowertotheheater.

14. Reset the thermostat to the desired temperature

setting and turn the gas control switch back to the

“ON”position.Note:Ifthewaterintheheaterishot,

theunitwillwaittooperateuntilthereisaneedfor

morehotwater.

BLOWER

DILUTION

AIRINTAKES

COUPLING

BLOWER

FLUE

COLLECTOR

HOOD

11/32”

NUTS

MOUNTING

PLATE

GEAR

CLAMP

VENT

PIPE

MOTOR

Figure 49.

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qualied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 50). 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51),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hotsurfaceignitershouldalsobedone

atleastonceayear(seeFigure50).

Sootbuild-upindicatesaproblemthatrequirescorrection

before further use. Turn “OFF” gas to water heater by

unpluggingthepowercordandleaveo󰀨untilrepairsare

made.Failuretocorrectthecauseofthesootingcanresult

inarecausingdeath,seriousinjury,orpropertydamage.

VIEWPORT

MAIN

BURNER

IGNITER

AND FLAME

ROD

IGNITER

AND

FLAME

ROD

Figure 50.

CORRECT FLAME

SOFT BLUE

INCORRECT

FLAMELAZY

YELLOW

BLUE TIPS

LIGHT BLUE INNER

CONES ARE

SATISFACTORY

Figure 51.

  45

COMBUSTION CHAMBER AND BURNER CLEANING

Intheeventyourburner or burner airopeningsrequire

cleaning,Callyourserviceagencytoremoveandclean

theburnerandcorrecttheproblemthatrequiredtheburner

tobecleaned.

HOUSEKEEPING

• Do not obstruct combustion air

openings at the rear of the water

heater.

• Do not use or store flammable

vapor products such as gaso-

line, solvents or adhesives in the

same room or area near water

heater or other appliance.

• Can cause serious injury or

death.

Fire and Explosion Hazard

DANGER

INSTALLEDINSUITABLEAREA:

To ensure sufficient ventilation and combustion air

supply, proper clearances from the water heater must

be maintained. See “Locating the New Water Heater”

section.Combustiblematerialssuchasclothing,cleaning

materials,or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, hydronic heating

devicesandwatersofteningmethodscanincreasetherate

ofanoderoddepletion.Oncetheanoderodisdepleted,

thetankwillstarttocorrodeeventuallydevelopingaleak.

Certainwaterconditionswillcauseareactionbetweenthe

anoderodandthewater.Themostcommon complaint

associated with the anode rod is a “rotten egg smell”

produced from the presence of hydrogen sulde gas

dissolved in the water. Important: Do not remove this

anode rod permanently as it will void any warranties.

A special anode rod may be available if water odor or

discolorationoccurs.Note:Thisanoderodmayreduce

butnoteliminatewaterodorproblems.Thewatersupply

system may require special ltration equipment from a

waterconditioningcompanytosuccessfullyeliminateall

waterodorproblems.

Articiallysoftened water canbe exceedinglycorrosive

because the process substitutes sodium ions for

magnesiumandcalciumions.Theuseofaexcessively

softwatermaydecreasethelifeofthewaterheatertank.

Theanoderodshouldbeinspectedafteramaximumof

threeyearsandannuallythereafteruntiltheconditionof

theanoderoddictatesitsreplacement.Note:Articially

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anoderod’sdiameterislessthan

3/8”.

• Signicant sections of the support wire (approx. 1/3

or more of the anode rod’s length) are visible (see

Figure52).

Iftheanoderodshowsignsofeitherorbothitshouldbe

replaced.Note:Whetherre-installingorreplacingthe

anoderod,checkforanyleaksandimmediatelycorrect

iffound.

Figure 52.

ANODE ROD

Important:Useonlyfactoryauthorizedreplacementparts.

If you lack the necessary skills to properly perform the

installation,youshouldnotproceed,butgethelpfroma

qualiedservicetechnician.

• Toolsrequired:

• Ratchetwith1-1/16”Socket

• Pliers

• Teon

Tapeoranapprovedpipesealant

Removing Anode Rod:

1. Set the gas control valve/thermostat to its lowest

setting by turning the knob counter-clockwise to

theVACpoint(seeFigure48).Ifthewaterheateris

running,waitforittoshutdown.

2. Turngascontrolswitchtothe“OFF”position.

3. Disconnecttheelectricalpowertothewaterheater

fromthewalloutlet.

4. Shuto󰀨theincomingwatersupplytothewaterheater

andopenanearbyhot-waterfaucettodepressurize

thewatertank.

5. Connectahosetothedrainvalveandterminateitto

adequatedrainortotheexteriorofthebuilding.Open

thedrainvalveandallowatleast5gallonsofwater

todrainfromthetank.Closedrainandremovehose.

6. Remove the anode cap on top of the heater and

removejustenoughinsulationsoyoucanaccessto

theanodehead(seeFigure53).Keeptheanodecap

inasafeplaceforreinstallationlater.

7. Remove the anode rod by using a ratchet and a

1-1/16”socketturningcounter-clockwise(seeFigure

53).

Installing Anode Rod:

1. Use Teon® tape or an approved pipe sealant on

threadsofthenewanoderod.

2. Placetheanoderodinthespud(topofthetank)and

turnclockwiseuntilthethreadsarehandtight.Using

aratchetand1-1/16”sockettightendownwatertight.

3. Openanearbyhot-waterfaucettopurgeairfromthe

waterline.Open the incomingwatersupply and ll

water heater tank completely (Note: To assure the

water heater tank is full, keep the hot-water faucet

openfor3minutesafteraconstantowofwateris

obtained).

4. Turning o󰀨 the hot-water faucet, check for water

leaksaroundanoderodandimmediatelycorrectany

iffound.

5. Reinstall the insulation and anode cap which were

removedinstep6ofremovalinstructions.

6. Withallcomponentscleanandsecure,reconnectthe

electricpowertotheheater.

7. Reset the thermostat to the desired temperature

setting and turn the gas control switch back to the

“ON”position(seeFigure48).

CAP

ANODE ROD *

* THE ANODE ROD IS COVERED

BY URETHANE FOAM LOCATED

UNDER THE CAP. CHIP AWAY

THE FOAM TO EXPOSE THE

TOP OF THE ANODE ROD

Figure 53.

TEMPERATURE-PRESSURE RELIEF VALVE TEST

• Burn hazard.

• Hot water discharge.

• Keep clear of

temperature-pressure

relief valve discharge.

BURN

HOT

DANGER

It is recommended that the temperature-pressure relief

valvebecheckedtoensureitisinoperatingconditionat

leastonceayear.

When checking the temperature-pressure relief valve

operation,makesurethat(1)nooneisinfrontoforaround

theoutlet oftheT&Pvalvedischarge line,and (2)that

waterdischargewillnotcauseanypropertydamage,as

water may be extremely hot. Use care when operating

valveasthevalvemaybehot.

To check the relief valve, lift lever at the end of valve

several times (see Figure 54). 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” section. Replace

theT&Pvalvewithaproperlyrated/sizednewone,see

“Temperature-Pressure Relief Valve” for instructions on

replacement.

Figure 54.

If the Temperature-Pressure Relief Valve on the water

heaterweepsordischargesperiodically,itmaybedueto

thermalexpansion.

Note: Excessive water pressure is the most common

cause of temperature-pressure relief valve leakage.

Excessivewatersystempressureismostoftencaused

by“thermalexpansion”ina“closedsystem.”See“Closed

WaterSystems”and“ThermalExpansion”sectionsofthis

manual.TheT&Pvalveisnotintendedfortheconstant

reliefofthermalexpansion.

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.

• Temperature-pressure relief

valve must comply with ANSI

Z21.22-CSA4.4 and ASME

code.

• Properly sized temperature-

pressure relief valve must be

installed in opening provided.

• Do not plug, block, or cap the

discharge line.

• Failure to follow this warning

can result in excessive tank

pressure, serious injury or

death.

Explosion Hazard

WARNING

DRAINING AND FLUSHING

Periodicdrainingandcleaningofsedimentfromthetank

maybe necessary. It is recommended that the tank be

drainedandushedevery6monthstoremovesediment

whichmaybuildup during operation.The water heater

should be drained if being shut down during freezing

temperatures. See “Typical Installation” section in this

manual for location of the water heater components

describedbelow.

• Burn hazard.

• Hot water discharge.

• Keep hands clear of drain

valve discharge.

BURN

HOT

DANGER

To drain the water heater storage tank:

1. Turn“OFF”theelectricalsupplytothewaterheater.

2. Turn“OFF”thegassupplyattheMainGasshut-o󰀨

Valveifthewaterheaterisgoingtobeshutdownfor

anextendedperiod.

3. CLOSEthecold-waterinletvalvetothewaterheater.

4. OPENanearbyhot-waterfaucetandleaveopento

allowfordraining.

5. Connectahosetothedrainvalveandterminateto

anadequatedrain.

Note:Ifthewaterheaterisgoingtobeshutdownand

drainedforanextendedperiod,thedrainvalveshouldbe

leftopenwithhoseconnectedallowingwatertoterminate

toanadequatedrain.

6. Closethewaterheaterdrainvalvewhenallwaterin

thestoragetankhasdrained.

7. Followinstructions inthe“Filling theWaterHeater”

section.

8. Turn “ON” the gas supply at the main gas shut-o󰀨

valve.

9. Follow the lighting instructions on the label or see

“LightingInstruction”torestartthewaterheater.

To ush the water heater storage tank:

1. Turn“OFF”theelectricalsupplytothewaterheater.

2. Ensurethecold-waterinletvalveisopen.

3. Connectahosetothedrainvalveandterminateitto

anadequatedrain.

4. Ensurethedrainhoseissecuredbeforeandduringthe

entireushingprocedure.Flushingisperformedwith

systemwaterpressureappliedtothewaterheater.

5. Openthewaterheaterdrainvalvetoushthestorage

tank.Caution:Waterwillbehot.

6. Flush the water heater storage tank to remove

sedimentandallowthewatertoowuntilitrunsclean.

7. Closethewaterheaterdrainvalvewhenushingis

completed.

8. Removethedrainhose.

9. Ensuretheheaterisfullofwater.

10. Turn“ON”electricalsupplytoplacewaterheaterback

inoperationandfollowthelightinginstructions.

11. Allowthe waterheatertocomplete several heating

cyclestoensureitisoperatingproperly.

Caution:Donotturnonpowertothewaterheaterunless

the tank is full. Open a hot-water faucet and allow the

waterto run untilthe airispurged andthewater ows

uninterruptedfromthefaucet.

Important:Whenoperatingacoldtank,condensationcan

occuranddripontheburner.Thisshouldnotbeconfused

withatankleak.

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qualiedinstallertocheckthewaterheater.

Ensuretheventingisproperlyattachedandsecured.

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. Water at the blower assembly is water vapor which

hascondensedoutofthecombustionproducts.This

iscausedbyaprobleminthevent.Adrainageportis

includedattheventpipeconnection.Contactthegas

utility.

B. *Condensationmaybeseenonpipesinhumidweather

orpipeconnectionsmaybeleaking.

C.*Theanoderodttingmaybeleaking.

D.Small amounts of water from temperature-pressure

reliefvalvemaybeduetothermalexpansionorhigh

waterpressureinyourarea.

E. *Thetemperature-pressurereliefvalvemaybeleaking

atthetanktting.

F. Waterfromadrainvalvemaybeduetothevalvebeing

slightlyopened.

G.*Thedrainvalvemaybeleakingatthetanktting.

H.Combustionproductscontainwatervaporwhichcan

condenseonthecoolersurfacesofthetank.Droplets

formanddripontotheburner.Thisiscommonatthe

timeofstart-up after installationandwhen incoming

wateriscold.

I. Water in the water heater bottom may be from

condensation,looseconnections,or thereliefvalve.

DONOTreplacethewaterheateruntilafullinspection

ofallpossiblewatersourcesismadeandnecessary

correctivestepstaken.

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Teontapeonthethreadsandreplace.

Thenfollow“FillingtheWaterHeater”instructionsin

the“InstallingtheNewWaterHeater”section.

Figure 55.

LEAKAGE CHECKPOINTS

REFERENCE PARTS LISTING

Replacement parts may be ordered

through your plumber or the local

distributor.Whenorderingreplacement

parts, always have the following

informationready:

1. Model,SerialandProductnumber

2. Typeofgas

3. Itemnumber

4. Partsdescription

1. VentTerminationElbowwithRodent

Screen

2. **VentPipe

3. **VentPipeCoupling(ifrequired)

4. **VentPipeElbow(longradius)

5. Blower High Limit Switch (see

Figure61)

6. T&PValve

7. Cold-WaterInletNipple/Diptube

8. Ba󰀪eAssembly

9. **DischargePipe

10.Gas Control Valve/Thermostat

(Honeywell/Resideo)

11.Gas Valve Electronic Control

ModuleAnd Cover (Honeywell/

Resideo)

12.DrainValve

13.OuterGasDoor

14.Manifold DoorAssembly (behind

outerdoor)(seeFigure58&Figure

59)

15.**FloorDrain

16.**MetalDrainPan

17.Flammable Vapor Sensor (under

cover)(seeFigure60)

18.Combo Heating System Return

Inlet(Optional)

19.AirInletSnorkel

20.Combo Heating System Supply

Outlet(Optional)

21.BlowerwithPowerCord(seealso

Figure61)

22.Air Switch (inside box) (see

Figure61)

23.JunctionBox(seeFigure61)

24.JunctionBoxCover(seeFigure61)

25.AirTubing(seeFigure61)

26.Rubber Coupling (see also

Figure61)

27.GearClamp(seealsoFigure61)

28.FlueCollector

29.Hot-WaterOutletNipple

30.Anode(undercap)

32.Flexible Manifold Tube (see

Figure58&Figure59)

33.Viewport (see Figure 58 &

Figure59)

34.FlameSensorRod(seeFigure58

&Figure59)

35.Gas Orifice (see Figure 58 &

Figure59)

36.SheetMetalBurner(seeFigure58

&Figure59)

37.Gas Manifold (see Figure 58 &

Figure59)

38.Hot-SurfaceIgniter(seeFigure58

&Figure59)

39.Manifold Door Gasket (see

Figure58&Figure59)

40.Manifold Door (see Figure 58 &

Figure59)

41.Two Piece Grommet With Clip

(Figure58&Figure59)

** parts not supplied with the water

heater

FrontView RearView

Figure 56. Figure 57.

Combustion

AirInlets

Blower

DilutionAir

Inlets

NaturalgasandPropanemain

burnerwithigniterassemblyfor

40kto50kBtu/hrmodels

FlareNut**

Figure 58.

32 34

NaturalgasandPropane

mainburnerwithigniter

assemblyfor60kto75k

Btu/hrmodels

Flare

Nut**

Figure 59.

Figure 60.

Figure 61.

Notes: * Natural gas models have Right-hand thread,

PropanemodelshaveLeft-handthread.

 **ForNaturalgasmodelstheFlareNuthasRight-

handthread.ForPropanemodelstheFlareNut

hasLeft-handthread.

  51

Theseguidelinesshouldbeutilizedbyaqualiedserviceagent.

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER FLAME

TOO HIGH

1. Airinletsblocked

2. Insu󰀩cientsecondaryair

3. Oricetoolarge

1. Unblockinletairopenings

2. Provideventilationtowaterheater

3. Replacewithcorrectorice

FLAME BURNS

AT ORIFICE

1. Lowgaspressure

2. Defectivegascontrolvalve/thermostat

1. Checkwithgasutilitycompany

2. Replacegascontrolvalve/thermostat

INSUFFICIENT

HOT WATER

1. Lowgaspressure

2. Oricetoosmall

3. Thermostatsettoolow

4. Gascontrolerrorcodes

5. Sedimentorlimeintank

6. Waterheatertoosmall

7. Wrongpipingconnections

8. Leakingfaucets

9. Wastedhotwater

10. Longrunsofexposedpiping

11. Hot-waterpipinginoutsidewall

1. Checkwithgasutilitycompany

2. Replacewithcorrectorice(seerating

plate)

3. Turntemperatureknobtohighersetting

4. Refertogascontrolerrorcodes

5. Drain/ush-provide water treatment if

needed

6. Installadequateheater

7. Correctpiping:diptubemustbeincold

inlet

8. Repairfaucets

9. Advisecustomer

10. Insulatepiping

11. Insulatepiping

WATER IS TOO HOT

1. Thermostatistoohigh

2. Defectivegascontrolvalve/thermostat

1. Turntemperatureknobtolowersetting.

Install or adjust Thermostatic Mixing

Valve for each point-of-use (see the

valvemanufacturer’sinstructions)

2. Replacethegascontrolvalve/

thermostat

SLOW HOT WATER

RECOVERY

1. Insu󰀩cientair/ueblockage

2. Lowgaspressure

3. Oricetoosmall

4. Thermostatsettoolow

5. Heatertoosmall

6. Wrongpipingconnection

7. Wastedhotwater

8. Flueclogged

9. Airinletsblocked

1. Provideventilationtowaterheater.

Checkueway,ueba󰀪eandburner

2. Checkwithgasutilitycompany

3. Replacewithcorrectorice(seerating

plate)

4. Turntemperatureknobtohighersetting

5. Installadequateheater

6. Correctpiping-diptubemustbeincold

inlet

7. Advisecustomer

8. Cleanue,locatesourceandcorrect

9. Unblockinletairopenings

DRIP FROM

RELIEF VALVE

1. Pressurebuild-up

2. Heaterstacking

3. Closedwatersystem

4. Improperlyseatedvalve

1. Use a pressure-reducing valve and

reliefvalve

2. Lowerthethermostatsetting

3. Seethermalexpansionsection

4. CheckReliefvalveforproperoperation

(DoNotplugT&Pvalve)

GASCONTROLVALVE/

THERMOSTAT FAILS TO

SHUT OFF

1. Defectivegascontrolvalve/thermostat 1. Replacegascontrolvalve/thermostat

SMELLY WATER

1. Suldesinwatersupply

2. Bacteriainwatersupply

3. Incompatibleanode

1. Chlorinationprocedure

2. Chlorinationprocedure

3. Replace with anode appropriate for

waterconditions

TROUBLESHOOTING GUIDELINES

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

CONDENSATION

1. Fillingthenewwaterheaterfortherst

time

2. Moisturefromtheproductsofcombustion

3. Waterdrippingfromblowerassembly

4. Undersizedwaterheater

1. Normal operation: the condensation

shoulddisappearafterheaterwarmsup

2. Normal operation: the condensation

shoulddisappearintime

3. Installcondensatehosetodrainporton

therubbercoupling

4. Installadequateheater

COMBUSTION ODORS

1. Airinletsblocked

2. Insu󰀩cientair

3. Flueclogged

4. Heaterinstalledinaconnedarea

5. Housetootight

1. Unblockinletairopenings

2. Providefreshairventilationtothewater

heater

3. Clean,locatesourceandcorrect

4. Providefreshairventilationtothewater

heater

5. Providefreshairventilationtothewater

heater

SMOKINGANDCARBON

FORMATION

1. Airinletsblocked

2. Insu󰀩cientair

3. Lowgaspressure

4. Oricetoolarge

5. Flueclogged

6. Defectivegascontrolvalve/thermostat

7. Heaterinstalledinaconnedarea

1. Unblockinletairopenings

2. Provideventilationtowaterheater.

Checkueway,ueba󰀪eandburner

3. Checkwithgasutilitycompany

4. Replacewithcorrectorice(seerating

plate)

5. Clean,locatesourceandcorrect

6. Replacegascontrolvalve/thermostat

7. Providefreshairventilation

UNABLE TO LIGHT

THE BURNER

1. Airingasline

2. Pressureswitch

3. Blockedexhaust

4. Wireconnection

5. Defectivegascontrolvalve/thermostat

1. Purgetheairfromgasline

2. Checkthepressureswitch,makesure

thepressureswitchhoseisnotkinked

3. Checkventpipeforblockage

4. Checkwireconnections

5. Replacethegascontrolvalve/

thermostat

SIZZLING,RUMBLING

NOISE

1. Scaleandsediment

2. Condensationdrippingonburner

1. Drain/ush-provide water treatment if

needed

2. Referto“Condensate”section

WATERLEAKAGE

1. Condensation

2. DrippingTemperature&PressureRelief

Valve

3. Drainvalvedripping/leaking

4. TankLeak

1. Referto“Condensate”section

2. Referto“Temperature&PressureRelief

Valve”section

3. Back flush to clean- out sediment,

replaceifnecessary.

4. Check“LeakageCheckpoints”

BLOWER WILL

NOT START

1. Nopowertounit

2. Thermostatsettoolow

3. Defectiveairpressureswitch

4. Defectiveblower

5. Disconnectedorloosewire

6. Controllockedout

1. Pluginpowercord,checkfusesand/or

supplyvoltage

2. Turntemperatureknobtohighersetting

3. Replaceairpressureswitch

4. Replaceblower

5. Repairandreconnectwires

6. Referto“ResettingTheHeaterControl”

–determinecauseoflockout

  53

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BLOWER RUNS

CONTINUOUSLY

1. Airpressureswitchnotclosingdueto

insu󰀩cientdraft–checkfor:

 a. Ventpipingblocked

 b. Pipinglengthtoolong

 c. Clogged/dirtyblower

2. Disconnected,tornorblockedpressure

switchhosefromairpressureswitchto

blowerhousing

3. Defectivepressureswitch

4. Highlimitswitchopenduetoexcessive

venttemperatureordefectiveswitch

1. Determinecauseofinsu󰀩cient

draft.Checkdraftwithmanometerat

pressureswitch

 a. Removeblockage

 b. Reduce vent length/increase vent

size

 c. Cleanblowerwheel

2. Reconnectorreplacepressureswitch

hose

3. Replacedefectivepressureswitch

4. Determinecauseofoverheatingcheck

for:overring,insu󰀩cientairsupply,

highambientairtemperature

HOT SURFACE IGNITER

NOT GLOWING

FOLLOWINGWARM-UP

PERIOD

1. 120VAC polarity reversed at 120VAC

outletreceptacle

2. Defectivehotsurfaceigniter

3. Defectivegascontrolvalve/thermostat

1. Reverse polarity at 120VAC outlet

receptacle

2. Replaceigniter

3. Replacegascontrolvalve/thermostat

VENT PIPE TOO HOT

1. Blowerhighlimitswitchfailstoopen-

switchdefective

2. Notenoughdilutionairtomixwithue

gases

3. Airinroomtoohotformixingwithue

gases

4. Wrongburnerorice

1. ReplaceblowerhighlimitswitchReplace

blowerhighlimitswitch

2. Properaircirculationmustbeprovided

forcombustionanddilutionofuetemp

3. Increase ventilation to lower room

temperature

4. Installcorrectorice.

RESETTING THE HEATER CONTROL

• Softlockoutsasdiagnosedbythesystemerrorcodes

requirethegascontroltobereset.

• Toresetthecontrol,slidethe“ON/OFF”switchtothe

“OFF” position. Wait for 10 seconds and move the

switchbacktothe“ON”position.

• Iftheproblemthatcausedthecontroltolockouthas

notbeencorrected,thecontrolwillremainoragaingo

backintolockout.

LOCKOUTS

Soft Lockout

• occurswhenasystemsafetydevicetripstobreakthe

sequenceofoperation.Thecontrolwillretrythesystem

inatimedbasisbutwillnotreinstateoperationuntilthe

failureiscorrected.

Hard Lockout

• occurs when the main controller fails and must be

replaced.

Thegascontrolvalve\thermostatincludesatemperature

limitingECO(EnergyCutO󰀨)systemthatwillshuto󰀨the

waterheaterifthewatertemperatureistoohigh.

Shouldthewatertemperaturegettoohigh,thediagnostic

statuslightwillindicateacode(4ashes),indicatingan

over-temperatureconditionandthemainburnerwillbe

shuto󰀨.Ifahightemperatureconditionoccurs,turnthe

maingassupplyOFFandhavethewaterheaterrepaired

byaqualiedservicetechnician.Contactyourlocaldealer

forserviceinformation.

Note:Shouldanover-temperatureconditionoccur,restart

thewaterheaterandverifytheLEDashsequence.Ifthe

4ashsequenceisobserved,slidethe“ON/OFF”switchto

the“OFF”position.TurnMainGasSupply“OFF”.Replace

the gas control valve\thermostat. See “Removing and

ReplacingtheGasControlValve/Thermostat.”

IGNITION STATE AND TIMING

IGNITION STATE TIMING

Pre-purge

5seconds(NGmodels)

15seconds(LPmodels)

HotSurfaceIgniter

(HSI)Warmup

10seconds

IgnitionActivation

Period(IAP)

3.5secondsmaximum

FlameRecognition

Period(FRP)

0.5second

TrialForIgnition IAP+FRP

FlameStabilization

Period

NotApplicable

Inter-purge 30seconds

FlameFailure

ResponseTime

2secondsmax

(@1uAamecurrent)

Post-purge 30seconds

PressureSwitch(PS)

ProvePeriod

2minutes

PressureSwitch(PS)

FaultDelay(failed

open/closed)

2minutes

SoftLockout 20minutes

EnergyCutO󰀨

(ECO)LimitLockout

Indenite

FlammableVapor

(FV)SensorLockout

Indenite(see“ResettingThe

HeaterControl”)

SYSTEM STATUS AND ERROR CODES

Themicro-controllerinsidethegascontrolmonitorsthe

ammablevaporsafetyfeatures,theignitionsequence,

temperaturesettingsandoveralloperationoftheheater.

Ifanyoftheseparametersdoesnotoperateproperlythe

controllerwillshutdownthewaterheater,diagnosethe

failureandashanerrorcode.Thetablebelowliststhe

SystemStatusCodesfortheHoneywell/Resideocontrol.

Refer to it and to the “Trouble Shooting Guidelines” to

diagnosetheproblembeforeattemptingcorrectiveaction.

Seealso“FlammableVaporSensor”.

LED Flash Sequence Control Status

Shortash

onceeveryfour

seconds

IDLE(nocallforheat,

nofaultconditions)

“Heartbeat”,

alternatesbright/dim

CallForHeat

(nofaultconditions)

OneFlash,

threesecondpause

LowFlameSignal

(controlcontinuestooperate)

TwoFlash,

threesecondpause

PressureSwitchFailed

Closed

ThreeFlash,

threesecondpause

PressureSwitchFailedOpen

FourFlash,

threesecondpause

ECO(EnergyCutO󰀨)Limit

Lockout

thermostattemperaturelimit

wasexceeded.

FiveFlash,

threesecondpause

FlameOutOfSequence

Six-OneFlash,

threesecondpause

SoftLockout

-RetryLimit

-FailedTrialForIgnition

Six-TwoFlash,

threesecondpause

SoftLockout

-RecycleLimit

-PressureSwitch/HighLimit

opened

Six-ThreeFlash,

threesecondpause

SoftLockout

-RecycleLimit

-FlameLost

Six-FourFlash,three

secondpause

SoftLockout

-FlameoutofSequence

Sensed

SevenFlash,

threesecondpause

FlammableVaporSensor

(FVS)Lockout

Eight-OneFlash,

threesecondpause

FlammableVaporSensor

FVSFaultDetected

Eight-TwoFlash,

threesecondpause

TemperatureSensorFault

Detected

Eight-ThreeFlash,

threesecondpause

ElectronicsFaultDetected

Eight-FourFlash,

threesecondpause

ValveFaultDetected

HardwareFault

Lockout

Indenite

  55

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  57

Thispageintentionallyleftblank.Maybeusedfornotesortorecordotherinstallationinformation.

  59

Limited Warranty provided by Manufacturer.

AO Smith G6-PVS4040NV Signature 500 Short 40-Gallon 6-Year Warranty 40000-BTU Power Vent Natural Gas Water Heater

Product's Documents

Installation Manual

Specifications

AO Smith G6-PVS4040NV Questions and Answers