Rheem XG40T06PN36U1 Performance Tall 40 Gal 36,000 BTU User Manual

FOR YOUR SAFETY!

— Do not store or use gasoline or other

flammable vapors or liquids or other

combustible materials in the vicinity of this or

any other appliance. To do so may result in an

explosion or fire.

— WHAT TO DO IF YOU SMELL GAS

● Do not try to light any appliance.

● Do not touch any electrical switch; do not

use any phone in your building.

● Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

● If you cannot reach your gas supplier, call the

fire department.

● Do not return to your home until authorized

by the gas supplier or fire department.

— Improper installation, adjustment, alteration,

service or maintenance can cause property

damage, personal injury, or death. Refer to

this manual. Installation and service must be

performed by a qualified installer, service

agency or the gas supplier.

WARNING: If the information in these instructions is not followed exactly, a fire or

explosion may result causing property damage, personal injury or death.

The purpose of this manual is twofold: one, to provide the installer with the basic directions

and recommendations for the proper installation and adjustment of the water heater;

and two, for the owner–operator, to explain the features, operation, safety precautions,

maintenance and troubleshooting of the water heater. This manual also includes a parts list.

It is very important that all persons who are expected to install, operate or adjust this

water heater read the instructions carefully so they may understand how to perform

these operations. If you do not understand these instructions or any terms within it, seek

professional assistance.

Any questions regarding the operation, maintenance, service or warranty of this water

heater should be directed to the seller from whom it was purchased. If additional

information is required, refer to the section on “If you need service.”

Do not destroy this manual. Please read carefully and keep in a safe place for future

reference.

Recognize this symbol as an indication of Important Safety Information!

Water Heaters

WITH ELECTRONIC CONTROL

Compliant with South Coast Air Quality Management District Rule 1121 10 ng/J NOx Emissions

Residential Gas - Low NOx Emissions

DO NOT RETURN this water heater to the store or place of purchase.

If you need technical or installation assistance, please call the Technical Support

Lines at 1-866-279-4566.

FVIR Certified

Use & Care Manual

With Installation Instructions for the Installer

WARNING: This water heater is not suitable

for use in manufactured (mobile) homes!

AP21685

FOR YOUR RECORDS

Write the model and serial numbers here:

You can find them on a label on the appliance.

Staple sales slip or cancelled check here.

Proof of the original purchase date is needed to obtain service under

the warranty.

Inside you will find many helpful hints on how to use and maintain

your water heater properly. A little preventive care on your part can

save you time and money over the life of your water heater.

You’ll find many answers to common problems in the

Troubleshooting Guide. If you review the chart of Troubleshooting

Tips first, you may not need to call for service.

READ THIS MANUAL

Your safety and the safety of others are very important. There

are many important safety messages in this manual and on your

appliance. Always read and obey all safety messages.

This is the safety alert symbol. Recognize this symbol

as an indication of Important Safety Information!

This symbol alerts you to potential hazards that can

kill or hurt you and others.

All safety messages will follow the safety alert symbol and

either the word “DANGER”, “WARNING”, “CAUTION” or

“NOTICE”.

These words mean:

DANGER

An imminently hazardous situation

that will result in death or serious

injury.

WARNING

A potentially hazardous situation that

could result in death or serious injury

and/or damage to property.

CAUTION

A potentially hazardous situation that

may result in minor or moderate

injury.

NOTICE:

Attention is called to observe a

specified procedure or maintain

a specific condition.

READ THE SAFETY INFORMATION

Care and Cleaning

Draining ................ 28

Maintenance ............. 28

Vent System Inspection .... 29

Burner Inspection ........ 29

Extended Shut-Down ......30

Safety Information

Safety Precautions ....... 3–6

LP Gas Models ........... 5

Installation Instructions

Location ................. 7

Water Supply Connections .. 9

Gas Supply .............. 11

Venting ...............12-18

Wiring Diagram ...........19

Pipe Insulation ............20

Heat Traps ...............21

Installation Checklist .......22

Potable/Space Heating .... 23

Operating Instructions

Lighting Instructions ...... 24

Water Temperature .....25-26

Troubleshooting Tips

Before You Call

For Service ........... 31-32

Gas Valve Error Codes .....33

Customer Service

Parts List .................34

If You Need Service .......36

Be sure to read and understand the entire Use and Care Manual before attempting to install or

operate this water heater. It may save you time and money. Pay particular attention to the Safety

Instructions. Failure to follow these warnings could result in serious bodily injury or death. Should

you have problems understanding the instructions in this manual, or have any questions, STOP, and

get help from a qualified service technician, or the local gas utility.

IMPORTANT SAFETY INFORMATION

READ ALL INSTRUCTIONS BEFORE USING

Failure to install the blower assembly and properly vent the water heater to the

outdoors as outlined in the Venting Section of the Installation Instructions in this

manual can result in unsafe operation of the water heater. To avoid the risk of fire,

explosion, or asphyxiation from carbon monoxide, never operate this water heater

unless it is properly vented and has an adequate air supply for proper operation. Be

sure to inspect the vent system for proper installation at initial start-up; and at least

annually thereafter. Refer to the Care and Cleaning section of this manual for more

information regarding vent system inspection.

DANGER!

INSTALL THE BLOWER ASSEMBLY AND PROPERLY

VENT THE WATER HEATER

Gasoline, as well as other flammable materials and liquids (which include but are not

limited to adhesives, solvents, paint thinners etc.), and the vapors they produce are

extremely dangerous. DO NOT handle, use or store gasoline or other flammable or

combustible materials anywhere near or in the vicinity of a water heater or any other

appliance. Be sure to read and follow warning label pictured below and other labels on

the water heater, as well as the warnings printed in this manual. Failure to do so can

result in property damage, bodily injury or death.

WARNING!

FLAMMABLES

Flammable Vapors

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death.

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

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

W ARNING

NOTICE: This water heater is equipped with a flammable vapor sensor that will automatically

shut down the water heater in the presence of gasoline vapors and some other flammable vapors.

If the flammable vapor sensor shuts down the water heater, contact a qualified service technician.

Clear any hazardous materials and ventilate the area around the water heater. DO NOT turn

off the appliance or adjust the ON/OFF switch in any way. DO NOT tamper with the flammable

vapor sensor. DO NOT submerse the flammable vapor sensor in water. DO NOT allow the

flammable vapor sensor to come into contact with any substances such as bleach or cleaners. See

the “Gas Valve Error Code” Section of this manual for a list of error codes.

Time/Temperature Relationship in Scalds

Water Temperature Time To Produce a Serious Burn

120°F More than 5 minutes

125°F 1

/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1

/2 seconds

155°F About 1 second

Table courtesy of Shriners Burn Institute

The chart shown above may be used as a guide in

determining the proper water temperature for your home.

DANGER: Households with small children,

disabled, or elderly persons may require a

120°F or lower gas control (thermostat) setting to

prevent contact with “HOT” water.

Maximum water temperatures occur just after the burner

has shut off. To find water temperature being delivered,

turn on a hot water faucet and place a thermometer in the

water stream and read the thermometer. (See page 24 and

25 for more details.)

The temperature of the water in the heater can be

regulated by rotating the dial on the front of the gas

control (thermostat). To comply with safety regulations

the gas control (thermostat) was set at “HOT” position

before the water heater was shipped from the factory.

The “HOT” dial position corresponds to a water

temperature of approximately 120°F. DANGER:

Hotter water increases the potential for Hot Water

SCALDS. The illustration below details the approximate

water temperature for each mark on the Gas Control

(Thermostat) Temperature Dial.

D ANGER

HOT

Water temperature over 125°

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.

BURN

DANGER!

WATER TEMPERATURE SETTING

Safety and energy conservation are factors to be considered when selecting the water

temperature setting of a water heater’s gas control. Water temperatures above 125°F

can cause severe burns or death from scalding. Be sure to read and follow the warnings

outlined on the label pictured below. This label is also located on the water heater.

NOTICE: Mixing valves are recommended for reducing

point of use water temperature by mixing hot and

cold water in branch water lines. It is recommended

that a mixing valve complying with the Standard for

Temperature Actuated Mixing Valves for Hot Water

Distribution Systems, ASSE 1017 be installed. See pages

22 & 24 for more details and contact a licensed plumber

or the local plumbing authority for further information.

IMPORTANT SAFETY INFORMATION

READ ALL INSTRUCTIONS BEFORE USING

Valve Set

Point

Estimated

Temperature

Burns on Adult Skin

LOW

90°F ------------------------

●

98°F ------------------------

●

105°F ------------------------

●

113°F ------------------------

HOT

120°F More than 5 minutes

130°F About 30 seconds

140°F Less than 5 seconds

150°F About 1-1/2 seconds

VERY HOT

160°F About 1/2 second

DANGER: Hotter water

increases the potential for

Hot Water SCALDS.

LP and Natural gas have an odorant added to aid in detecting a gas leak. Some people

may not physically be able to smell or recognize this odorant. If you are unsure or

unfamiliar with the smell of LP or natural gas, ask the gas supplier. Other conditions,

such as “odorant fade”, which causes the odorant to diminish in intensity, can also hide or

camouflage a gas leak.

DANGER!

LIQUEFIED PETROLEUM (LP PROPANE OR BUTANE)

AND NATURAL GAS MODELS

● Water heaters utilizing LP gas are

different from natural gas models. A

natural gas water heater will not function

safely on LP gas and vice versa.

● No attempt should ever be made to

convert the water heater from natural

gas to LP gas. To avoid possible

equipment damage, personal injury or

fire, DO NOT connect the water heater

to a fuel type not in accordance with the

unit data plate. LP for LP units. Natural

gas for natural gas units. These units are

not certified for any other fuel type.

● LP appliances should not be installed

below grade (for example, in a basement)

if such installation is prohibited by

federal, state and/or local laws, rules,

regulations or customs.

● LP gas must be used with great caution.

It is heavier than air and will collect first

in lower areas making it hard to detect at

nose level.

● Before attempting to light the water

heater, make sure to look and smell for

gas leaks. Use a soapy solution to check

all gas fittings and connections. Bubbling

at a connection indicates a leak that must

be corrected. When smelling to detect a

gas leak, be sure to sniff near the floor

also.

● Gas detectors are recommended in LP

& natural gas applications and their

installation should be in accordance

with the detector manufacturer’s

recommendations and/or local laws,

rules, regulations or customs.

● It is recommended that more than one

method, such as soapy solution, gas

detectors, etc., be used to detect leaks in

gas applications.

DANGER: If a gas leak is present or

suspected:

● DO NOT attempt to find the cause

yourself.

● DO NOT try to light any appliance.

● DO NOT touch any electrical switch.

● DO NOT use any phone in your building.

● Leave the house immediately and make

sure your family and pets leave also.

● Leave the doors open for ventilation

and contact the gas supplier, a qualified

service agency or the fire department.

● Stay away from the house (or building)

until the service call has been made, the

leak is corrected and a qualified agency

has determined the area to be safe.

IMPORTANT SAFETY INFORMATION

READ ALL INSTRUCTIONS BEFORE USING

WARNING!

For your safety, the information in this manual must be followed to minimize the risk of fire

or explosion, electric shock, or to prevent property damage, personal injury, or loss of life.

FOR INSTALLATIONS IN THE STATE OF CALIFORNIA

California Law requires that residential water heaters must be braced, anchored or

strapped to resist falling or horizontal displacement due to earthquake motions. For

residential water heaters up to 52-gallon capacity, a brochure with generic earthquake

bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street,

Suite 5100, Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater

dealer.

However, applicable local codes shall govern installation. For residential water heaters of

a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable

bracing procedures.

Have the installer show you the location of the gas shut-off valve and how to shut it off

if necessary. Turn off the manual shut-off valve if the water heater has been subjected to

overheating, fire, flood, physical damage or if the gas supply fails to shut off.

● Read this manual entirely before installing

or operating the water heater.

● Use this appliance only for its intended

purpose as described in this Use and Care

Manual.

● Be sure your appliance is properly installed

in accordance with local codes and the

provided installation instructions.

● DO NOT attempt to repair or replace

any part of your water heater unless it is

specifically recommended in this manual.

All other servicing should be referred to a

qualified technician.

SAFETY PRECAUTIONS

READ AND FOLLOW THIS SAFETY INFORMATION

CAREFULLY.

SAVE THESE INSTRUCTIONS

Combustion Air Inlet

Openings

Installing the water heater

This water heater must be installed in accordance with these instructions, local codes, utility company

requirements, and/or in the absence of local codes, use the latest edition of the American National

Standard/National Fuel Gas Code. A copy can be purchased from either the American Gas Association,

400 N. Capitol Street NW, Washington, DC 20001 as ANSI standard Z223.1 or National Fire Protection

Association, 1 Batterymarch Park, Quincy, MA 02269 as booklet NFPA 54.

Location

The water heater should not be located

in an area where leakage from the tank

or connections will result in damage

to the area adjacent to the heater or to

lower floors of the structure.

When such areas cannot be avoided it is

recommended that a suitable catch pan,

adequately drained, must be installed

under the water heater.

The pan must not restrict air flow to the

combustion air inlet openings (perforation

openings) located around the lower

perimeter of the water heater.

Catch pan kits are available from the store

where the water heater was purchased, or

any water heater distributor.

Make certain the floor underneath the

water heater is strong enough to

sufficiently support the weight of the water

heater once it is filled with water.

A gas fired water heater or any other

appliance should not be installed in a space

where liquids which give off flammable

vapors are to be used or stored. Such

liquids include gasoline, LP gas (butane

or propane), paint or adhesives and their

thinners, solvents or removers.

When installed in a closet, DO NOT block

or obstruct any of the combustion air inlet

openings located around the perimeter

of the water heater. A minimum of 1” is

required between these combustion air inlet

openings and any obstruction.

Because of natural air movement in a room

or other enclosed space, flammable vapors

can be carried some distance from where

liquids which give off flammable vapors

are to be used or stored. The open flame

of the water heater’s pilot or main burner

can ignite these vapors and create a shut

down condition of the water heater which

will not allow the water heater to ignite

until examined by a Qualified Service

Technician.

DO NOT obstruct or block the flammable

vapor sensor.

Rheem Water Heating FVIR certified

gas water heaters can be installed on a

residential garage floor without the use of

an 18-inch stand in accordance with the

National Fuel Gas Code, NFPA 54, ANSI

Z223.1 2006, unless otherwise directed by

State and Local code requirements. The

water heater must be located so it is not

subject to physical damage, for example,

by moving vehicles, area flooding, etc

● The water heater should be installed

so as to minimize the length of plastic

vent pipe and the number of vent

connection fittings required. (Refer to

the “INSTALLATION” Section of this

manual.)

● Long hot water lines should be insulated

to conserve water and energy.

● The water heater and water lines should

be protected from exposure to freezing

temperatures.

● DO NOT install the water heater in

bathrooms, bedrooms, any occupied

rooms normally kept closed, or in

unprotected outdoor areas.

● Minimum clearance from combustible

construction:

If the clearances stated on the

Instruction/Warning Label, located on

the front of the heater differ, install the

water heater according to the clearances

stated on the label.

● If the water heater is installed in an

alcove or closet, the entire floor must

be covered by a wood or metal panel.

A minimum of 24” clearance from the

front and top should be available for

adequate inspection and servicing.

● The water heater may be installed on

combustible floors, but not directly on

carpeting. If the water heater must be

installed on carpeting, place a metal or

wood panel beneath the water heater,

extending beyond its full width and

depth at least 3” in all directions.

The auxiliary catch pan installation

MUST conform to local codes.

Diameter of

water heater

plus 2” min.

Max.

2”

WARNING: Combustible

construction refers to adjacent

walls and ceilings and should

not be confused with

combustible or flammable

products and materials.

Combustible and/or flammable

products and materials should

never be stored in the vicinity

of this or any gas appliance.

Location Front Sides Rear Top

Alcove

3”

(7.6 cm)

0”

(0 cm)

0”

(0 cm)

12”

(30.5 cm)

Closet

3”

(7.6 cm)

1”

(2.5 cm)

0”

(0 cm)

12”

(30.5 cm)

Installing the water heater

Combustion and Ventilation Air

Ventilation (ambient) air temperature

must be 100°F or less. Proper operation

of the water heater requires air for

combustion and ventilation. Provisions

for combustion and ventilation air

must comply with referenced codes and

standards.

DO NOT block or obstruct any of the

combustion air inlet openings located

around the perimeter of the water

heater. A minimum of 1” is required

between these combustion air inlet

openings and any obstruction.

NOTICE: If the water heater is

installed in an unconfined space within a

building of conventional frame, masonry

or metal construction, infiltration

air is normally adequate for proper

combustion and ventilation. If the

water heater is installed in a confined

space, provisions for combustion and

ventilation air must be made.

DO NOT obstruct or block the Flammable

Vapor Sensor.

A confined space is one having a volume

of less than 50 cubic feet per 1000 Btuh

of the aggregate input of all appliances

within that space.

The air must be supplied through two

permanent openings of equal area. One is

to be located within 12” above the floor

and the other is to be located within 12”

from the ceiling.

The minimum net free area of each opening

must not be less than one square inch

per 1000 Btuh of the total input rating

of all the appliances in the enclosure

(but not less than 100 square inches), if

each opening communicates with other

unconfined areas inside the building.

Buildings of unusually tight construction

shall have the combustion and ventilation

air supplied from outdoors, or a freely

ventilated attic or crawl space.

If air is supplied from outdoors, directly or

through vertical ducts, there must be two

openings located as specified above and

each must have a minimum net free area

of not less than one square inch per 4000

Btuh of the total input rating of all the

appliances in the enclosure.

If horizontal ducts are used to

communicate with the outdoors, each

opening must have a minimum net free

area of not less than one square inch per

2000 Btuh of the total input rating of all

the appliances in the enclosure. If ducts

are used, the minimum dimensions of

rectangular air ducts shall not be less than

3”.

NOTICE: If the duct openings which

supply combustion and ventilation air

are to be covered with a protective

screen or grill, the net free area

(openings in the material) of the

covering material must be used in

determining the size of the openings.

Protective screening for the openings

MUST NOT be smaller than 1/4”mesh

to prevent clogging by lint or other

debris.

Corrosive Atmospheres

The air in beauty shops, dry cleaning

establishments, photo processing

labs, and storage areas for liquid and

powdered bleaches or swimming pool

chemicals often contain such halogenated

hydrocarbons.

An air supply containing halogenated

hydrocarbons may be safe to breathe,

but when it passes through a gas flame

corrosive elements are released that

will shorten the life of any gas burning

appliance.

Propellants from common spray cans

or gas leaks from A/C and refrigeration

equipment are highly corrosive after

passing through a flame.

The water heater warranty is voided when

failure of the heater is due to operation in

a corrosive atmosphere.

NOTICE: The water heater

should not be installed near

an air supply containing

halogenated hydrocarbons.

Inspect Shipment

Inspect the water heater for possible

damage. Check the markings on the rating

plate of the water heater to be certain the

type of gas supplied corresponds to the

water heater requirements.

NOTICE: DO NOT install

the water heater in attics

where the temperature may

exceed 100°F. This water

heater is equipped with a

temperature sensing device

that will shut off the water

heater if the maximum

allowable vent pipe

temperature is exceeded.

Thermal Expansion

Determine if a check valve exists in the inlet water

line. Check with your local water utility company.

It may have been installed in the cold water line as

a separate back flow preventer, or it may be part

of a pressure reducing valve, water meter or water

softener. A check valve located in the cold water

inlet line can cause what is referred to as a “closed

water system”. A cold water inlet line with no

check valve or back flow prevention device is

referred to as an “open” water system.

As water is heated, it expands in volume and

creates an increase in the pressure within the water

system. This action is referred to as “thermal

expansion”. In an “open” water system,

expanding water which exceeds the capacity of the

water heater flows back into the city main where

the pressure is easily dissipated.

A "closed water system”, however, prevents the

expanding water from flowing back into the main

supply line, and the result of “thermal expansion”

can create a rapid and dangerous pressure increase

in the water heater and system piping. This rapid

pressure increase can quickly reach the safety

setting of the relief valve, causing it to operate

during each heating cycle. Thermal expansion,

and the resulting rapid, and repeated expansion

and contraction of components in the water heater

and piping system can cause premature failure

of the relief valve, and possibly the heater itself.

Replacing the relief valve will not correct the

problem!

The suggested method of controlling thermal

expansion is to install an expansion tank in the

cold water line between the water heater and

the check valve (see illustration below). The

expansion tank is designed with an air cushion

built in that compresses as the system pressure

increases, thereby relieving the over pressure

condition and eliminating the repeated operation

of the relief valve. Other methods of controlling

thermal expansion are also available. Contact your

installing contractor, water supplier or plumbing

inspector for additional information regarding this

subject.

Refer to the following illustration for suggested

typical installation. The installation of unions

or flexible connectors is recommended on the

hot and cold water connections so that the water

heater may be easily disconnected for servicing if

necessary. If flexible water connections are used,

the must comply with the standard for flexible

Water Connectors, ASME A112.18.6/CSA-B125.6.

The HOT and COLD water connections are clearly

marked on the water heater. Install a shutoff valve

in the cold water line near the water heater. Refer

to the following illustration for suggested typical

installation.

Water Supply Connections

IMPORTANT: DO

NOT apply heat to

the HOT or COLD

water connections. If

sweat connections are

used, sweat tubing to

adapter before fitting

adapter to the cold

water connections

on heater. Any heat

applied to the cold

water supply fittings

will permanently

damage the dip tube

and heat traps.

NOTICE: The

National Fuel Gas

Code (NFGC)

mandates a manual

gas shut-off valve:

See (NFGC)

for complete

instructions.

Local codes or

plumbing authority

requirements

may vary from

the instructions

or diagrams

provided and take

precedent over these

instructions.

Typical Installation

Jacket door

Heat trap 6” minimum

To gas supply

Cap

Ground joint union

Drain Pan Pipe

to suitable drain.

To cold water supply

6” Air gap

Blower assembly

1/4” per foot maximum slope up or

down for horizontal venting.

Auxiliary catch pan

Union

Vent connector

Sediment trap

Thermostatic gas valve

Manual gas shut-off

Temperature and

pressure relief valve

Shut-off valve

Shut-off

valve

Thermal expansion tank (if required)

Combustion Air Inlet Openings

Hot water outlet to fixtures

Water Heater Jacket

Relief valve discharge line to

suitable open drain.

Flammable Vapor Sensor

(Not visible in this view.)

Union

Installing the water heater

A new combination temperature and pressure relief valve, complying with the Standard for Relief Valves

and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22, is supplied and must

remain in the opening provided and marked for the purpose on the water heater. No valve of any type

should be installed between the relief valve and the tank. Local codes shall govern the installation of relief

valves.

Relief Valve

The pressure rating of the relief valve

must not exceed 150 PSI, the maximum

working pressure of the water heater as

marked on the rating plate.

The Btuh rating of the relief valve must

equal or exceed the Btuh input of the

water heater as marked on its rating plate.

Position the outlet of the relief valve

above a suitable open drain to eliminate

potential water damage. Piping used

should be of a type approved for hot water

distribution.

The discharge line must be no smaller

than the outlet of the valve and must

pitch downward from the valve to allow

complete drainage (by gravity) of the

relief valve and discharge line.

The end of the discharge line should not

be threaded or concealed and should be

protected from freezing. No valve of

any type, restriction, or reducer coupling

should be installed in the discharge line.

To Fill the Water Heater

Make certain that the drain valve is closed,

then open the shut-off valve in the cold

water supply line.

Open each hot water faucet slowly to allow

the air to vent from the water heater and

piping.

A steady flow of water from the hot water

faucet(s) indicates a full water heater.

DO NOT allow the flammable vapor

sensor to become submerged in water.

WARNING: The tank

must be full of water before

heater is turned on. The

water heater warranty does

not cover damage or failure

resulting from operation

with an empty or partially

empty tank.

Condensation

Condensation can form on the tank when

it is first filled with water. Condensation

might also occur with a heavy water

draw and very cold inlet water

temperatures.

Drops of water falling on the burner can

produce a sizzling or pinging sound.

This condition is not unusual, and will

disappear after the water becomes heated.

If, however, the condensation continues,

examine the piping and fittings for possible

leaks.

WARNING: DO NOT attempt to convert this water heater for use with a different type of gas other than

the type shown on the rating plate. Such conversion could result in hazardous operating conditions.

Leak Testing

The water heater and its gas connections

must be leak tested at normal operating

pressures before it is placed in operation.

Turn on the manual gas shut-off

valve near the water heater.

Use a soapy water solution to test for

leaks at all connections and fittings.

Bubbles indicate a gas leak that must

be corrected.

The factory connections to the gas

control (thermostat) should also be leak

tested after the water heater is placed in

operation.

Pressure Testing the Gas Supply System

The water heater and its manual gas

shut-off valve must be disconnected from

the gas supply piping system during

any pressure testing of that system at

pressures in excess of 3/8 psi (10.5” w.c.)

for natural gas.

The water heater must be isolated from

the gas piping system by closing the

manual gas shut-off valve during any

pressure testing of the gas supply piping

at pressures equal to or less than

3/8 psi (10.5” w.c.) for natural gas

Gas Supply

The branch gas supply line to the water

heater should be clean 1/2” black steel

pipe or other approved gas piping

material.

A ground joint union or ANSI design

certified semi-rigid or flexible gas

appliance connector should be installed

in the gas line close to the water heater.

The National Fuel Gas Code (NFGC)

mandates a manual gas shut-off valve: See

(NFGC) for complete instructions.

If flexible connectors are used, the

maximum length shall not exceed 36”

and must meet the requirements in ANSI

Z21.24-Connectors for Gas Appliances.

If lever type gas shut-offs are used, they

shall be T-Handle type.

Compound used on the threaded joints of

the gas piping must be of the type resistant

to the action of LP gas. Use compound

sparingly on male threads only.

Where a sediment trap is not incorporated

as part of the appliance, a sediment trap

shall be installed downstream of the

equipment shutoff valve as close to the

inlet of the appliance as practical at the

time of the appliance installation. The

sediment trap shall be either a tee fitting

with a capped nipple in the bottom outlet

or other device recognized as an effective

sediment trap.

DO NOT use excessive force (over 31.5 ft

lbs.) in tightening the pipe joint at the gas

control (thermostat) inlet, particularly if

teflon pipe compound is used, as the valve

body may be damaged.

The inlet gas pressure to the water heater

must not exceed 10.5” w.c. for natural

gas. For purposes of input adjustment, the

minimum inlet gas pressure (with main

burner on) is shown on the water heater

rating plate. If high or low gas pressures

are present, contact your gas supplier for

correction.

WARNING:

Never use an open

flame to test for gas

leaks, as property

damage, personal

injury, or death

could result.

WARNING: Failure

to install a water

heater suitable for the

altitude at the location

it is intended to serve,

can result in improper

operation of the

appliance resulting in

property damage and/

or producing carbon

monoxide gas, which

could result in personal

injury, or death.

High Altitude

This water heater is suitable and certified

for use at high altitude. Refer to the

altitude label on the water heater for

maximum allowable installation altitude.

Refer to "Vent Lengths" and "Vent

Restrictor Installation" sections of this

manual for important information about

venting in high altitude locations.

WARNING: Installations above the

rated altitude as specified on the

altitude label are not authorized and

may result in improper and inefficient

operation of the appliance, producing

carbon monoxide gas in excess of

acceptable limits, which could result in

serious injury or death.

Installing the water heater

Blower Assembly Installation

(if not factory installed)

Connect blower assembly with the electrical connector. Attach

Blower Assembly to top pan using the six (6) screws provided

(See diagram to the left). Install rubber coupling (supplied in

the box with water heater) on blower housing and secure it.

NOTICE: The Blower Assembly is model specific and only

the blower assembly supplied should be used on this water

heater.

Blower

Assembly

Rubber

Coupling

Flue Bafe

Ambient Installation Temperatures and Vent System Material Specications

Up to 100°F (38°C) 100°F (38°C) to 125°F (52°C)

0 to Max. ft.

Equivalent Vent

System Length

0 to Max. ft.

Equivalent Vent

System Length

0 to Max. ft.

Equivalent Vent

System Length

PVC, CPVC, or ABS CPVC, or ABS CPVC, or ABS

Venting

DANGER: Failure to

install the blower assembly

if shipped detached from

the water heater and

properly vent the water

heater to the outdoors as

outlined in the Venting

section of this manual will

result in unsafe operation of

the water heater causing

bodily injury, explosion,

fire or death.

To avoid the risk of fire,

explosion, or asphyxiation

from carbon monoxide,

NEVER operate the water

heater unless it is properly

vented and has adequate air

supply for proper operation

as outlined in the Venting

section of this manual.

The vent pipe must overlap

a minimum of ½ in. on each

connection. It is important

that the vent pipe engages

fully into any pipe fitting

and be kept in that position

until the adhesive has fully

cured. DO NOT drill or

punch holes in the plastic

pipe or fittings.

NOTICE: This unit is

equipped with a Flammable

Vapor Sensor. DO NOT

apply power until enough

time has passed to allow the

vapors from the primer and

cement to dissipate.

This water heater is a Category III

appliance.

For proper installation of the vent system,

follow the instructions as detailed in this

manual. DO NOT connect this water heater

to an existing vent or chimney. Common

venting is NOT permitted. It must be vented

separately from all other appliances.

Multi-story venting is permitted in

accordance with the National Fuel Gas

Code, ANSI Z223.1/NFPA 54, and/or the

Natural Gas and Propane Installation Code,

CSA B149.1, (current editions).

IMPORTANT: Multi-story and common

venting is NOT permitted for direct vent

water heaters, water heaters for installation

in manufactured homes (mobile homes),

water heaters for installation in recreational

vehicles, or water heaters for outdoor

installation.

NOTICE: This water heater is approved

to use the following materials for pipe of

the vent system:

PVC (DWV, ASTM-D2665 or

CSA B181.2)

PVC (Schedule 40, ASTM-D1785 or CSA

B137.3)

PVC (SDR Series, ASTM-D2241 or CSA

B137.3)

CPVC (CPVC 4120, ASTM-D2846 or CSA

B137.6)

CPVC (Schedule 40, ASTM-F441 or CSA

B137.3)

CPVC (SDR Series, ASTM-F442)

ABS (Schedule 40, DWV, ASTM-D2661 or

CSA B181.1)

This water heater is approved to use the

following materials for the fittings of the

vent system:

PVC (Schedule 40 DWV, ASTM D2665)

CPVC (Schedule 40, ASTM F438)

ABS (Schedule 40 DWV, ASTM D2661)

DO NOT mix ABS pipe and fittings with

PVC or CPVC pipe fittings. Note: It is

acceptable to interchange PVC and CPVC

pipe and fittings.

Use of PVC cellular core (ASTM-F891),

ABS Schedule 40, DWV cellular

core (ASTM – F628), or Radel®

(polyphenolsulfone) in

non-metallic venting systems is prohibited.

The vent system must be adequately

supported along both vertical and horizontal

lengths.

The vent system of this water heater may

be installed horizontally through a wall or

vertically through the roof.

Maximum unsupported length is

recommended to be no more than 4 feet

(1.22 m).

It is imperative that the first hanger

be located on the horizontal length

immediately adjacent to the first 90-degree

elbow from the vertical rise of vent pipe

connected to the water heater.

The support method used should isolate

the vent pipes from floor joists or other

structural members to help prevent the

transmission of noise and vibration.

DO NOT support, pin or otherwise

secure the vent 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 vent,

water heater, a thorough inspection of the

existing vent system must be performed

prior to any installation work.

Verify that the correct materials as

specified in this manual have been

used, and that the minimum or

maximum vent lengths and terminal

location as detailed in this manual

have been met.

Carefully inspect the entire vent

system for any signs of cracks or

fractures, particularly at the joints

between elbows or other fittings and

the straight length of vent pipe.

Check the vent for signs of sagging or

other stresses in the joints as a result

of misalignment of any components in

the systems.

If any of the conditions above are

found, they must be corrected in

accordance with the instructions in

this manual before completing the

installation and putting the water

heater into service.

Additional installation information for

The Commonwealth of Massachusetts is

located on the back page of this manual.

NOTICE: This water

heater may be installed in

attics provided ambient

temperatures DO NOT

exceed 125°F (52°C) and

CPVC or ABS pipe and

fittings are used for the

entire vent system.

NOTICE: The vent piping

must be connected to the

blower assembly using

the rubber coupling and

supplied clamp. The vent

pipe connection at the

blower assembly must be

leak tested with soap and

water solution upon initial

startup. Repair any leaks

before allowing the water

heater to operate.

Maximum and Minimum Vent Lengths for Power Vent Models:

Read these instructions thoroughly and make

sure you understand all steps and procedures

before proceeding with the installation.

When using 2 in. (5.1 cm) di-

ameter pipe and ttings:

1. Connect the vent system piping to the

blower assembly using the already in-

stalled 2 in. (5.1 cm) diameter rubber

coupling and clamp. (See Figure 1).

2. Tighten the clamp between 30 to 40 in. lbs.

3. For the vent terminal, use the 2 in. (5.1

cm) diameter, Schedule 40, PVC, 45° el-

bow supplied with the water heater.

When using 3 in. (7.6 cm) di-

ameter pipe and ttings:

1. Install a straight length of 2 in. (5.1 cm) diameter

pipe to the rubber coupling on the blower as-

sembly, followed by a 2 in. (5.1 cm) to 3 in. (7.6

cm) diameter pipe increaser tting (See Figure 2).

2. Tighten the clamp between 30 to 40 in. lbs.

3. For the vent terminal, use a 3 in. (7.6 cm) diam-

eter, Schedule 40, PVC, 45° elbow (not supplied).

DO NOT use unequal diameters of pipe and ttings

for the vent systems except as dened previously.

IMPORTANT: Ensure that the coupling clamp is

tight before allowing the water heater to operate.

When using CPVC or ABS pipe and t-

tings, use 90° elbows of the corresponding

size and material for the vent terminal.

The minimum and maximum equivalent lengths

for the vent system are shown in Table 1.

• The vent termination is not included

in the equivalency calculations.

Short bend elbows are not recommended. Note

in the table above that they will greatly in-

crease the equivalent length of venting.

Elbow Examples

Short Bend 90° Elbow

(Not Recommended)

Standard Bend 90° Elbow

(OK to Use)

Long Bend 90° Elbow

(Preferred)

Elbow

Type

Equivalent Length of Straight

Pipe

2" Vent Pipe 3" Vent Pipe

Short Bend

90° Elbow

12 10

Standard or

Long Bend

90° Elbow

6 5

45° Elbow 3 2.5

A vent restrictor disc must be installed for

certain vent lengths. Use the table below to

determine the required length for restrictor

use. DO NOT install the restrictor in venting

that is longer that what is shown here. DO

NOT use a vent length shorter than the

minimum values shown. Restrictor discs (2”

and 3”) are supplied with this water heater,

and only one of these will be used depending

on the diameter pipe used in your system.

Review the previous sections for calculating

the total vent length in your system.

If a restrictor disc is required for your venting

and the installation altitude above sea level

is greater than 7,000 ft. (2134m) a special

restrictor kit will need to be ordered. Refer

to the “If You Need Service” section of this

manual to learn how to contact customer

service personnel and request this kit.

Installing the water heater

Vent Pipe

Mesh

Vent Restrictor (If Required)

Vent Terminal

Table 1

From Sea Level Through 7,000 ft. (2134 m) Above Sea Level

Vent System Diameter

Min. Allowed Equivalent

Vent Length

Max. Allowed Equivalent

Vent Length

Vent System

Termination

Inches Feet Meters Feet Meters

2 9* 2.7* 50 15.2 45° Elbow

3 8* 2.4* 100 30.5 45° Elbow

From 7,000 ft. (2134 m) to 10,000 ft. (3048 m) Above Sea Level

Vent System Diameter

Min. Allowed Equivalent

Vent Length

Max. Allowed Equivalent

Vent Length

Vent System

Termination

Inches Feet Meters Feet Meters

2 9* 2.7* 25 15.2 45° Elbow

3 8* 2.4* 50 30.5 45° Elbow

Vent Pipe Size

Vent Pipe Length in Feet

(ft) Requiring Restrictor

Installation

2" 9 to 12

3" 8 to 11

* For shorter vent lengths a vent restrictor disc must be installed. See “Vent Restrictor Installation”

section below for more information.

Vent Lengths

Vent Restrictor Installation

Additional Considerations

DO NOT install vent terminal under any patio or deck.

To help prevent moisture from freezing on walls and under

eaves, DO NOT locate vent terminal on the side of a build-

ing with prevailing winter winds.

When terminating the vent pipe through brick or masonry

surfaces, a rust-resistant sheet metal backing plate behind the

vent termination is recommended.(See illustration.)

DO NOT locate vent terminal too close to shrubbery, as flue

gasses may damage them.

Caulk all cracks, seams and joints within six (6) feet of vent

terminal.

All painted surfaces should be primed to lessen the chance of

physical damage. Painted surfaces will require maintenance.

Insulate vent pipe exposed to cold conditions (attics, crawl

spaces, etc.) with inflammable material to help prevent

moisture from accumulating in vent pipe.

DO NOT extend exposed vent pipe outside of building.

If soffit vent is too

close, block off and

install new vent at

another location

Inside

corner

Caulk

6’ caulk

zone or to edge of window

etc., starting within 6 ft.

Rising moisture will

collect under eaves

4’

6’ caulk zone

2’ sq. sheet metal plate on

brick or masonary surface is recommended.

6’

WARNING: Moisture in the flue gas will condense as it

leaves the vent terminal. In cold weather this condensate can

freeze on the exterior wall, under the eaves and on

surrounding objects. Some discoloration to the exterior of the

building is to be expected. However, improper location or

installation can result in severe damage to the structure or

exterior finish of the building

Horizontal Vent Terminal Location

The location of the vent terminal depends on the following

minimum clearances and considerations (see illustration):

Vent Terminal must be at least twelve (12) inches above

grade level and above normal snow levels.

Vent Terminal must be at least four (4) feet below, or four

(4) feet horizontally from any door, operable window, soffit,

under eave vent or gravity air inlet to the building or other

appliances, or from gas or electric meters. DO NOT locate

vent above walkways, doors, windows, air inlets, gas or

electric meters or other equipment.

Vent Terminal must be at least three (3) feet above any

forced air inlet located within ten (10) feet. Any fresh or

make-up air inlet such as for a dryer or furnace area is

considered to be a forced air inlet.

Vent Terminal must be at least eighteen (18) inches from an

inside corner formed by two exterior walls.

Soffit vents

18"

Electric

meter

Inside

corner

3' above

if within 10'

Fresh

air

intake

12" (Above grade/snow level)

window or vent

NOTICE: All pipe, fittings, solvent cement, primers and procedures must conform to American National

Standards Institute and American Society for Testing and Materials (ANSI/ASTM) standards.

2 ft. sq. sheet metal plate on brick or

masonry surface is recommended.

NOTICE: All pipe, fittings, solvent cement, primers and procedures must conform to American

National Standards Institute and American Society for Testing and Materials (ANSI/ASTM)

standards.

Vertical Vent Installation

Once the vent terminal location has been

determined, make a hole through the roof

and interior ceiling to accommodate the

vent pipe.

Complete the vent pipe installation to the

water heater's vent connector fitting on the

blower outlet.

Support vertical or horizontal lengths as

previously mentioned.

Install adequate flashing where the vent

pipe passes through the roof.

Determine the vent terminal height and cut

vent pipe accordingly. Refer to the above

section for proper vent terminal height.

Connect vent elbow onto vertical pipe

through roof.

Connect short piece of vent pipe

(approximately 3" long) to elbow, then

insert 1/2" mesh metal screen into terminal

elbow and join it to the short piece of vent

pipe.

Horizontal Vent Installation

Once the vent terminal location has been determined, make a hole

through the exterior wall to accommodate the vent pipe. Vent pipe

must exit exterior wall horizontally only.

Insert a small length of vent pipe through the wall and connect the

coupling as shown to the left.

Place the 1/2" mesh metal screen inside the terminal fitting

and connect it as shown to the vent pipe on the exterior of the

building.

Complete the rest of the vent pipe installation to the water heater's

vent connector fitting on the blower outlet.

If necessary support horizontal run as previously mentioned.

2' x 2' Sheet

Metal Shieldon

Brick or

Masonry Walls

Outside of

Building Wall

From

Water Heater

Vent Pipe

Pipe Coupling

Vent Terminal

with

" Mesh

Protective

Screen Inside

Vertical Vent Termination Location

The location of the vent terminal depends on the following

minimum clearances and considerations (see illustration):

Minimum twelve (12) inches above roof.

Minimum twelve (12) inches above anticipated snow level.

Maximum twenty-four (24) inches above roof level without

additional support for vent.

Four (4) feet from any gable, dormer or other roof structure

with building interior access (i.e., vent, window, etc.).

Ten (10) feet from any forced air inlet to the building. Any

fresh or make-up air inlet such as a dryer or furnace area is

considered to be a forced air inlet.

Short Piece of Vent Pipe

Min. 12" Above Roof

Min. 12" Above

Anticipated Snow

Level.

Max. 24" Above Roof

(Without Additional

Support)

Insert 1/2" Mesh Protective Screen

Inside Terminal Elbow

Vent Pipe

Through Roof

Elbow

Vent Terminal

Installing the water heater

All joints in the vent piping must be

properly sealed and the following

materials are recommended:

PVC materials should use ASTM D2564

grade cement.

CPVC materials should use ASTM F493

grade cement.

ABS materials should use ASTM D2235

grade cement.

Cleaner-Primer and Medium Body

Solvent Cement:

Cut pipe end square, remove jagged

edges and burrs. Chamfer end of pipe,

then clean fitting socket and pipe joint

area of all dirt, grease or moisture.

After checking pipe and socket for

proper fit, wipe socket and pipe with

cleaner-primer. Apply a liberal coat of

primer to inside surface of socket and

outside of pipe. DO NOT allow

primer to dry before applying cement.

Apply a thin coat of cement evenly in

the socket. Quickly apply a heavy coat

of cement to the pipe end and insert

pipe into fitting with a slight twisting

motion until it bottoms out.

NOTICE: Cement must be fluid; if not,

recoat.

Hold the pipe fitting for 30 seconds to

prevent the tapered socket from

pushing the pipe out of the fitting.

Wipe all excess cement from the joint

with a rag. Allow 15 minutes before

handling. Cure time will vary

according to fit, temperature and

humidity.

NOTICE: Stir the solvent cement

frequently while using. Use a natural

bristle brush or the dauber supplied

with the can. The proper brush size is

one inch.

NOTICE: This unit is equipped with

a Flammable Vapor Sensor. DO NOT

apply power until enough time has

passed to allow the vapors from the

primer and cement to dissipate.

Cementing Joints

WARNING: DANGER OF

FIRE OR BODILY INJURY -

Solvent cements and primers

are highly flammable. Provide

adequate ventilation and DO

NOT assemble near heat source

or open flame. DO NOT smoke.

Avoid skin or eye contact.

Observe all cautions and

warnings on material

containers.

CAUTION:

For proper installation:

DO NOT use solvent cement

that has become curdled, lumpy

or thickened.

DO NOT thin solvent cement.

Observe shelf precautions

printed on the containers.

For applications below 32°F

use only low temperature type

solvent cement.

Appropriate solvent and cleaner

must be used for the type of

vent pipe used (PVC, CPVC or

ABS).

NOTICE: All pipe, fittings, solvent cement, primers and procedures must conform to American National

Standards Institute and American Society for Testing and Materials (ANSI/ASTM) standards.

FIXED

CLOSED

ERAB

PERABLE

FIXED

CLOSED

V= Vent Terminal X = Air Supply Inlet Αrea Where Terminal Is Not Permitted

US Installations

A - Clearance above grade, veranda, porch,

deck or balcony

12 in. (30 cm)

B - Clearance to window or door that may be

opened

4 ft. (1.2 m) below or to side of opening; 1 ft (300 m) above

opening

C - Clearance to permanently closed window *

D -

ed above the terminal within a horizontal

distance of 2 feet (61 cm) from the center

line of the terminal

E -

F - Clearance to outside corner *

G - Clearance to inside corner *

H - Clearance to each side of centerline extend-

ed above meter/regulator assembly

I - Clearance to service regulator vent outlet *

J - Clearance to nonmechanical air supply inlet

to building or the combustion air inlet to any

other appliance

4 ft. (1.2 m) below or to side of opening; 1 ft (30 cm) above

opening

K - Clearance to a mechanical air supply inlet 3 ft. (91 cm) above if within 10 ft. (3 m) horizontally

L - Clearance above paved sidewalk or paved

driveway located on public property

M - Clearance under veranda, porch, deck, or

balcony

1 In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code

"Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's installation

instructions"

Installing the water heater

Wiring

If local codes permit, the water heater may

be connected to electric service with the

power cord provided (DO NOT use an

extension cord). A grounded receptacle is

required.

If local codes do not permit the use of

cord connections, a 120 V, 50/60 Hz

power supply, with suitable disconnecting

means, must be connected to the black and

white leads in the heater control enclosure.

A knock-out hole is provided to permit use

of conduit or metal-clad cable connectors.

The maximum current draw is

approximately 5.0 amps.

The water heater must be electrically

grounded in accordance with local

codes, or, in the absence of local codes,

in accordance with latest edition of the

National Electric Code ANSI/NFPA No.

70. Refer to the figures below for water

heater internal wiring.

NOTICE: It is not recommended that

this unit be installed on a GFCI circuit.

CAUTION! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and

dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Insulation Blankets

Insulation blankets, available to the general

public, for external use on gas water heaters

are not necessary. The purpose of an

insulation blanket is to reduce the standby

heat loss encountered with storage tank

heaters. This water heater meets or exceeds

the National Appliance Energy Conservation

Act standards with respect to insulation

and standby loss requirements making an

insulation blanket unnecessary.

The manufacturer’s warranty does not cover

any damage or defect caused by installation,

attachment or use of any type of energy

saving or other unapproved devices (other

than those authorized by the manufacturer)

into, onto or in conjunction with the water

heater. The use of unauthorized energy saving

devices may shorten the life of the water

heater and may endanger life and property.

The manufacturer disclaims any responsibility

for such loss or injury resulting from the use

of such unauthorized devices.

CAUTION: If local codes require the

application of an external insulation

blanket to this water heater, pay careful

attention to the following so as not to

restrict the proper function and operation

of the water heater:

● DO NOT cover the operating or warning

labels attached to the water heater or

attempt to relocate them on the exterior of

insulation blanket.

 DO NOT apply insulation to the top of the

water heater. This will interfere with the

safe operation of the blower assembly.

 DO NOT cover the burner access door,

jacket door, gas control (thermostat)/gas

valve or pressure and temperature relief

valve.

 DO NOT apply insulation to the bottom

of the water heater or the area where

the combustion air inlet openings and

Flammable Vapor Sensor are located. This

area must be unobstructed so as not to

restrict combustion air flow to the burner

or operation of the sensor.

 Inspect the insulation blanket frequently

making certain it has not sagged and

it is not restricting the air flow to the

combustion air inlet openings (perforation

holes) or the Flammable Vapor sensor

located around the lower perimeter of the

water heater jacket. This could result in an

unsafe operating condition.

WARNING: If

local codes require

external application

of insulation blanket

kits the

manufacturer’s

instructions included

with the kit must be

carefully followed.

For increased energy efficiency, some

water heaters have been supplied with two

24” sections of pipe insulation.

Please install the insulation, according

to the illustrations above, that best meets

your requirements.

Typical vertical piping arrangement

Typical horizontal piping arrangement

Hot and Cold Pipe Insulation Installation

For increased energy efficiency, this

water heater has been supplied with a

2 3/8” section of T&P insulation. Please

install the insulation as shown below.

T&P Insulation Installation

Slip the insulation cover over the T&P

Valve through the center hole and align

the hole in the side with the opening of

the T&P Valve.

Ensure the T&P Valve opening is not

obstructed by the insulation.

Typical Side Connect T & P Arrangement.

Typical Top Connect T & P Arrangement.

Installing the water heater

❑ DO check inlet gas pressure to ensure

that it is within the range specified on the

rating plate.

❑ DO provide adequate air for combustion

and ventilation as discussed in the Use and

Care Manual and the National Fuel Gas

Code.

❑ DO maintain proper clearances to

combustibles as specified on the rating

plate.

❑ DO allow enough time for joint cement

vapors to dissipate BEFORE applying

power to the water heater.

❑ DO ensure that the venting system

complies with the guidelines found in the

Use and Care Manual and National Fuel

Gas Code.

❑ DO contact a qualified service

technician if the main burner will not stay

lit. The burner chamber is designed to be

sealed utilizing a gasket and tamper resistant

screws.

DON’T

❑ DON’T block or restrict Combustion

Air Inlet Openings or the Flammable Vapor

Sensor located around the lower portion of

the water heater jacket.

❑ DON’T block or restrict the Blower

Assembly Dilution Air holes (see diagram

to the left).

❑ DON’T remove the Burner Access

Door unless absolutely necessary. This

should only be done by a qualified service

technician. A new burner access door gasket

must be installed on any burner access door

that has been removed.

❑ DON’T install this water heater where

standing water may occur. The base of the

water heater is meant to be mounted on a

dry surface.

❑ DON’T allow cleaners, solvents, or

other materials to come into contact with the

Flammable Vapor Sensor.

❑ DON’T operate the water heater if the

sight glass or burner access door grommet is

damaged or broken (see to the left).

During Installation of this water heater

Heat Traps

For increased energy efficiency, some

water heaters have been supplied with

factory installed 3/4” NPT heat traps in

the hot outlet line and cold water inlet

line.

These heat traps may require a minimum

of one (1) 90° 3/4” NPT elbow and may

require an additional 90° 3/4” NPT elbow

or a 3/4” coupling depending on your

installation needs. See Illustration of

nipples and heat traps on page 33.

Location of Dilution Air Holes

Sight Glass

Flammable

Vapor Sensor

Burner Access

Door Grommet

Installation Checklist

A. Water Heater Location

B. Water Supply

C. Gas Supply

D. Relief Valve

E. Venting

❑ Close to area of vent.

❑ Indoors and protected from freezing

temperatures.

❑ Proper clearance from combustible surfaces

observed and water heater not installed on

carpeted floor.

❑ Sufficient fresh air supply for proper

operation of water heater.

❑ Air supply free of corrosive elements and

flammable vapors.

❑ Provisions made to protect area from water

damage.

❑ Sufficient room to service heater.

❑ Combustible materials, such as clothing,

cleaning materials, rags, etc. clear of the

base of the heater.

❑ Clearances of 1” from combustion air

inlet openings observed

❑ Flammable vapor sensor is not blocked.

❑ Water heater completely filled with water.

❑ Air purged from water heater and piping.

❑ Water connections tight and free of leaks.

❑ Gas line equipped with shut-off valve, union

and sediment trap.

❑ Approved pipe joint compound used.

❑ Soap and water solution used to check all

connections and fittings for possible gas

leak.

❑ Gas Company inspected installation (if

required).

❑ Temperature and Pressure Relief Valve

properly installed and discharge line run to

open drain.

❑ Discharge line protected from freezing.

❑ Heater vented separately from all other appliances.

❑ Flue baffle properly hung in top of heater’s

flue.

❑ Blower assembly properly installed.

❑ Proper materials and techniques used in vent

assembly.

❑ Vent pipe properly secured to blower housing.

❑ Vent pipe supported at required intervals.

❑ Appropriate minimum clearances observed.

❑ Precautions taken to prevent moisture damage

around vent termination.

❑ Vapors from vent pipe cement and primer have

dissipated prior to applying electrical power.

F. Wiring

❑ Correct power supply (120 V).

❑ Electrical connections tight.

❑ Heater properly grounded and proper polarity

observed.

Tee fitting for vertical hot

water supply lines.

Hot water

supply to

house

From HOT

outlet on

water heater

Hot water

supply to

heating

unit

Supplemental instructions for gas water heaters installed

in potable water/space heating applications

Local codes or plumbing authority requirements may vary from the instructions or diagrams provided in

this manual and take precedent over these instructions.

Tee fitting for horizontal hot

water supply lines.

From HOT

outlet on

water heater

Hot water

supply to

house

Hot water supply

to heating unit

Combination Potable Water and Space Heating Application

Tee fitting must be installed as shown.

This ensures that any air in the water lines

will be purged through the domestic water

faucets and showers.

DANGER: When this system

requires water for space heating at

elevated temperatures (above 125°F

[52°C.]), a mixing valve complying with

the Standard for Temperature Actuated

Mixing Valves for Hot Water

Distribution Systems, ASSE 1017 must

be installed in the hot water supply line

to the house in order to reduce the scald

hazard potential.

DANGER: Any piping or components

used in the installation of this water

heater in a combination potable and

space heating application must be

suitable for use with drinking water.

NOTICE: Suitable for (potable) water

heating and space heating applications.

DO NOT use for space heating

application only.

DANGER: If this water heater is

installed in an application intended to

supply domestic hot water needs and

hot water for space heating purposes,

DO NOT connect the heater to an

existing heating unit or components of a

heating system that have previously

been used with a non drinking water

system. Toxic chemicals such as those

used for boiler treatment may be

present and will contaminate the

drinking water supply causing possible

health risks. Never introduce toxic

chemicals, such as those used for boiler

treatment, into this system.

NOTICE: 50' - 0" maximum

distance from water heater to fan

coil (developed length) is required

for Massachusetts State.

Typical Piping Diagram for Combination Potable/Space Heating Installation

Spring loaded check valve in heating unit

hot water supply line and cold water return

line (not supplied with water heater)

NOTICE: This check valve is incorporated

in some heating units. Refer to the

installation instructions supplied with

specific heating unit to determine if it is

required.

All water piping shall be insulated in

accordance with Local and State Energy

Code.

Isolation valve in

cold water return line

from heating unit (not

supplied with water

heater)

Nominal 3/4" size mixing or tempering valve

(refer to warning above). Follow mixing or

tempering valve manufacturer’s instructions for

installation of the valve.

Temperature and pressure relief

valve discharge line

Air Handler

Drain valve

(not supplied with

water heater)

Hot water

to space heater

Temperature and Pressure Relief

Valve, tie to location approved by

local code

See diagrams above for proper

pipe application for vertical

or horizontal supply lines.

Isolation valve in hot water supply line

to heating unit (not supplied with water

heater)

3/4" cold water supply

3/4" Tempered

domestic hot water

supply to house.

Gas line to water heater

6” Air Gap

Combustion Air Inlet

Openings

2 Gallon Thermal

Expansion Tank (if

required-not supplied

with water heater)

Air vent

Heat Trap

6” Min.

3/4" Shut-Off Valve (Typ.)

3/4" Check Valve with 1/8" Hole

Pressure Gauge

3/4" Shut-Off Valve

(Typ.)

3/4" Shut-

Off Valve

(Typ.)

Hot water coil

All bronze pump.

Check valve

internal in pump.

Air bleed valve.

Water Sample Tap.

FAN

OFF

HEAT

COOL

To HVAC Unit.

Electronically controlled pump timer.

Activates every 6 hours for 60 seconds.

Wire to bronze pump.

3/4" HWS & HWR

to Heating Coil.

Minimum of 2'-0" developed length

of 3/4" pipe.

Water Heater drain pan

installed in accordance

with the Local and

State Code

Water Heater to be in accordance with

the Local and State Energy Code

Gas Fired

Water Heater

Gas Direct Vent discharge

must comply with Local

and State Codes

Vacuum Relief Valve

(Not Supplied)

If required, install per local codes

and valve manufacturer’s

instructions.

120° to 130°F

140°F

Gas Control (Thermostat)

Lighting the water heater

Before operating this water heater, be sure to read and follow the instructions on the label pictured below

and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so

can result in unsafe operation of the water heater resulting in property damage, personal injury, or death.

Should you have any problems reading or following the instructions in this manual, STOP, and get help

from a qualified person.

AX4978

FOR YOUR SAFETY READ BEFORE OPERATING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

If you cannot reach your gas supplier,

call the re department.

instuctions.

Do not use this appliance if any part has

been under water. Immediately call a

qualied installer or service agency to

replace a ooded water heater. Do not

attempt to repair the unit! It must be

replaced!

Use only your hand to turn the gas control

knob. Never use tools. If the knob will

not turn by hand, do not try to repair it,

call a qualied service technician. Force

or attempted repair may result in re or

explosion.

10.

Stop! Read the safety information above

on this label.

Slide the “ON/OFF” switch located on the

gas valve to the “OFF” position.

Turn o all electric power to the

appliance.

Set the valve thermostat dial to “LOW”.

This appliance has an automatic spark

ignition system. DO NOT attempt to light

the pilot by hand.

Wait ve (5) minutes to clear out any gas.

If you smell gas, stop! Follow “B’ in the

safety information above on the label. If

you do not smell gas, go to the next step.

Turn on electric power to the appliance.

Slide the ”ON/OFF” switch located in the

gas valve to the “ON” position.

Set the thermostat dial to the desired

setting.

Immediately call your gas supplier from a

neighbor’s phone. Follow the gas suppliers

Do not try to light any appliance.

Do not touch any electric switch; do not

use any phone in your building.

WHAT TO DO IF YOU SMELL GAS

This appliance is equipped with an

ignition device which automatically lights

the pilot. DO NOT try to light the pilot by

hand.

BEFORE PUTTING THIS APPLIANCE INTO

SERVICE - Smell all around the appliance

area for gas. Be sure to smell next to the

oor because some gas is heavier than air

and will settle on the oor.

If the appliance will not operate,

follow the instructions “TO TURN OFF

GAS TO APPLIANCE” and call your

service technician or gas supplier.

Turn o all electric power to the appliance if service is to be performed.

Close manual gas shut-o valve.

WARNING: If you do not follow these instructions and use the Use & Care

Manual instructions exactly, a re or explosion may result causing property

damage, personal injury or loss of life.



Safety Precautions

DO turn off manual gas shut-off valve if water

heater has been subjected to over heating, fire,

flood, physical damage or if the gas supply fails to

shut off.

DO NOT turn on water heater unless it is

completely filled with water.

DO NOT turn on water heater if cold water

supply shut-off valve is closed.

DO NOT allow combustible materials such as

newspaper, rags or mops to accumulate near water

heater.

DO NOT store or use gasoline or other flammable

vapors and liquids, such as adhesives or paint

thinner, in vicinity of this or any other appliance.

If such flammables must be used, open doors and

windows for ventilation, and all gas burning

appliances in the vicinity should be shut off

including their pilot burners, to avoid vapors

lighting.

NOTICE: Flammable vapors can be drawn by air

currents from surrounding areas to the water

heater.

If there is any difficulty in understanding or

following the Operating Instructions or the Care

and Cleaning section, it is recommended that a

qualified person or serviceman perform the work.

Operating the water heater

CAUTION: Hydrogen gas can be produced in a hot water system served by this water heater that has

not been used for a long period of time (generally two weeks or more). HYDROGEN GAS IS

EXTREMELY FLAMMABLE!! To dissipate such gas and to reduce risk of injury, it is recommended that

the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance

connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air

escaping through the pipe as the water begins to flow. DO NOT smoke or use an open flame near the faucet

at the time it is open.

DANGER: Hotter water

increases the Potential for Hot

Water SCALDS. Households

with small children, disabled,

or elderly persons may

require a 120°F or lower gas

control (thermostat) setting

to prevent contact with

HOT water.

Water Temperature Setting

The temperature of the water in the

water heater can be regulated by

turning the knob on the front of the

gas control (thermostat). Safety and

energy conservation are factors to

be considered when selecting the

water temperature setting of the water

heater’s gas control (thermostat(s)).

The lower the temperature setting,

the greater the savings in energy and

operating costs.

To comply with safety regulations,

the gas control (thermostat) was

set at 120°F before the water heater

was shipped from the factory.

The recommended starting point

temperature is 120°F.

Water temperatures above 125°F can

cause severe burns or death from

scalding. Be sure to read and follow

the warnings outlined in this manual

and on the label located on the water

heater near the gas control thermostat.

Mixing valves are recommended for

reducing point of use water temperature

by mixing hot and cold water in branch

water lines. It is recommended that a

mixing valve complying with the Standard

for Temperature Actuated Mixing Valves

for Hot Water Distribution Systems, ASSE

1017 be installed. See page 4 for more

details and contact a licensed plumber or

the local plumbing authority for further

information.

The chart on the next page may be

used as a guide in determining the

proper water temperature for your

home.

Operating Procedure

This heater is equipped with an

electronically lit pilot to light the main

burner. The pilot is automatically

lit each time there is a demand for

heating the water. On initial start-up,

it is recommended that the outer door

be removed (leave inner door in place

for safety) to determine if the pilot and

main burner are operating properly.

Once filled with water, it is necessary

to plug the power cord in and make

sure the gas control switch is in the

“ON” position. The blower will start

and within seconds the pilot will light

followed by the main burner. After

the main burner ignites, replace the

outer door. If no main burner flame

is established, the gas control will go

through three trials for ignition before

going into a lock-out. A warning

light will alert the user of this lock-

out condition. If this happens, refer to

“Troubleshooting Guide.”

Operating the water heater

The following is additional information which

aid in determining a safe working temperature

to meet each household need.

Maximum water temperatures occur just after

the burner has shut off. To determine the

water temperature, turn on a hot water faucet

and place a thermometer in the water stream.

If an adjustment to the water temperature

is preferred, then refer to the Water Heater

User Display – Operation Instructions for

instruction on adjusting the local and remote

user display temperature setpoints.

A condition known as “stacking” or

“layering” can occur when a series of short

and frequent hot water draws are taken. The

hottest temperature water will be at the top of

the tank, closest to the outlet pipe delivering

hot water to the home.

Stacking can cause this top layer of water to

be hotter than the water toward the bottom

of the tank near the gas control (thermostat).

Therefore, always remember to test the water

temperature with your hand before use and

remember that hotter water increases the risk

of scald injury.

Also, always supervise young children or

others who are incapacitated.

The gas control (thermostat) is constructed

with a built in safety shut-off device designed

to shut off the gas supply to the burner if the

main burner is extinguished for any reason.

The gas control (thermostat) is also

equipped with a gas shut off device that

will shut off the gas supply to the burner if

the water heater exceeds normal operating

temperatures. Refer to the “Before You

Call For Service” section of this manual, or

contact your dealer.

WARNING: Should overheating occur

or the gas supply fail to shut off, turn off

the manual gas control valve to the

appliance

If the water heater has been subjected to

fire, flood or physical damage, turn off the

manual gas control (shut-off) valve and DO

NOT operate the water heater again until

it has been checked by a qualified service

technician.

NOTICE: DO NOT use this appliance

if any part has been under water.

Immediately call a qualified installer or

service agency to replace a flooded water

heater. DO NOT attempt to repair the unit!

It must be replaced.

Time/Temperature Relationship in Scalds

Water Temperature Time To Produce a Serious Burn

120°F More than 5 minutes

125°F 1

/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1

/2 seconds

155°F About 1 second

Table courtesy of Shriners Burn Institute

90° F

113°F

98°F

105°F

120°F

130°F

140°F

150°F

160°F

Water Temperature Setting

Sequence of Operation

1. During initial start-up or a call for heat,

the control will verify the vacuum switch

is open.

2. Once the control verifies the blower

vacuum switch is open, the control will

energize the blower motor for the pre-

purge sequence (approximately 5 seconds).

3. The control will verify the blower vacuum

switch has closed, ensuring that the

blower is functioning properly and that the

venting system is not blocked.

4. The control will then proceed through

a sequence of self-diagnostics before

initiating a trial for ignition.

5. During the trial for ignition, the pilot will

spark in an attempt to light the pilot. Once

the pilot flame is established, the main gas

valve will open allowing gas to flow to the

main burner.

6. The main burner and pilot will remain lit

throughout the heat cycle until the water

temperature setting is reached.

7. Once the water temperature setting is

reached, the control will close the main

gas valve and pilot valve which will

extinguish both the main burner and pilot

burner flames.

8. The blower motor will stay energized

for an additional 30 seconds after the

control verifies that the burner flame is

extinguished in order to clear combustion

gases from the water heater.

9. After the post-purge sequence, the control

will de-energize the blower motor and go

into a stand-by mode awaiting the next

call for heat.

This water heater is equipped with a

flammable vapor sensor that is monitored

continuously by the electronic control in all

modes of operation.

In the event that flammable vapors are

detected, the control will automatically shut

down the water heater and prevent the water

heater from being started again.

The following is a list of materials that will

cause the Flammable Vapor Sensor to shut

down the water heater.

 Vapors of Gasoline.

 Vapors of certain flammable paints, stains,

and thinners.

 Vapors of vent pipe Cement & Solvents.

 Bleach (direct contact with flammable vapor

sensor).

 Some other flammable materials and their

vapors.

If the flammable vapor sensor shuts down

the water heater, then the electronic control

will display the appropriate error code and

you should then promptly contact a qualified

service technician.

Refer to the “WARNING” on page 3 for

additional information.

Care and cleaning of the water heater

Draining the Water Heater

CAUTION: Shut off gas to the

water heater at the gas control

(thermostat) gas cock or manual shut-

off valve before draining water.

DANGER: Before manually

operating the temperature and

pressure relief valve, make certain no

one will be exposed to the hot water

released by the valve. The water drained

from the tank may be hot enough to

present a scald hazard and should be

directed to a suitable drain to prevent

injury or damage.

Before turning off the cold water supply

to the water heater, open a hot water

faucet allowing sufficient cold water into

the tank to prevent the risk of a scald

injury while draining the water heater.

Once the water in the tank is no longer

hot, turn off the cold water supply to the

water heater. Open a hot water faucet or

lift the handle on the relief valve to admit

air to the tank.

Attach a garden hose to the drain valve

on the water heater and direct the stream

of water to a drain. Open the valve.

Routine Preventative Maintenance

Properly maintained, your water heater

will provide years of dependable trouble-

free service.

It is recommended that a periodic

inspection of the gas control (thermostat),

burner, relief valve, internal flue-way

and venting system should be made

by service personnel qualified in gas

appliance repair.

It is suggested that a routine preventative

maintenance program be established and

followed by the user.

Inspect plastic vent pipe. Make certain

that all joints are secure and that vent

pipe supports are all in place. Check the

outdoor vent terminal to see that it is

free of obstructions, and that there is no

damage nearby caused by condensate.

Inspect dilution air inlet and combustion

air inlet openings. Make certain no

blockage exists. Clean any lint, dirt or oil

accumulation that may exist.

At least once a year, lift and release the

lever handle on the temperature pressure

relief valve, located near the top of the

water heater, to make certain the valve

operates freely. Allow several gallons

to flush through the discharge line to an

open drain.

NOTICE: If the temperature and

pressure relief valve on the water

heater discharges periodically, this

may be due to thermal expansion in a

closed water system. Contact the water

supplier or your plumbing contractor

on how to correct this. DO NOT plug

the relief valve outlet.

A water heater’s tank can act as a

settling basin for solids suspended in

the water. It is therefore not uncommon

for hard water deposits to accumulate

in the bottom of the tank. If allowed

to accumulate, these solids can cover

the gas control (thermostat) sensors,

causing the sensors to operate erratically.

Because accumulated solids can prevent

the gas control (thermostat) sensors from

accurately reading the water temperature,

the water at the fixture can be hotter than

the gas control (thermostat) setting. It

is suggested that a few quarts of water

be drained from the water heater’s tank

every month to clean the tank of these

deposits.

Rapid closing of faucets or solenoid

valves in automatic water using

appliances can cause a banging noise

heard in a water pipe. Strategically

located risers in the water pipe system or

water hammer arresting devices can be

used to minimize the problem.

The anode rod should be removed from

the water heater’s tank annually for

inspection and replaced when more than

6” of core wire is exposed at either end

of the rod.

Make sure the cold water supply is turned

off before removing anode rod.

This water heater incorporates a

combustion shut off device that shuts

the operation of the water heater down

if undesirable combustion conditions

occur, such as the presence of flammable

vapors or blockage of the combustion air

inlet openings. Please contact a Qualified

Service Technician if this occurs.

DANGER: Before

manually operating the

relief valve, make certain

no one will be exposed to

the danger of the hot water

released by the valve. The

water may be hot enough

to create a scald hazard.

The water should be

released into a suitable

drain to prevent injury or

property damage.

DANGER: Failure to

perform the recommended

Routine Preventative

Maintenance can harm the

proper operation of this

water heater, which can

cause carbon monoxide

dangers, excessive hot

water temperatures and

other potentially hazardous

conditions.

DANGER: Hotter water

increases the potential for

Hot Water Scalds.

Location of Dilution Air Holes

Housekeeping

Visually inspect the pilot.

To ensure sufficient ventilation

and combustion air supply, proper

clearances must be maintained.

When installed in a closet, DO NOT

block or obstruct any of the combustion

air inlet openings located around

the perimeter of the water heater. A

minimum of 1” is required between

these combustion air inlet openings and

any obstruction.

DO NOT obstruct or block the

Flammable Vapor Sensor. The sensor

does not require any maintenance or

cleaning. DO NOT expose to cleaning

agents.

DANGER: Combustible

materials, such as clothing,

cleaning materials, or

flammable liquids, etc., must

not be placed against or next

to the water heater.

Burner Inspection

Visually inspect the pilot flame and

main burner annually.

Through the sight glass, inspect

the pilot and burner lighting. If any

unusual pilot or burner operation is

noted, the water heater should be shut

off until qualified service assistance

can be obtained.

The burner operates in radiant mode

and glows bright orange when burning

correctly. Allow approximately 30

seconds after turning on for the burner

to reach the radiant mode

CAUTION: For your safety,

cleaning of the burner must be

performed only by qualified service

personnel, as it involves the

disconnection of gas piping and leak

testing. The burner chamber is a

sealed area. If the burner access door

is removed, the burner access door

gasket must be replaced.

For cleaning, remove the burner from

the water heater. A vacuum cleaner can

be used on the burner and floor shield

inside the water heater. The burner can

also be cleaned by scrubbing with mild

detergent.

Proper burner flame pattern

Venting System Inspection

The water heater’s internal flue must

be inspected annually to be certain it is

clean by removing the blower assembly

and flue baffle.

When reinstalling the flue baffle make

certain it is hung securely by its hanger

at the top of the flue way.

Reinstall the blower assembly.

Inspect plastic vent pipe. Make certain

that all joints are secure and that vent

pipe supports are all in place. Check the

outdoor vent terminal to see that it is

free of obstructions, and that there is no

damage nearby caused by condensate.

Inspect dilution air holes. Make certain

no blockage exists. Clean any lint, dirt

or oil accumulation that may exist.

Test for spillage at the dilution air holes

after 5 minutes of burner operation.

Place a blown out match or candle

close to the dilution air holes. The

smoke from the candle or match should

be drawn into the dilution air holes.

If the smoke is pushed away from

the dilution air holes, the blower or

vent system may be blocked. Contact

qualified service personnel.

Location of Dilution Air Holes

Gas ame

should be visible

on entire burner

surface.

Vacation and Extended Shut-Down

If the water heater is to remain idle for an

extended period of time, the power and

water to the appliance should be turned

off to conserve energy and prevent a

build-up of dangerous hydrogen gas.

The water heater and piping should be

drained if they might be subjected to

freezing temperatures.

After a long shut-down period, the

water heater’s operation and controls

should be checked by qualified service

personnel. Make certain the water heater

is completely filled again before placing

it in operation.

NOTICE: Refer to the

Hydrogen Gas Caution in

the Operating Instructions.

Anode Rod

This water heater is equipped with an

anode rod designed to prolong the life

of the glass lined tank. The anode rod is

slowly consumed, thereby eliminating or

minimizing corrosion of the glass lined

tank.

Water sometimes contains a high sulfate

and/or mineral content and together with

cathodic protection process can produce

a hydrogen sulfide, or rotten egg odor

in the heated water. Chlorination of

the water supply should minimize the

problem.

NOTICE: DO NOT remove

the anode rod from the

water heater’s tank, except

for inspection and/or

replacement, as operation

with the anode rod removed

will greatly shorten the

life of the glass lined tank

and will exclude warranty

coverage.

Care and cleaning of the water heater

Before You Call For Service

Troubleshooting Tips

Save time and money! Review the charts on the following pages first and you may not need to call for service.

This water heater incorporates a combustion shut off device that shuts the operation of the water heater

down if undesirable combustion conditions occur, such as the presence of flammable vapors or blockage of

the combustion air inlet openings. Please contact a Qualified Service Technician if this occurs.

CAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or other

safety devices. Refer repairs to qualified service personnel.

Problem Possible Causes What To Do

Condensation This usually happens when  This is normal. After the water in the tank warms

a new water heater is up, the condensation will disappear. If, however, the

filled for the first time. condition persists, examine the piping and fittings

for possible leaks.

Moisture from the products  This is normal and will disappear in time. Excessive

of combustion condensing condensation can cause main burner outage.

on the tank surface.

An undersized water  Use a water heater size that meets the requirements

heater will cause of your needs.

condensation.

Yellow flame Scale on top of the burner.  Contact a qualified service technician to remove scale.

or soot

Flue or Combustion air inlet  Remove obstruction or debris from flue or

openings are restricted. combustion air inlet openings on water heater jacket.

Not enough combustion or  Proper operation of the water heater requires air for

ventilation air supplied to combustion and ventilation. See the Combustion and

the water heater location. Ventilation Air information in the “Installing The

Water Heater” section of this manual.

Unable to light Air in gas line.  Contact a qualified service technician to purge the air

the main burner from the gas line.

Blocked Exhaust Contact a qualified service technician to evaluate vent

pipe for blockage.

Pressure Switch  Make sure the pressure switch hose is not "kinked".

Wire Connection not fully  Contact a qualified service technician to confirm wire

secured. connections.

Combustion Shut-off Device  Combustion shut-off device should be inspected by a

tripped, qualified service technician.

Gas Control Problem  Contact a qualified service technician.

Main burner does not Combustion Shutoff Device  The combustion shutoff device should be inspected

stay lit Tripped. by a qualified service technician.

Problem Possible Causes What To Do

Rumbling noise Scale and sediment  Drain the water heater to remove scale and sediment from

the tank. Refer to the top of page 27.

Relief valve Pressure build up  This is an unacceptable condition and must be

producing popping caused by thermal corrected. Contact the water supplier or plumbing

noise or draining expansion to a contractor on how to correct this. DO NOT plug the

closed system. relief valve outlet.

Not enough or Water usage may have  Wait for the water heater to recover after an

no hot water exceeded the capacity abnormal demand.

of the water heater.

Low gas pressure.  Check gas supply pressure and manifold pressure.

The gas control (thermostat)  See the “Water Temperature Setting” of The Water

may be set too low. Heater section of this manual.

Leaking or open hot  Make sure all faucets are closed.

water faucets.

Check valve error codes.  Refer to gas valve error code table on page 32.

“ON/OFF” switch turned off.  Turn “ON”.

Blower unplugged.  Plug in. Verify power supply (120VAC).

Combustion Shutoff System  Contact a qualified service technician.

tripped

Water is too hot The gas control (thermostat) ● See the “Water Temperature Setting” of The Water

is set too high. Heater section of this manual.

Gas Control (Thermostat) ● Contact a qualified service technician to replace the

Defective. gas control (thermostat).

Before You Call For Service

Troubleshooting Tips

Save time and money! Review the charts on the following pages first and you may not need to call for service.

This water heater incorporates a combustion shut off device that shuts the operation of the water heater down

if undesirable combustion conditions occur, such as the presence of flammable vapors or blockage of the

combustion air inlet openings. Please contact a Qualified Service Technician if this occurs.

CAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or

other safety devices. Refer repairs to qualified service personnel.

CAUTION: Make certain power to water heater is “OFF” before removing protective cover FOR ANY REASON.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and

dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING.

Gas Valve Error Codes

GAS VALVE

LED

STATUS/PROBLEM PROBABLE CAUSE SOLUTION

Short ash once

every four seconds

IDLE (no call for heat,

no fault conditions)

Temperature setpoint achieved and

burner is off

No solution required

“Heartbeat”, alter-

nates bright/dim

Call For Heat (no fault

conditions)

Water temperature is below set-

point and burner is on

No solution required

One Flash, three

second pause

Low ame signal

(control continues to

operate)

Pilot tube restriction, carbon build-

up on electrode, pilot wire damage

or gas supply

1. Gas supply pressure is low

2. Low voltage supply

3. Pilot replacement

Two Flash, three

second pause.

Pressure switch failed

closed

Pressure switch tube blockage or

faulty pressure switch.

1. Pressure switch wiring incorrect

2. Replace pressure switch

Three Flash, three

second pause

Pressure switch failed

open.

Vent blockage or improper instal-

lation, switch tube blockage, faulty

switch, blower improper operation

or temperature switch open

1. Pressure switch wiring incorrect

2. Replace pressure switch

3. Air intake or exhaust obstructed

4. Replace blower temperature switch

5. Replace blower

Four Flash, three

second pause

TCO limit lockout

Thermal well fault, gas control

fault or tank is not lled with

water

1. Reset valve and check for proper

valve cycling

2. Make sure tank is full of water

Four Flash, three

second pause

Flame out of sequence

Pilot or burner valve has failed

open

1. Replace gas valve control

Six-One Flash,

three second pause

Failed trial for ignition

Insufcient gas supply, unstable

pilot, carbon buildup on electrode

or wire/pilot tube damage

1. Check gas supply

2. Replace pilot

Six-Two Flash,

three second pause

Recycle limit - PS/limit

opened

Vent blockage or improper instal-

lation, switch tube blockage, faulty

switch, blower improper operation,

blower temperature switch open or

excessive wind at vent termination

1. Pressure switch wiring incorrect

2. Replace pressure switch

3. Air intake or exhaust obstructed

4. Replace blower temperature switch

5. Replace blower

6. Check for vent termination compli-

ance as stated in this manual

Six-Three Flash,

three second pause

Recycle limit - ame

lost

Pilot tube restriction, low gas sup-

ply pressure, carbon buildup on

electrode, wire/pilot tube damage

or combustion air port blockage

1. Gas supply pressure is low

2. Jacket air holes obstructed

3. Pilot replacement

Six-Four Flash,

three second pause

Soft Lockout - ame

out of sequence sensed

Valve stuck in open position 1. Replace gas valve control

Seven Flash, three

second pause

Flammable vapor sen-

sor lockout

Gasoline or other ammable gas

was detected near the appliance or

the sensor has failed

1. Verify no gasoline or ammable

vapors are present

2. Replace the ammable vapor sensor

Eight-One Flash,

three second pause

FVS fault detected

Flammable vapor sensor resistance

is out of range, wiring to FV sen-

sor is faulty or control is faulty

1. Replace FV sensor

2. Replace FV sensor wiring

3. Replace gas control valve

Eight-Two Flash,

three second pause

Temperature sensor

fault detected

Thermal well fault

1. Check thermal well wiring connec-

tion

2. Replace thermal well

Eight-Three Flash,

three second pause

Electronics fault de-

tected

Thermal well fault or gas control

fault

1. Replace gas control valve

2. Replace thermal well

Eight-Four Flash,

three second pause

Valve fault detected

Gas control valve needs to be reset

or has been damaged

1. Cycle power to gas control valve

2. Replace gas control valve

Nine Flash, three

second pause

Chamber sensor fault

1. Sensor unplugged

2. Sensor malfunction

1. Replace sensor

Nine-Two Flash,

three second pause

Chamber temperature

fault

Insufcient supply air detected

1. Contact Authorized Service Pro-

vider

CAUTION: Make certain power to water heater is “OFF” before removing protective cover FOR ANY REASON.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous

operation. VERIFY PROPER OPERATION AFTER SERVICING.

CAUTION: For your safety DO NOT attempt repair of gas piping, remote control, burners, vent connectors or other

safety devices. Refer repairs to qualified service personnel.

Replacement Parts

For 40 and 50 gallon models using natural or LP gas.

Instructions For Placing a Parts

Order

All parts orders should include:

The model and serial number of the

water heater from the rating plate.

Specify type of gas (natural or LP)

as marked on the rating plate.

** Heat

Trap Nipple

Temperature and pressure

relief valve

Gas Control (Thermostat)

Dip tube

Dip tube gasket

Anode rod

Rubber

Coupling

Drain valve

Heat Trap Nipple

*Burner

Pilot and Bracket Assembly

Inner Door Burner Assembly

Burner Access Door Gasket

Filter Door

Jacket Door

Baffle Assembly

Inner Door Screws

Part description (as noted below)

and number of parts desired.

CAUTION: For your safety, DO

NOT attempt repair of gas piping, gas

control (thermostat), burners, vent

connectors or other safety devices.

Refer repairs to qualified service

personnel.

Notes:

1. Should you have any questions about your new water heater, or if it requires adjustment, repair, or routine

maintenance, it is suggested that you first contact your installer, plumbing contractor or previously agreed upon service

agency. In the event the firm has moved, or is unavailable, refer to the telephone directory, commercial listings or local

utility for qualified service assistance.

2. Should your problem not be solved to your complete satisfaction, you should then contact the Manufacturer’s National

Service Department at the following address:

800 Interstate Park Drive

Montgomery, Alabama 36109

Phone: 1-866-279-4566.

When contacting the manufacturer, the following information will be requested:

a. Model and serial number of the water heater as shown on the rating plate attached to the jacket of the heater.

b. Address where the water heater is located and physical location.

c. Name and address of installer and any service agency who performed service on the water heater.

d. Date of original installation and dates any service work was performed.

e. Details of the problems as you can best describe them.

f. List of people, with dates, who have been contacted regarding your problem.

The Commonwealth of Massachusetts requires compliance with regula-

tion 5.08: Modications to NFPA-54, Chapter 10 : 248 CMR 4.00

and 5.00 for installation of through – the – wall vented gas appliances as

follows:

(1) Revise NFPA-54 section 10.5.4.2 by adding a second exception as fol-

lows:

Existing chimneys shall be permitted to have their use continued when a gas

conversion burner is installed, and shall be equipped with a manually reset

device that will automatically shut off the gas to the burner in the event of a

sustained back-draft.

(2) Revise 10.8.3 by adding the following additional requirements:

(a) For all side wall horizontally vented gas fueled equipment 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:

1. 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 monox-

ide 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 mon-

oxide detector with an alarm is installed on each additional level of the dwell-

ing, building or structure served by the side wall 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

a. 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 detec-

tor with alarm and battery back-up may be installed on the next adjacent oor

level.

b. 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, however, that during

said thirty (30) day period, a battery operated carbon monoxide detector with

an alarm shall be installed.

2. 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 IAS certied.

3. 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 horizon-

tally 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".

4. INSPECTION. The state or local gas inspector of the side wall horizon-

tally 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.

(b) 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 in-

stalled in a room or structure separate from the dwelling, building or structure

used in whole or in part for residential purposes.

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.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING

SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved

side wall horizontally vented gas fueled equipment does not provide the parts

for venting the ue gases, but identies "special venting systems", the fol-

lowing 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.

(e) 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.

(3) After NFPA-54 section 10.10.4.2 add a new section 10.10.4.3 as follows:

When more than four gas appliances are to be vented through a common gas vent

or common horizontal vent manifold, a plan of the proposed vent installation

shall be submitted to the Inspector and the serving gas supplier for review and

approval.

Important Instructions for the Commonwealth of Massachusetts

IF YOU NEED SERVICE

Rheem XG40T06PN36U1 Performance Tall 40 Gal 36,000 BTU

Product's Documents

Use and Care Manual

Specifications

Rheem XG40T06PN36U1 Questions and Answers