RESIDENTIAL GAS WATER HEATERS
Installation and Operating Manual
February, 2023 100366731_2000622624_REV.A
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
Series 200/201
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
WARNING
- Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of
this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas sup-
plier's instructions.
• If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed by
a qualified installer, service agency or the
gas supplier.
WARNING: If the information in these instruc-
tions is not followed exactly, a fire or explosion
may result causing property damage, personal
injury or death.
2
TABLE OF CONTENTS
Safe Installation, Use And Service ................ 3
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction.................................. 6
Qualified Installer Or Service Agency ............ 6
Preparing For The Installation.................. 6
Installation Requirements For The Commonwealth Of
Massachusetts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation ............................ 9
Get To Know Your Water Heater - Gas Models (List
Referencing Figures 1-7) ..................... 9
Replacement Parts And Deliming Products ...... 10
Combo Heating Inlet And Outlet Side Taps........11
Water Piping - Mixing Valve Usage ..............11
Mixing Valves
Water Heater Operation ..................... 12
Electrical Requirements & Wiring Diagram ....... 13
Safety Lockouts ............................. 14
High Limit Controls (Energy Cut Off)............ 14
Thermostat/Water Temperature
Blower High Limit Switch
Blower Air Pressure Switch ................... 14
Flammable Vapor Sensor .................... 14
Locating The New Water Heater ................ 15
Facts To Consider About The Location .......... 15
Storage Of Flammable Liquids ................ 15
Clearances to Combustibles
Floors with Carpeting
Clearance for Servicing
Insulation jackets and Blankets................ 17
Air Requirements .......................... 17
Direct Vent Appliances ...................... 17
Exhaust Fans ............................. 17
Indoor Combustion Air....................... 18
Outdoor Air Supply ......................... 18
Chemical Vapor Corrosion ................... 19
Installing The New Water Heater ................ 20
Water Piping .............................. 20
Space Heating And Potable Water Systems...... 20
Combo Heating ............................ 21
System Requirements
Installation
Closed Water Systems ...................... 22
Recirculation Loops......................... 22
Thermal Expansion ......................... 22
Temperature-Pressure Relief Valve............. 23
T&P Valve Discharge Pipe Requirements:
Temperature-Pressure Relief Valve and Pipe
Insulation
High Altitude Installation ..................... 24
Gas Piping................................ 24
Sediment Traps ............................ 25
Filling The Water Heater ..................... 26
Venting .................................. 26
Termination Clearances Sidewall Power Vent..... 27
Blower Assembly Installation.................. 28
Installation Of Vent System ................... 28
Planning The Vent System ................... 28
High Ambient Temperature Installations ......... 29
Polypropylene Vent Systems ................. 29
Condensate............................... 30
Exhaust Venting ........................... 30
Important Notes and Warnings
Venting Terminations and Sizing
Vent Screen Installation
Calculating Equivalent Feet
Venting Instructions
Vent Pipe Connection to Blower
Coupling Installations According to Vent Sizes
Blower Exhaust Direction .................... 36
Vent Pipe Preparation ....................... 36
Installation Checklist ........................ 39
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operating The Temperature Control System ....... 41
Gas Control Valve/Thermostat ................ 42
For Your Information.......................... 43
Start Up Conditions ......................... 43
Condensate
Smoke/Odor
Strange Sounds
Operational Conditions ...................... 43
Smelly Water
“Air” In Hot-Water Faucets ................... 43
Periodic Maintenance......................... 44
General Upkeep ........................... 44
Venting System Inspection ................... 44
Blower Maintenance ........................ 44
Cleaning The Blower. ....................... 44
Burner Operation And Inspection .............. 45
Combustion Chamber And Burner Cleaning ...... 46
Housekeeping ............................. 46
Temperature-Pressure Relief Valve Test ......... 46
Draining And Flushing ....................... 47
To Drain the Water Heater Storage Tank
To Flush the Water Heater Storage Tank
Anode Rod Maintenance..................... 48
Leakage Checkpoints......................... 49
Service .................................. 49
Reference Parts Listing ....................... 50
Troubleshooting Guidelines .................... 52
Resetting The Heater Control ................. 54
Lockouts ................................. 54
Soft Lockout
Hard Lockout
Ignition State And Timing .................... 55
System Status And Error Codes ............... 55
Notes ..................................... 56
Limited Warranty
3
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you
and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use or service this water heater.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could
result in property damage
CAUTION indicates a potentially
hazardous situation which, if not avoided,
could result in minor or moderate injury.
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or injury.
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or injury.
CAUTION
WARNING
CAUTION
DANGER
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message
and how to avoid the risk of injury.
This product is certified to comply with a maximum weighted average of 0.25% lead content as required in some areas.
IMPORTANT DEFINITIONS
Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the ”National Fuel Gas
Code” as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this
Installation and Operating manual.
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the ”National Fuel
Gas Code” as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understanding of this Installation and Operating manual, and be able to perform repairs strictly in accordance with the
service guidelines provided by the manufacturer.
Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances
within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping
up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service
and inspection of appliances within the building.
4
GENERAL SAFETY
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
WARNING
For continued protection against
risk of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
Fire Hazard
WARNING
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled are at highest risk
of scald injury.
Feel water before bathing or
showering.
Temperature limiting valves
are available.
Read instruction manual for
safe temperature setting.
BURN
HOT
HOT
DANGER
• Overheated water can cause
water tank explosion.
• Properly sized temperature and
pressure relief valve must be
installed in opening provided.
Explosion Hazard
WARNING
Read instruction manual before
installing, using or servicing
water heater.
• Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive
gas pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after
extended period of non-use.
Fire or Explosion Hazard
WARNING
5
GENERAL SAFETY
• Do not operate water heater if flood damaged.
• Inspect anode rods regularly, replace when significantly
depleted.
• Install in location with drainage.
• Fill tank with water before operation.
• Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
Improper Installation, use and service may result
in property damage.
CAUTION
• Before servicing the water heater, make
sure the blower assembly is unplugged
or the electrical supply to the water
heater is tumed "OFF".
• Label all wires prior to disconnection
when servicing controls. Wiring error can
cause improper and dangerous opera-
tion. Verify proper operation after
servicing.
• Failure to do this could result in death,
serious bodily injury, or property
damage.
WARNING
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Install vent system in accordance with codes.
• Do not operate water heater if flood damaged.
• For operation above 10,100’, a high altitude
orifice must be installed.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake with
insulating jacket or blanket.
• Do not obstruct blower air intake.
• Do not place chemical vapor emitting products
near water heater.
• Gas and carbon monoxide detectors are
available.
• No vent damper installation is compatible with
this power vented water heater.
Breathing Hazard - Carbon Monoxide Gas
WARNING
323546-000
1. Turn the thermostat counter-clockwise to the lowest setting.
2. Set the gas control switch to the “OFF” position.
3. Turn off electrical power to the appliance if service is to be performed.
TO TURN OFF GAS TO APPLIANCE
1. STOP! Read the safety
information above on this
label.
2. Turn off all electric power to the
appliance.
3. Turn the thermostat
counter-clockwise to the
lowest setting.
4. Set the switch on the control to
the “OFF” position.
5. Do not attempt to light manually.
6. Wait five (5) minutes to clear out
any gas. If you then smell gas, STOP!
Follow “B” in the safety information above on
this label. If you don't smell gas, go the next
step.
7. Turn on all electric power to
the appliance.
8. Set the switch on the control
to the “ON” position.
9. Turn thermostat to desired
setting.
DANGER Hotter water
increases the risk of
scald injury. Consult the
instruction manual before
changing temperature.
10. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
DANGER
A. This appliance does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do NOT try
to light the burner by hand.
B. BEFORE OPERATING smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier
than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; Do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to turn the gas control
buttons. Never use tools. If the control
buttons will not turn, don't try to repair them,
call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has
been under water. Immediately contact a
qualified installer or service agency to
replace a flooded water heater. Do not
attempt to repair the unit. It must be
replaced!
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
FLAMMABLEFLAMMABLE
WARNING: If you do not follow these instructions exactly, a fire
or explosion may result causing property damage, personal
injury or loss of life.
FOR YOUR SAFETY READ BEFORE LIGHTING
Read and follow water heater warnings and instructions in furnished manual.
If manual is missing, you may obtain one free of charge by calling 1-800-821-2017.
Si Ud. no puede ni leer ni entender el inglés y si necesita manuales, etiquetas
o rótulos en español, Ud. los puede obtener si al llama 1-800-821-2017.
WARNING / ADVERTENCIA
HOT
BURN
Water temperature over 125°F can
cause severe burns instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See instruction manual before
setting temperature at water heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
DANGER
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance. Storage or
use of gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in serious injury
or death.
Can result in serious injury or death
FIRE AND EXPLOSION HAZARD
Flammable Vapors
FLAMMABLES
WARNING
6
INTRODUCTION
Thank You for purchasing this water heater. Properly
installed and maintained, it should give you years of trouble
free service.
This water heater is suitable for potable water heating
and space heating applications but not for space heating
only applications.
Abbreviations found in this Installation and Operating
manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• UL - Underwriters Laboratories Inc.
• AHRI - Air Conditioning, Heating and Refrigeration
Institute.
This gas fired water heater is design-certified by CSA
International as a Category IV vented water heater under
Water Heater Standard ANSI Z21.10.1 • CSA 4.1 (current
edition).
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by
ANSI below) in the field involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical
supply are required in addition to electrical testing skills
when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in
person or through a representative is engaged in and is
responsible for (a) the installation, testing or replacement
of gas piping or (b) the connection, installation, testing,
repair or servicing of appliances and equipment; that
is experienced in such work; that is familiar with all
precautions required and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualified (as defined by ANSI above) and
licensed or certified as required by authority having
jurisdiction to perform a given task, do not attempt to
perform any of the procedures described in this manual.
If you do not understand the instructions given in this
manual do not attempt to perform any procedures outlined
in this manual.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section of this manual
first and then entire manual carefully. If you don’t
follow safety rules, the water heater will not operate
properly. It could cause DEATH, SERIOUS BODILY
INJURY AND/OR PROPERTY DAMAGE. This manual
contains instructions for installation, operation,
and maintenance of the gas-fired water heater. It
also contains warnings throughout the manual that
you must read and be aware of. All warnings and
instructions are essential to proper operation of the
water heater and your safety. Since we cannot put
everything on the first few pages, READ ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
2. The installation must conform with these instructions
and local code authority having jurisdiction. In absence
of local codes, installation must comply with current
editions of the “National Fuel Gas Code”, ANSI
Z223.1/NFPA 54 and “National Electrical Code”,
NFPA 70. All documents are available from:
CSA International,
8501 East Pleasant Valley Road,
Cleveland, Ohio, United States
44131-5575.
NFPA documents are also available from:
National Fire Protection Association,
1 Batterymarch Park,
Quincy, MA 02269.
3. The water heater, when installed, must be electrically
grounded in accordance with the local codes or in
the absence of local codes: the “National Electrical
Code”, NFPA 70 (current edition).
4. If after reading this manual you have any questions or
do not understand any portion of the instructions, call
the local gas utility or the manufacturer whose name
appears on the rating plate.
5. Carefully plan the place where you are going to put
the water heater. Correct air supply for combustion
and blower operation, vent action, and vent pipe
installation are very important in preventing death
from possible carbon monoxide poisoning and
fires (see Figure 13 and Figure 14). Examine the
location to ensure the water heater complies with
the “Locating The New Water Heater” section in this
manual.
6. For installation in areas subject to earthquakes, this
water heater must be braced, anchored, or strapped
to avoid falling or moving during an earthquake. For
installations in California, see correct installations
procedures. Instructions may be obtained from:
California Office of the State Architect,
400 P Street,
Sacramento, CA 95814.
7. Massachusetts Code requires this water heater to be
installed In accordance with Massachusetts 248-CMR
2.00: State Plumbing Code and 248-CMR 5.00.
8. Complies with California Health and Safety code
116875 (known as AB-1953) and with weighted
average maximum of 0.25% lead.
7
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters
installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned
or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above
finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall
be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated
or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or
structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner
to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and
be ANSI/ UL 2034 listed and CSA certified.
SIGNAGE
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign shall read, in print size no less than one- half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with
the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS
The following equipment is exempt from 248 CMR 5.08(2) (a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from
the dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system
design or venting system components with the equipment, the instructions provided by the manufacturer for installation
of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by
the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
8
• If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following
graphic during installation and during modifications to the water supply system.
• Refer to your manual for additional requirements.
• Some models are not designed to be used with an air handler. Refer to your manual to determine if
the air handler portion of the graphic applies to your model.
• Keep this sheet with your manual.
IN
REMOVE A
MUST BE VERTICAL TO
IR BUBBLES
E
OUT
COIL
AIR
HANDLER
TO
AIR
HANDLER
SHUT-OFF
VALVE
*
EXPANSION TANK
VACUUM
RELIEF
VALVE
COLD WATER INLET
VA
FLOW CONTROL
LV
PUMP
*
SHUT-OFF
CHECK VALVE
†
(1/8” HOLE
DRILLED IN CLAPPER)
VALVE
CHECK
VALVE
†
TEMP/
PRESSURE
RELIEF
VALVE
TEMPERED WATER
TO FIXTURES
(MUST MEET TEMPS LISTED
IN MASS. CODE 248 CMR
†
)
MIXING VALVE
(MUST BE INSTALLED BELOW
TOP OF WATER HEATER
AS PER MANUFACTURER’S
RECOMMENDATIONS)
UNION
UNION
HOT
WATER
OUT
*
MASSACHUSETTS INSTALLATION REQUIREMENTS:
1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS
FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.
2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR
& 780 CMR).
3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.
† REQUIRED FOR MASSACHUSETTS.
‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.
WATER HEATER ACCEPTED
BY THE BOARD FOR
INSTALLATION IN
MASSACHUSETTS.
†
TYPICAL MIXING VALVE INSTALLATION
COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM
SEE
NOTE ‡
INSTALLATION GRAPHIC:
COMBINATION SPACE HEATING/POTABLE WATER SYSTEM
100’-0” MAXIMUM DISTANCE
FROM WATER HEATER
TO FAN COIL AND BACK
(DEVELOPED LENGTH) NOT
INCLUDING COIL IN HEATING UNIT.
†
9
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-7)
1 Vent Termination Elbow with Rodent
Screen
2 *Vent Pipe
3 *Vent Pipe Coupling (if required)
4 *Vent Pipe Elbow (long radius)
5 Blower High Limit Switch (see
Figure 6)
6 T&P Valve
7 Cold-Water Inlet Nipple/Diptube
8 Baffle Assembly
9 * Discharge Pipe
10 Gas Control Valve/Thermostat
(Honeywell)
11 Gas Valve Electronic Control Module
And Cover (Honeywell)
12 Drain Valve
13 Outer Gas Door
14 Manifold Door Assembly (behind
outer door) (see Figure 3 and
Figure 4)
15 *Floor Drain
16 *Metal Drain Pan
17 Flammable Vapor Sensor (under
cover) (see Figure 5)
18 **Combo Heating System Return
Inlet (Optional)
19 Air Inlet Snorkel
20 **Combo Heating System Supply
Outlet (Optional)
21 Blower with Power Cord (see also
Figure 6)
22 Air Switch (inside box) (see
Figure 6)
23 Junction Box (see Figure 6)
24 Junction Box Cover (see Figure 6)
25 Air Tubing (see Figure 6)
26 Rubber Coupling (see also Figure 6)
27 Gear Clamp (see also Figure 6)
28 Flue Collector
29 Hot-Water Outlet Nipple
30 Anode (under cap)
31 ***Control Harness
32 Flexible Manifold Tube (see Figure 3
and Figure 4)
33 Viewport (see Figure 3 and Figure 4)
34 Flame Sensor Rod (see Figure 3
and Figure 4)
35 Gas Orifice (see Figure 3 and
Figure 4)
36 Sheet Metal Burner (see Figure 3
and Figure 4)
37 Gas Manifold (see Figure 3 and
Figure 4)
38 Hot-Surface Igniter (see Figure 3
and Figure 4)
39 Manifold Door Gasket (see Figure 3
and Figure 4)
40 Manifold Door (see Figure 3 and
Figure 4)
41 Two Piece Grommet With Clip (see
Figure 3 and Figure 4)
42 *Inlet Water Shut-off Valve
43 *Gas Supply*
44 *Main Manual Gas Shut-off Valve
45 *Ground Joint Union (gas
connection)
46 *Sediment Trap
47 *Union (water connection)
48 Rating Plate
49 *Thermal Expansion Tank (required
for all closed systems)
*, **, ***, **** see notes on following
page
Front View
1 2
3
4
27
26
21
21
48
8
43
44
45
46
32
17
16
15
13
32
31
18
10
9
7
20
6
11
14
Figure 1.
Combustion
Air Inlets
Blower
Dilution Air
Inlets
Rear View
42
49
47
28
7
19
30
29
47
27
Figure 2.
10
Natural gas and Propane main
burner with igniter assembly for
40k to 50k Btu/hr models (item
14 in Figure 1).
34
35
36
37
38
39
4041
33
32
Figure 3.
Natural gas and Propane
main burner with igniter
assembly for 60k to 75k
Btu/hr models (item 14 in
Figure 1).
32
34
35
33
41
40
39
38
37
36
Figure 4.
17
Figure 5.
26
27
2522
23
24
5
21
Figure 6.
Vacuum relief valve
install per local
codes (not supplied
with heater).
Figure 7.
Figure 8.
Notes:
* Items not supplied with the water heater.
** The side recirculation loop connections may not be
used as the primary water inlet and outlet connections.
See “Combo Heating Inlet And Outlet Side Taps”.
*** Caution harness has 120VAC in operation.
**** See “Planning The Vent System”, “Condensate” and
“Blower Assembly Installation” for more information.
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be
ordered through authorized servicers or distributors. When
ordering parts, provide complete model and serial numbers
(see rating plate), quantity and name of part desired.
Standard hardware items may be purchased locally.
11
COMBO HEATING INLET AND OUTLET SIDE TAPS
Models equipped with Combo Heating capabilities are
shipped with the two side plumbing taps OPEN (item 18
and item 20 in Figure 1 and see also and Figure 26). If
the heater is to be operated without using the side taps,
these openings must be closed with the two pipe plugs
supplied with the heaters.
WATER PIPING - MIXING VALVE USAGE
Mixing Valves
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled are at highest risk
of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing valves must
be installed when required
by codes and to ensure safe
temperatures at fixtures.
BURN
HOT
HOT
DANGER
Water heated to a temperature which satisfies space
heating, clothes washing, dish washing, and other
sanitizing needs can scald and cause permanent injury
upon contact. Short repeated heating cycles caused by
small hot-water uses can cause a temperature increase of
the hot water by 30F° higher than the heater’s temperature
settings. If you choose a higher temperature setting,
Thermostatic Mixing Valves (see Figure 8) located at
each point-of-use are particularly important to help avoid
scalding.
This appliance has been design certified as complying
with American National Standard/CSA Standard for water
heaters and certain models with side plumbing connections
are considered suitable for Water (Potable) Heating and
Space Heating but not space heating only applications.
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures.
Some people are more likely to be permanently injured
by hot water than others. These include the elderly,
children, the infirm and the physically/mentally disabled.
Table 1 (published by U.S. Government Memorandum,
1978) shows the approximate time-to-burn relationship
for normal adult skin. If anyone using hot water provided
by the water heater being installed fits into one of these
groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special
precautions must be taken.
Water
Temperature
°F
Time for 1st
Degree Burns
(Less Severe Burns)
Time for Permanent
Burns 2nd & 3rd
Degree (Most
Severe Burns)
110 (normal shower temp.)
116 (pain threshold)
116 35 minutes 45 minutes
122 1 minute 5 minutes
131 5 seconds 25 seconds
140 2 seconds 5 seconds
149 1 second 2 seconds
154 instantaneous 1 seconds
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)
Table 1.
In addition to using lowest possible temperature setting
that satisfies demand of application, to reduce the risk of
scalding, install Thermostatic Mixing Valves (temperature
limiting valves) (see Figure 8) at each point-of-use. These
valves automatically mix hot and cold water to limit the
temperature at the tap.
Thermostatic Mixing Valves are available from your
local plumbing supplier. Consult a Qualified Installer or
Service Agency. Follow mixing valve manufacturer’s
instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
“Operating The Temperature Control System” section in
this manual.
12
WATER HEATER OPERATION
Figure 9 shows the water heater’s sequence of operation
when a call for heat is initiated. The ignition control module
will attempt to light the burner three times. If the ignition
control does not detect ignition it will enter lockout mode
and flash the corresponding error code.
HEATER CONTROL
CHECKS TO ENSURE
BLOWER PRESSURE
SWITCH IS OPEN
BLOWER IS
ENERGIZED
CONTROL CHECKS TO
ENSURE PRESSURE
SWITCH CLOSES
INDICATING BLOWER
IS OPERATING AND
THERE ARE NO
VENTING BLOCKAGES
(INLET OR OUTLET)
IGNITER IS ENERGIZED
AND MAIN GAS VALVE
IS OPENED
MAIN BURNER COMES
ON AND THE FLAME IS
SENSED BY CONTROL
MAIN BURNER
CONTINUES TILL
THE WATER IN THE
TANK REACHES
THERMOSTAT SETTING
MAIN BURNER SHUTS
OFF. BLOWER
CONTINUES FOR A
POST PURGE TIME
HEATER
THERMOSTAT
CALLS FOR
HEAT
HEATER
REMAINS ON
STANDBY UNTIL
NEXT CALL FOR
HEAT
Figure 9.
13
ELECTRICAL REQUIREMENTS & WIRING DIAGRAM
Failure to do so can result in
death or electrical shock.
Replace all parts and panels
before operating.
Disconnect power before
servicing.
Electric Shock Hazard
WARNING
Before plugging in the water heater, always make sure:
• The voltage and frequency correspond to that specified
on the water heater wiring diagram.
• The electrical outlet has the proper overload fuse or
breaker protection.
1. The unit must be connected to a 120VAC power
supply. A dedicated circuit is preferred.
2. The water heater must be properly grounded.
3. This water heater is a polarity sensitive appliance and
will not operate properly if the power supply polarity
is reversed.
4. Do not use a GFI outlet.
Note: Always reference the wiring diagram for the correct
electrical connections.
After making all electrical connections, completely fill the
tank with water and check all connections for leaks. Open
the nearest hot-water faucet and let it run for 3 minutes to
purge the water lines of air and sediment and to ensure
complete filling of the tank. The electrical power may then
be turned on. Verify proper operation after servicing. See
also “Installation Checklist”.
Figure 10.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN
CAUSE IMPROPER AND DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER SERVICING.
NOTE: REFER TO THE “INSTALLATION CHECKLIST”
BEFORE OPERATING THIS HEATER.
N
1
2
3
HOT SURFACE IGNITER
HIGH LIMIT SWITCH
CAPACITOR
L1
EARTH GND
PRESSURE SWITCH
BLOWER
4
5
6
4
3
2
1
2
1
3
4
FLAME SENSOR
FLAMMABLE VAPOR SENSOR
P1
P2
P3
4
6
1
5
3
2
7
Circled numbers indicate
sequence of operation.
P4
1
Figure 11.
14
SAFETY LOCKOUTS
This water heater has several lockout features designed
to prevent the heater from operating in unsafe conditions.
HIGH LIMIT CONTROLS (ENERGY CUT OFF)
Thermostat/Water Temperature
This feature is a part of the gas control valve/thermostat
(see Figure 1, item 10) and limits the maximum water
temperature. In the event of the water overheating, this
safety feature shuts off the fuel supply to the burner.
Blower High Limit Switch
This device is located on the blower (see Figure 6, item
5) and limits the maximum temperature of the blower.
If the blower temperature rises above the temperature
setting, the switch opens causing the heater to shut down.
The switch will auto reset once the temperature drops
sufficiently.
BLOWER AIR PRESSURE SWITCH
This device, located in the junction box, monitors the air
pressure produced by the blower. In the event that the
exhaust venting becomes blocked or sufficiently restricted,
the switch will shut the heater down (see Figure 6, item 22).
FLAMMABLE VAPOR SENSOR
When using a gas fired water heater there is a risk of
flammable vapors entering the combustion chamber, being
ignited by the burner flame and causing a flashback. In
order to detect such flammable vapors before they enter
the combustion chamber, this water heater is equipped
with a flammable vapors sensor (FVS). It is a chemical-
absorption based sensor that is connected to the gas
control/thermostat (see Figure 12). When exposed to
flammable vapors it will trigger the control to stop the flow
of gas and enter the FVS lockout state. While in the FVS
lockout state the LED on the control will flash the gas lockout
code. (Refer to the “System Status And Error Codes”
section of this manual for an explanation of the codes
applicable to the control installed on your water heater.)
If this error occurs, check around the water heater for
sources of chemical contamination such as: flammable
vapors including gas vapors, solvents, paint and thinners
as well as sources of water and detergents.
Note: Resetting the heater will reset the FVIR circuit if
all sources of contamination have been removed and the
sensor clears. If all sources of contamination have been
removed and the system will not reset, the sensor will
need to be replaced (see “Resetting The Heater Control”).
If there is a problem with the wiring of the flammable vapor
sensor or the flammable vapor interface, the LED will flash the
failure status code (see “System Status And Error Codes”).
MOUNTING
BRACKET
FLAMMABLE
VAPOR SENSOR
(PULL TO REMOVE)
COVER*
* ROTATE LEFT (CCW)
TO REMOVE
Figure 12.
15
LOCATING THE NEW WATER HEATER
FACTS TO CONSIDER ABOUT THE LOCATION
Carefully choose an indoor location for the new water
heater because the placement is a very important
consideration for the safety of the occupants in the building
and for the most economical use of the appliance. This
water heater is not for use in manufactured (mobile) homes
or outdoor installation.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must
be observed:
1. Select a location indoors as close as practical to
the vent termination or location to which the water
heater vent piping is going to be connected, and as
centralized with the water piping system as possible.
2. Selected location must provide adequate clearances
for servicing and proper operation of the water heater.
3. Ensure the area has a continuous supply of air for
combustion, blower dilution and ventilation.
4. Avoid locations that could cause the water heater to
freeze from outside air.
5. Selected location must provide access to a properly
grounded electrical branch circuit. A dedicated circuit
is preferred. Do not use a GFI outlet.
6. Avoid locations that expose the water heater to direct
sunlight.
7. Keep combustibles such as boxes, magazines,
clothes, etc., away from the water heater area.
Important: Do not use an extension cord to connect the
water heater to an electrical outlet.
Important: This heater has special venting requirements
when installed in areas where the ambient temperatures
exceed 110°F (see “High Ambient Temperature Installations”).
• All water heaters eventually leak.
• Do not install without adequate drainage.
Property Damage Hazard
CAUTION
Installation of the water heater must be accomplished in
such a manner that if the tank or any connections should
leak, the flow of water will not cause damage to the
structure. For this reason it is not advisable to install the
water heater in an attic or upper floor. In all cases, a metal
drain pan should be installed under the water heater. Metal
drain pans are available at your local hardware store. Such
a metal drain pan must have a clearance of at least 1”
greater than any point on the water heater’s outer jacket
and must be piped to an adequate drain. The pan must
have a maximum depth of 1.75”.
Water heater life depends upon water quality, water
pressure and the environment in which the water heater
is installed. Water heaters are sometimes installed in
locations where leakage may result in property damage,
even with the use of a metal drain pan piped to a drain.
However, unanticipated damage can be reduced or
prevented by a leak detector or water shut-off device used
in conjunction with a piped metal drain pan. These devices
are available from some plumbing supply wholesalers and
retailers, and detect and react to leakage in various ways:
• Sensors mounted in the metal drain pan that trigger an
alarm or turn off the incoming water to the water heater
when leakage is detected.
• Sensors mounted in the metal drain pan that turn off
the water supply to the entire building when water is
detected in the metal drain pan.
• Water supply shut-off devices that activate based on
the water pressure differential between the cold-water
and hot-water pipes connected to the water heater.
• Devices that will turn off the gas supply to a gas water
heater while at the same time shutting off its water
supply.
STORAGE OF FLAMMABLE LIQUIDS
Flammable liquids (such as gasoline, solvents, propane
(LP or butane, etc.) and other substances (such as
adhesives, paints, etc.) emit flammable vapors which can
be ignited by a gas water heater’s hot surface igniter (HSI)
or main burner. The resulting flashback and fire can cause
death or serious burns to anyone in the area.
This water heater is equipped with a FV (Flammable Vapor)
sensor for detecting the presence of flammable vapors.
When the sensor detects those vapors, the unit will shut
down and not operate. Should this happen, please refer
to the “Troubleshooting Guidelines” section of this manual.
Even though this water heater is a flammable vapor ignition
resistant (FVIR) water heater and is designed to reduce
the chances of flammable vapors being ignited, gasoline
and other flammable substances should never be stored
or used in the same vicinity or area containing a gas water
heater or other open flame or spark producing appliance.
Examples of such locations are garages, storage and
utility areas.
The water heater must be located and/or protected so it
is not subject to physical damage by a moving vehicle.
16
Read instruction manual before
installing, using or servicing
water heater.
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
Fire or Explosion Hazard
WARNING
323546-000
1. Turn the thermostat counter-clockwise to the lowest setting.
2. Set the gas control switch to the “OFF” position.
3. Turn off electrical power to the appliance if service is to be performed.
TO TURN OFF GAS TO APPLIANCE
1. STOP! Read the safety
information above on this
label.
2. Turn off all electric power to the
appliance.
3. Turn the thermostat
counter-clockwise to the
lowest setting.
4. Set the switch on the control to
the “OFF” position.
5. Do not attempt to light manually.
6. Wait five (5) minutes to clear out
any gas. If you then smell gas, STOP!
Follow “B” in the safety information above on
this label. If you don't smell gas, go the next
step.
7. Turn on all electric power to
the appliance.
8. Set the switch on the control
to the “ON” position.
9. Turn thermostat to desired
setting.
DANGER Hotter water
increases the risk of
scald injury. Consult the
instruction manual before
changing temperature.
10. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
DANGER
A. This appliance does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do NOT try
to light the burner by hand.
B. BEFORE OPERATING smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier
than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; Do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to turn the gas control
buttons. Never use tools. If the control
buttons will not turn, don't try to repair them,
call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has
been under water. Immediately contact a
qualified installer or service agency to
replace a flooded water heater. Do not
attempt to repair the unit. It must be
replaced!
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
FLAMMABLEFLAMMABLE
WARNING: If you do not follow these instructions exactly, a fire
or explosion may result causing property damage, personal
injury or loss of life.
FOR YOUR SAFETY READ BEFORE LIGHTING
Read and follow water heater warnings and instructions in furnished manual.
If manual is missing, you may obtain one free of charge by calling 1-800-821-2017.
Si Ud. no puede ni leer ni entender el inglés y si necesita manuales, etiquetas
o rótulos en español, Ud. los puede obtener si al llama 1-800-821-2017.
WARNING / ADVERTENCIA
HOT
BURN
Water temperature over 125°F can
cause severe burns instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See instruction manual before
setting temperature at water heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
DANGER
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance. Storage or
use of gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in serious injury
or death.
Can result in serious injury or death
FIRE AND EXPLOSION HAZARD
Flammable Vapors
FLAMMABLES
WARNING
For continued protection against
risk of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
Fire Hazard
WARNING
Clearances to Combustibles
Minimum clearances between water heater and
combustibles are 0” at the sides and rear, 5.5” from the
front and 12” from top (standard clearance.) If clearances
stated on the heater differ from standard clearances, install
water heater according to clearances stated on the heater
(see Figure 13).
Floors with Carpeting
This water heater must not be installed directly on
carpeting. Carpeting must be protected by a metal or
wood panel beneath the appliance extending beyond
the full width and depth of the appliance by at least 3” in
every direction, or if the appliance is installed in an alcove
or closet, the entire floor must be covered by the panel.
Failure to heed this warning may result in a fire hazard.
Clearance for Servicing
Adequate clearance of 24” for servicing this appliance
should be considered before installation, such as changing
the anodes, etc.
A minimum clearance of 5.5” must be allowed for access
to replaceable parts such as thermostats, drain valve and
relief valve.
When installing the heater, consideration must be given to
proper location. Location selected should be as close to
the wall as practicable and as centralized with the water
piping system as possible.
TOP VIEW
OF CLOSET
WITHOUT DOOR
AIR INTAKE*
TOP VIEW OF
CLOSET WITH
DOOR
0” MIN.
0” MIN. 0” MIN.
5.5” MIN.
* DO NOT BLOCK OR RESTRICT IN ANY MANNER,
THE AIR INTAKES AT THE BACK OF THE WATER HEATER.
Figure 13.
A gas water heater cannot operate properly without the
correct amount of air for combustion and ventilation. Do
not install in a confined area such as a closet unless
you provide air as shown below and described in the
“Air Requirements” section (see Figure 14). Never obstruct
the flow of ventilation air for dilution and combustion. If you
have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amount of combustion air
can result in a fire or explosion and cause death, serious
bodily injury, or property damage.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Install water heater in accordance with the
instruction manual and NFPA 54.
• To avoid injury, combustion and ventilation air
must be taken from outdoors.
• Do not place chemical vapor emitting products
near water heater.
Breathing Hazard - Carbon Monoxide Gas
WARNING
Figure 14.
17
If this water heater will be used in beauty shops, barber
shops, cleaning establishments, or self-service laundries
with dry cleaning equipment, it is imperative that the water
heater or water heaters be installed so that combustion
and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
react to form corrosive hydrochloric acid when exposed to
the combustion products of the water heater. The results
can be hazardous, and also cause product failure.
INSULATION JACKETS AND BLANKETS
Insulation jackets and blankets are available to the
general public for external use on gas water heaters
but are not necessary with these products. The purpose
of an insulation blanket is to reduce standby heat loss
encountered with storage tank heaters. Your water heater
meets or exceeds the current standards with respect to
insulation and standby loss requirements, making an
insulation blanket unnecessary.
Should you choose to apply an insulation blanket to
this heater, you should follow these instructions (For
identification of components mentioned below, see Figure 1
through Figure 7). Failure to follow these instructions will
restrict the air flow required for proper combustion and
dilution, potentially resulting in fire, asphyxiation, serious
personal injury or death.
• Do not apply insulation to the top of the water heater,
as this will interfere with safe operation of the blower
assembly.
• Do not cover the outer door, thermostat or T&P relief
valve, FV sensor, or Air Intake Snorkel.
• Do not cover the “Installation And Operating manual”.
Keep it on the side of the water heater or nearby for
future reference.
• Do obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over
the existing labels.
• Do inspect the insulation blanket frequently to make
certain it does not sag, thereby obstructing combustion
air flow.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Do not obstruct water heater air intake(s) with
insulating jacket or blanket.
• Gas and carbcn monoxide detectors are available.
• Install water heater in accordance with the
instruction manual and NFPA 54.
Breathing Hazard - Carbon Monoxide Gas
WARNING
AIR REQUIREMENTS
For safe operation an adequate supply of fresh,
uncontaminated air for combustion, dilution and ventilation
must be provided.
Note: Contaminated or dusty air may cause build-up on
the blower wheel resulting in nuisance shut downs.
An insufficient supply of air can cause recirculation of
combustion products resulting in contamination that may
be hazardous to life. Such a condition often will result in
a yellow, luminous burner flame, causing sooting of the
combustion chamber, burners and flue tubes and creates
a risk of asphyxiation.
Ensure the water heater is installed where an adequate
supply of air for combustion, dilution and ventilation is
brought into that space following the requirements of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54.
If indoor air volume is determined to be insufficient by
either method listed below, outdoor air shall be provided
as described.
Never obstruct the flow of dilution/ventilation air. If you
have any doubts or questions at all, call your gas supplier.
Failure to provide the proper amounts of air can result in
a fire or explosion and cause property damage, serious
bodily injury or death. The combustion and dilution air
inlets are shown in Figure 2.
Important: Power Vented water heaters require air for
combustion and dilution air for the blower.
DIRECT VENT APPLIANCES
Other appliances installed in a Direct Vent configuration
that derive all air for combustion from the outdoor
atmosphere through sealed intake air piping are not
factored in the total appliance input Btu/hr calculations
used to determine the size of openings providing fresh
air into the space.
EXHAUST FANS
Where exhaust fans are installed, additional air should be
provided to replace the exhausted air. When an exhaust
fan is installed in the same space with a water heater,
sufficient openings to provide fresh air must be provided
that accommodate the requirements for all appliances in
the room and the exhaust fan. Undersized openings will
cause air to be drawn into the room through the water
heater’s vent system causing poor combustion.
Sooting, serious damage to the water heater and the risk
of fire or explosion may result. It can also create a risk of
asphyxiation.
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and fireplaces
should also be considered in determining the adequacy of
a space to provide combustion, ventilation and dilution air.
18
INDOOR COMBUSTION AIR
The standard method for determining the minimum volume
of indoor air requires 50 cubic feet per 1,000 Btu/hr of the
total input rating of all appliances installed in the space.
Rooms communicating directly with the space in which the
appliances are installed, through openings not furnished
with doors, are considered a part of the appliance space.
If there are doors to the adjoining space, openings are
required that connect to that space in order to be included
in the indoor air volume calculation (See Figure 15).
The appliance space shall be provided with two permanent
openings communicating directly with an additional
room(s) if the combined volume of all spaces is to be
considered. The total input of all gas utilization equipment
installed in the combined space shall be considered in
making this determination.
Each opening shall have a minimum free area of one
square inch per 1,000 Btu/hr of the total input rating of all
gas utilization equipment in the appliance space, but not
less than 100 square inches. One opening shall commence
within 12” of the top and one commencing within 12” of
the bottom of the enclosures.
Figure 15.
Alternatively, if the air infiltration rate of the structure is
known, that value, to a minimum of 0.60 Air Changes per
Hour (ACH), may be used to calculate the required volume
of the indoor air. Use the appropriate formula below.
When any combustion appliance is other than fan-assisted
calculate using the following equation:
Required volume
other
≥
21 ft
3
ACH
(
I
other
1,000 Btu/hr
)
When all combustion appliances are fan-assisted,
calculate using the following equation:
Required volume
fan
≥
15 ft
3
ACH
(
I
fan
1,000 Btu/hr
)
OUTDOOR AIR SUPPLY
Use this method if indoor combustion air is insufficient.
(See Figure 16 through Figure 18).
The appliance space shall be provided with two permanent
openings, one commencing within 12” of the top and one
commencing within 12“ from the bottom of the enclosure.
The openings shall communicate directly, or by ducts,
with the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
1. When directly communicating with the outdoors,
each opening shall have a minimum free area of
1 square inch per 4,000 Btu/hr of total input rating
of all equipment in the enclosure (see Figure 16).
Figure 16.
2. When communicating with the outdoors through
vertical ducts, each opening shall have a minimum
free area of 1 square inch per 4,000 Btu/hr of total
input rating of all equipment in the enclosure (see
Figure 17).
3. When communicating with the outdoors through
horizontal ducts, each opening shall have a
minimum free area of 1 square inch per 2,000
Btu/hr of total input rating of all equipment in the
enclosure (see Figure 18).
19
Figure 17.
4. When ducts are used, they shall be of the same
cross-sectional area as the free area of the
openings to which they connect. The minimum
short side dimension of rectangular air ducts shall
not be less than 3” (see Figure 18).
Figure 18.
5. Alternatively a single permanent opening may
be used when communicating directly with the
outdoors, or with spaces that freely communicate
with the outdoors. The opening shall have a
minimum free area of 1 square inch per 3,000 Btu/
hr of total input rating of all equipment in enclosure
(see Figure 19).
Figure 19.
6. Louvers and Grilles: In calculating free area,
consideration shall be given to the blocking effect
of louvers, grilles or screens protecting openings.
Screens used shall not be smaller than 1/4”
mesh. If the free area through a design of louver
or grille is known, it should be used in calculating
the size opening required to provide the free
area specified. If the design and free area is not
known, it may be assumed that wood louvers will
be 20-25 percent free area and metal louvers and
grilles will have 60-75 percent free area. Louvers
and grilles shall be fixed in the open position or
interlocked with the equipment so that they are
opened automatically during equipment operation.
7. Special Conditions Created by Mechanical
Exhausting or Fireplaces: operation of exhaust
fans, ventilation systems, clothes dryers or
fireplaces may create conditions requiring special
attention to avoid unsatisfactory operation of
installed gas utilization equipment.
CHEMICAL VAPOR CORROSION
CORROSION OF THE FLUEWAYS AND VENT SYSTEM
MAY OCCUR IF AIR FOR COMBUSTION CONTAINS
CERTAIN CHEMICAL VAPORS. SUCH CORROSION
MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and
air conditioning refrigerants, swimming pool chemicals,
calcium and sodium chloride (water softener salt), waxes,
and process chemicals are typical compounds which
are potentially corrosive. Do not store products of this
sort near the heater. Also air which is brought in contact
with the heater should not contain any of the chemicals.
If necessary, uncontaminated air should be obtained
from remote or outside sources. The Limited Warranty is
voided when failure of water heater is due to a corrosive
atmosphere. See Limited Warranty for complete terms
and conditions.
20
INSTALLING THE NEW WATER HEATER
WATER PIPING
To reduce the risk of unusually hot water reaching
the fixtures in the house, install Thermostatic Mixing
Valves (see Figure 8) at each point-of-use.
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled are at highest risk
of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing valves must
be installed when required
by codes and to ensure safe
temperatures at fixtures.
BURN
HOT
HOT
DANGER
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures.
HOT WATER CAN SCALD:
Water heaters are intended to produce hot water. Water
heated to a temperature which will satisfy space heating,
clothes washing, dish washing, cleaning and other
sanitizing needs can scald and permanently injure you upon
contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly,
children, the infirm, or physically/mentally handicapped.
If anyone using hot water fits into one of these groups
or if there is a local code or state law requiring certain
temperature water at the hot-water tap, then you must take
special precautions. In addition to using lowest possible
temperature setting that satisfies demand of application,
to reduce the risk of scalding, install Thermostatic Mixing
Valves (temperature limiting valves) (see Figure 8) at each
point-of-use. These valves automatically mix hot and cold
water to limit the temperature at the tap.
SPACE HEATING AND POTABLE WATER SYSTEMS
This appliance has been design certified as complying
with American National Standard/CSA Standard for water
heaters and is suitable for combination water (potable)
heating and space heating but not space heating only
applications.
Toxic Chemical Hazard
WARNING
• Do not connect to non-potable water system.
Consult a Qualified Installer or Service Agency. Follow
manufacturer’s instructions for installation of valves.
Before changing the factory setting on thermostat, read
“Operating The Temperature Control System” section in
this manual.
• This water heater should not be connected to any
heating systems or components previously used with
a non-potable water heating appliance.
• All piping components connected to this unit for space
heating applications should be suitable for use with
potable water.
• Toxic chemicals, such as those used for boiler treatment
shall not be introduced into the potable water used for
space heating.
• If the space heating system requires water temperatures
in excess of 120°F, install a Thermostatic Mixing Valve
(see Figure 8) in the domestic (potable) hot water
supply at each point-of-use to limit the risk of scald
injury.
Note: Water piping and vent piping occupy the space
above the water heater. Plan the water piping to ensure
it does not cause interference with the vent piping (see
“Planning The Vent System”).
If this water heater is to be used to supply both space
heating and potable water, the instructions listed below
must be followed:
• Combo heating systems and hot water supply
recirculation loop systems require adequate check
valves in the loop piping to prevent passive circulation
through the water heater when the system pump is
not operating.
• Be sure to follow the manual(s) shipped with the air
handler or other type heating system.
• This water heater is not to be used as a replacement
for an existing boiler installation.
• Do not use with piping that has been treated with
chromates, boiler seal or other chemicals and do not
add any chemicals to the water heater piping.
• If the space heating system requires water temperatures
in excess of 120°F, a mixing valve must be installed,
per the manufacturer’s instructions, in the potable hot-
water supply to limit the risk of scald injury.
• Pumps, valves, piping and fittings must be compatible
with potable water.
• A properly installed flow control valve is required to
prevent thermosiphoning. Thermosiphoning is the
result of a continuous flow of water through the air
handler circuit during the off cycle. Weeping (blow off)
of the temperature-pressure relief valve (T&P) or higher
than normal water temperatures are the first signs of
thermosiphoning.
• The hot-water line from the water heater should be
vertical past any mixing valve or supply line to the
heating system to remove air bubbles from the system.
• Do not connect the water heater to any system or
components previously used with non-potable water
heating appliances when used to supply potable water.
21
COMBO HEATING
This section serves as a guide for the installation and use
of “Combo” heating systems utilizing a domestic water
heater that has been specifically approved for such use.
It is written for those knowledgeable in the required trades
and professionals involved in the design and installation
of Combo Heating Systems.
It is the responsibility of the installer/designer to follow all
applicable codes to ensure the effectiveness and safety
of the installation.
System Requirements
The following requirements must be met for the installation
of Combo Heating Systems:
1. All components used for the distribution of water in
the heating loop must be suitable for potable water.
These include all piping, fittings, solder and fluxes,
pumps for circulation of water, valves, etc.
2. The water heater must not be connected to a hydronic
heating system that has been used previously. This
heater is not designed to be used in a space heating
only application.
3. No boiler treatment chemicals of any kind shall be
introduced into the system.
4. The Combo System components must be selected
and sized to meet and maintain the total calculated
demands for both domestic service hot water
and space heating requirement. The sizing and
installation must be performed in accordance with
good engineering practice such as “ASHRAE
Handbooks”, HRAI’s Unified Combo Guidelines,
“Hydronics Institute Manuals”, ANSI Z223.1, CSA
F280, National/Provincial Building Codes, ANSI
and/or codes having jurisdiction.
5. The air handler (fan coil) and/or the circulating pump
in a baseboard hydronic loop will require a dedicated
120VAC circuit. This must be provided and identified
for this purpose.
6. All piping between the water heater and the air handler
or hydronic baseboard loop must be adequately
insulated to reduce heat loss.
7. If the local jurisdiction requires a back-flow preventer
in the cold water line, an expansion tank of adequate
size must be installed.
8. “Combo” Heating Systems require higher water
temperatures than other applications. When the
system is used to supply water for Combo Heating
applications, a means, such as Thermostatic Mixing
Valves (see Figure 8) at each point-of-use, must be
installed to temper the water in order to reduce scald
hazard potential (see Figure 20 and Figure 21).
Installation
The heating mode may be one of the following options:
A. A fan coil/air handler (Figure 20).
B. A hydronic baseboard (finned tube) loop/In floor
heating (Figure 21).
The following is a list of requirements for the installation
of option A or B.
1. Install shut-off valves and unions so that the water
heater can be isolated from the heating module should
servicing of the water heater become necessary.
2. Install a drain valve at the lowest point of the heating
loop so that water can be drained from the heating
module without affecting the water heater.
3. If the air handler does not have a venting means at
the highest point of the piping arrangement, install
an air bleed at the highest point of the plumbing
arrangement.
4. Important: Install a spring loaded check valve in
the side tap return line to prevent cold water from
continuously entering the water heater. Failure to
install such a valve could cause “stacking” and cause
the T&P valve to open.
WATER
HEATER
HOT
OUTLET
EXPANSION TANK (OPTIONAL)
MIXING
VALVE
COLD
INLET
CHECK VALVE (IF USED
REQUIRES EXPANSION TANK)
COLD SUPPLY
HOSE BIB
(OPTIONAL)
FLOW
CONTROL
SUPPLY
RETURN
EXTERNAL
CIRCULATOR
AIR
HANDLER
HOT WATER
TO HOUSE
FIXTURE
C
H
M
INTERNAL
CIRCULATOR
DRAIN/
PURGE
VALVE
SPRING
LOADED
CHECK
VALVE
(see also
Massachusetts
code requirements
on page 7)
Figure 20.
WATER
HEATER
HOSE BIB
(OPTIONAL)
FLOW
CONTROL
SUPPLY
RETURN
EXTERNAL
CIRCULATOR
HYDRONIC
BASEBOARDS
(SERIES
CONNECTED
SHOWN)
HOT
OUTLET
EXPANSION TANK (OPTIONAL)
MIXING
VALVE
COLD
INLET
CHECK VALVE (IF USED
REQUIRES EXPANSION TANK)
COLD SUPPLY
HOT WATER
TO HOUSE
FIXTURE
C
H
M
SPRING
LOADED
CHECK
VALVE
(see also
Massachusetts
code requirements
on page 7)
Figure 21.
22
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements
or such conditions as high line pressure, among others,
have installed devices such as pressure-reducing valves,
check valves, and back flow preventers. Devices such
as these cause the water system to be a closed system.
RECIRCULATION LOOPS
Combo heating systems and hot water supply recirculation
loop systems require adequate check valves in the loop
piping to prevent passive circulation through the water
heater when the system pump is not operating.
Passive flow, also known as thermo-siphoning, can be
generated when the loop system water is cooler than the
temperature of the water in the heater. This can happen
during long standby periods, during the off heating season
or when the air handler is in air conditioning mode. Passive
flow can cause unwanted firing of the heater resulting in
overheating which can relieve the T&P valve.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will increase. As the
volume of water increases, there will be a corresponding
increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure
(leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause
intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure
build up. The temperature-pressure relief valve is not
intended for the constant relief of thermal expansion. This
condition is not covered under the limited warranty.
A properly-sized thermal expansion tank should be
installed on all closed systems to control the harmful
effects of thermal expansion. Contact a plumbing service
agency or your retail supplier regarding the installation of
a thermal expansion tank.
Note: To protect against untimely corrosion of hot and cold
water fittings, it is recommended that dielectric unions or
couplings be installed on this water heater when connected
to copper pipe.
• Avoid water heater damage.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold water inlet.
• Contact qualified installer or service agency.
Property Damage Hazard
CAUTION
METAL
DRAIN
PAN
FLOOR
DRAIN
HOT-WATER
OUTLET
COLD-
WATER
INLET
UNION
UNION
3/4” SWEAT
FITTING
3/4” SWEAT
FITTING
TEMPERATURE-
PRESSURE
RELIEF VALVE
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
MAX.
AIR GAP
DRAIN
VALVE
SHUT-OFF VALVE
SOME
COMPONENTS
NOT SHOWN
FOR CLARITY.
Figure 22.
Figure 22 shows typical attachment of water piping to the
water heater. The water heater is equipped with 3/4” NPT
water connections.
Note: If using copper tubing, solder tubing to an
adapter before attaching the adapter to the water heater
connections. Do not solder the water lines directly to the
water heater connections - it will harm the dip tube and
heat traps and damage the tank.
23
TEMPERATURE-PRESSURE RELIEF VALVE
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperature-
pressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
Explosion Hazard
WARNING
This water heater is provided with a properly rated/sized
and certified combination Temperature-Pressure Relief
Valve (T&P valve) by the manufacturer. The valve is
certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed
equipment of materials as meeting the requirements for
Relief Valves for Hot Water Supply Systems, ANSI
Z21.22-CSA 4.4, and the code requirements of ASME.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination temperature-
pressure relief valve rated/sized and certified as indicated
in the above paragraph. The new valve must be marked
with a maximum set pressure not to exceed the marked
hydrostatic working pressure of the water heater (150 psi)
and a discharge capacity not less than the water heater
Btu/hr input rate as shown on the water heater’s model
rating plate.
For safe operation of the water heater, the temperature-
pressure relief valve must not be removed from its
designated opening nor plugged. The T&P valve must be
installed directly into the fitting of the water heater designed
for the relief valve. Install discharge piping so that any
discharge will exit the pipe within 6” above an adequate
floor drain, or external to the building. In cold climates it is
recommended that it be terminated at an adequate drain
inside the building. Be certain that no contact is made with
any live electrical part.
The discharge opening must not be blocked or reduced
in size under any circumstances. Excessive length (over
30’), or use of more than four elbows can cause restriction
and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
T&P valve and the tank. Do not connect discharge piping
directly to the drain unless a maximum of 6” air gap is
provided. To prevent bodily injury, hazard to life, or property
damage, the relief valve must be allowed to discharge
water in adequate quantities should circumstances
demand. If the discharge pipe is not connected to a drain
or other suitable means, the water flow may cause property
damage.
• Temperature-pressure relief valve discharge pipe
must terminate at an adequate drain.
Water Damage Hazard
CAUTION
T&P Valve Discharge Pipe Requirements:
• Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in the
discharge line.
• Must not be capped, blocked, plugged or contain
any valve between the relief valve and the end of the
discharge line.
• Must terminate a maximum of 6” above a floor drain
or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated
at an adequate drain inside the building.
• Must be capable of withstanding 250°F without
distortion.
• Must be installed to allow complete drainage of both
the valve and discharge line.
Important: Allowing the T&P discharge pipe to blow down
into the drain pan can result in flooding of the area and
result in serious property damage. Significant quantities
of water can be released by an open T&P valve. Ensure
the system has adequate capacity to channel water to
the drain.
• Burn hazard.
• Hot water discharge.
• Keep clear of
temperature-pressure
relief valve discharge.
BURN
HOT
HOT
DANGER
The T&P valve must be manually operated at least once
a year. Caution should be taken to ensure (1) no one is
in front of or around the outlet of the discharge line, and
(2) the water manually discharged will not cause any
bodily injury or property damage because the water may
be extremely hot. If after manually operating the valve, it
fails to completely reset and continues to release water,
immediately close the cold-water inlet to the water heater,
follow the draining instructions in this manual, and replace
the temperature-pressure relief valve with a properly rated/
sized new one.
24
Note: The purpose of a temperature-pressure relief valve
is to prevent excessive temperatures and pressures in the
storage tank. The T&P valve is not intended for the constant
relief of thermal expansion. A properly sized thermal
expansion tank must be installed on all closed systems to
control thermal expansion, see “Closed Water Systems”
and “Thermal Expansion” sections.
Temperature-Pressure Relief Valve and Pipe
Insulation
The T&P valve installed on this water heater is covered by
insulation to minimize heat loss. The insulation has a hole
on the bottom side to accommodate the valve outlet and
allow for the piping connection. Do not restrict the outlet
opening of the T&P valve.
T&P Relief Valve
T&P Relief Valve
Drain Line
Manual Relief Lever
T&P Relief Valve Insulation
(Outlet opening on underside)
Figure 23.
Locate the temperature and pressure relief valve on the
water heater (also known as a T&P relief valve). See
Figure 23.
1. Locate the slit running the length of the T&P relief
valve insulation.
2. Spread the slit open and fit the insulation over the T&P
relief valve. See Figure 23. Apply gentle pressure to
the insulation to ensure that it is fully seated on the T&P
Relief Valve. Once seated, secure the insulation with
duct tape, electrical tape, or equivalent. Important:
The insulation and tape must not block the discharge
opening or hinder access to the manual relief lever
(Figure 23). Ensure a discharge pipe is installed into
the T&P valve discharge opening per the instructions
in this manual.
3. Locate the hot water (outlet) and cold water (inlet)
pipes to the water heater.
4. Locate the slit running the length of a section of pipe
insulation.
5. Spread the slit open and slip the insulation over the
cold water (inlet) pipe. Apply gentle pressure along
the length of the insulation to ensure that it is fully
seated around the pipe. Also, ensure that the base
of the insulation is flush with the water heater. Once
seated, secure the insulation with duct tape, electrical
tape, or equivalent.
6. Repeat Step 5 and Step 6 for the hot water (outlet)
pipe.
7. Add additional sections of pipe insulation as needed.
HIGH ALTITUDE INSTALLATION
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• For operation above 10,100 ft.
a high altitude orifice must be
installed.
• Contact a qualified installer or
service agency.
Breathing Hazard - Carbon Monoxide Gas
WARNING
This heater is approved for operation up to 10,100 ft.
without alteration.
Failure to replace standard orifice with a high altitude
orifice when installed above 10,100 ft. could result in
improper and inefficient operation of the appliance,
producing carbon monoxide gas in excess of safe limits,
which could result in serious injury or death. Contact
your gas supplier for any specific changes which may be
required in your area.
GAS PIPING
• Do not use water heater with
any gas other than the gas
shown on the rating plate.
• Excessive pressure to gas
control valve can cause serious
injury or death.
• Turn off gas lines during
installation.
• Contact qualified installer or
service agency.
Fire and Explosion Hazard
WARNING
Explosion Hazard
Have a qualified technician make sure that the L.P.
gas operating pressure does not exceed 13" water
column.
Failure to do so can result in death, explosion, or
fire.
WARNING
25
Make sure the gas supplied is the same type listed on
the model rating plate. The inlet gas pressure must not
exceed 14 inch w.c. for natural gas and propane gas. The
minimum inlet gas pressure shown on the rating plate is
that which will permit firing at rated input.
All gas piping must comply with local codes and ordinances
or with the “National Fuel Gas Code”, ANSI Z223.1/
NFPA-54 (current edition). Copper or brass tubing and
fittings must be certified for gas service.
If the gas control valve/thermostat is subjected to
pressures exceeding 1/2 psi, the damage to the gas
control valve/thermostat could result in a fire or explosion
from leaking gas.
If the main gas line shut-off serving all gas appliances is
used, also turn “OFF” the gas at each appliance. Leave
all gas appliances shut “OFF” until the water heater
installation is complete.
A gas line of sufficient size must be run to the water heater.
Consult the current edition of “National Fuel Gas Code”,
ANSI Z223.1/NFPA 54 and your gas supplier concerning
pipe size.
There must be:
• A readily accessible manual shut-off valve in the gas
supply line serving the water heater, and
• A sediment trap ahead of gas control valve/thermostat
to help prevent dirt and foreign materials from entering
the gas control valve/thermostat.
• A flexible gas connector or a ground joint union between
the shut-off valve and gas control valve/thermostat to
permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting
the water heater. Use a soapy water solution, not a match
or open flame. Repair and retest as required. When
finished, rinse off soapy solution and wipe dry.
• Use joint compound or tape
compatible with propane.
• Leak test before operating
heater.
• Disconnect gas piping and
shut-off valve before pressure
testing system.
Fire and Explosion Hazard
WARNING
Use pipe joint compound or Teflon
©
tape marked as being
resistant to the action of gases.
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
The appliance and its individual shut-off valve should be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psi. It should be isolated from the gas supply
piping system by closing its individual manual shut-off
valve during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 psi.
Connecting gas piping to the gas control valve/thermostat
of water heater can be accomplished by either of two
methods shown in Figure 24 & Figure 25.
FLEX PIPE
(PROPERLY SIZED
FOR THE HEATER
INPUT RATE)
SEDIMENT
TRAP
GAS
CONTROL
VALVE
GROUND
JOINT
UNION
(OPTIONAL)
CAP
3” MIN.
Figure 24.
BLACK PIPE
SEDIMENT
TRAP
GAS
CONTROL
VALVE
GROUND
JOINT
UNION
(OPTIONAL)
CAP
3” MIN.
Figure 25.
SEDIMENT TRAPS
• Contaminants in gas lines can
cause fire or explosion.
• Clean all gas piping before
installation.
• Install sediment trap in accor-
dance with NFPA 54.
Fire and Explosion Hazard
WARNING
A sediment trap should be installed as close to the inlet of
the water heater as practical at the time of water heater
installation. The sediment trap should be either a tee fitting
with a capped nipple in the bottom outlet or other device
recognized as an effective sediment trap. If a tee fitting is
used, it should be installed in conformance with one of the
methods of installation shown in Figure 24 & Figure 25.
Contaminants in the gas lines may cause improper
operation of the gas control valve/thermostat that may
26
result in fire or explosion. Before attaching the gas line be
sure that all gas pipe is clean on the inside. To trap any
dirt or foreign material in the gas supply line, a sediment
trap must be incorporated in the piping. The sediment trap
must be readily accessible. Install in accordance with the
“Gas Piping” section. Refer to the current edition of the
“National Fuel Gas Code”, ANSI Z223.1/NFPA 5 4.
HOT-WATER
OUTLET
COLD-
WATER
INLET
UNION
TEMPERATURE-
PRESSURE
RELIEF VALVE
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
6” MAX. AIR GAP
BELOW DISCHARGE
PIPE
METAL
DRAIN
PAN
FLOOR
DRAIN
DRAIN
VALVE
SHUT-OFF VALVE
SOME
COMPONENTS
NOT SHOWN
FOR CLARITY.
SIDE TAP
(OUTLET)
SIDE TAP
(INLET)
Figure 26.
FILLING THE WATER HEATER
• Avoid water heater damage.
• Fill tank with water before operating.
Property Damage Hazard
CAUTION
• Do not insert the power cord into the electrical
receptacle until the heater has been fully installed.
• Never use this water heater unless it is completely full
of water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot-water
faucet before turning “ON” gas to the water heater.
To fill the water heater with water:
1. Close the water heater drain valve by turning handle
to the right (clockwise). The drain valve is on the lower
front of water heater (see Figure 26).
2. If the heater is equipped with plumbing side taps and
they are not connected to piping, ensure that the side
taps have been closed with pipe plugs.
3. Open all hot-water faucets served by the water heater
to allow air to escape from the tank and the water
piping. Ensure any shut-off valves between the heater
and the faucets are the open position.
4. Open the cold-water supply valve to the water heater.
Notes:
• The cold-water supply valve must be left open when
the water heater is in use.
• Avoid water leakage when filling the tank. Do not
allow the insulation of the water heater to get wet as
water can reduce the effectiveness of the insulation.
5. To ensure complete filling of the tank, allow air to exit
by opening nearest hot-water faucet. Allow water to
run until a constant flow is obtained. This will let air
out of the water heater and the piping.
6. Check all water piping and connections for leaks.
Repair as needed.
VENTING
Power Vent configurations use room air for combustion.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Install vent system In accordance with codes.
• Do not operate water heater if flood damaged.
• Install water heater in accordance with the
instruction manual.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake(s) with
insulating jacket or blanket.
• Do not place chemical vapor emitting products near
water heater.
• Gas and carbon monoxide detectors are available.
• Never operate the heater unless it is vented to the
outdoors and has adequate air supply to avoid risks
of improper operation, fire, explosion or asphyxia-
tion.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing Hazard - Carbon Monoxide Gas
WARNING
Important: DO NOT common vent this water heater with
any power vented appliance. DO NOT vent into a common
chimney.
27
TERMINATION CLEARANCES SIDEWALL POWER VENT
Note: The following figure and table are intended to illustrate clearance requirements, and do not serve as a substitute
for locally adopted installation codes.
FIXED
CLOSED
INSIDE CORNER
DETAIL
OPERABLE
FIXED
CLOSED
OPERABLE
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
V
X
X
V
V
V
V
V
V
V
V
V
B
B
B
B
B
J
A
K
M
F
B
L
D
X
G
A
C
E
Figure 27.
Power Vent Terminal Clearances (uses room air for combustion)
A
above grade, veranda, porch, deck
or balcony
12 in. G to inside corner 18 in.
B
to window or door that may be
opened
4 ft. below or to side of
opening;
1 ft. above opening
J
to a non mechanical air supply inlet
into building or combustion air inlet
to any other appliance
4 ft. below or to side of
opening;
1 ft. above opening.
C to permanently closed window 0 in. K to a mechanical air supply inlet
3 ft. above if within
10 ft. horizontally
D
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 ft. from the
center line of the terminal
12 in.† L
above paved sidewalk or paved
driveway located on public property
7 ft.†
E to unventilated soffit 12 in. M
under veranda, porch, deck, or
balcony
12 in.‡
F to outside corner 24 in.
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code:
† 1. Where local experience indicates condensate is a problem with Category IV appliances, the vent shall not terminate:
• over public walkways; or
• near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property
damage; or
• where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves or other equipment.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
28
BLOWER ASSEMBLY INSTALLATION
1. This power vented water heater comes with blower
assembly installed (see Figure 28).
2. After unit is set in place, make sure blower assembly is
still mounted securely. Make sure there is no damage
to blower.
HOSE
CONNECTION
PORT FOR
CONDENSATE
DRAIN
DILUTION
AIR
INLETS
8”
LOOP
TO
DRAIN
BLOWER
ASSEMBLY
Figure 28.
3. Make sure there is no packing material in the inlet or
discharge of the blower.
4. Make sure that the plastic tubing is still attached
from the air pressure switch to the port on the blower
housing. Make sure the plastic tubing is not folded
anywhere between the pressure switch and the blower
housing (see Figure 36 through Figure 40).
5. This water heater is a polarity sensitive appliance and
will not operate properly if the power supply polarity
is reversed. Power to this water heater must be wired
properly (correct polarity).
6. Do not plug in power cord until vent system is
completely installed. The Power Vent operates on 110
-120VAC, therefore a grounded outlet must be within
reach of the 6 foot flexible power cord supplied with
the heater. The power cord supplied may be used on
a unit only where local codes permit. If local codes do
not permit use of flexible power supply cord:
a. Make sure the unit is unplugged from the wall
outlet. Remove the screw and open panel on the
front of the junction box on the blower.
b. Cut the flexible power cord, leaving enough to
be able to make connections. Remove the strain
relief fitting from the box.
c. Install a suitable conduit fitting inside the
enclosure.
d. Splice field wiring into existing wiring using code
authorized method (wire nuts, etc).
e. Be certain that the neutral and line connections
are not reversed when making these connections.
f. Ground heater properly. This water heater must
be grounded in accordance with the “National
Electrical Code”, NFPA 70 (current edition)
and/or local codes. These must be followed in
all cases. The water heater must be connected
to a grounded metal, permanent wiring system
or an equipment grounding conductor must be
run with the circuit conductors and connected to
the equipment grounding terminal or lead on the
water heater (see Figure 10; the wiring diagram).
g. Close the panel on the junction box. Make sure
that the access panel is secured shut.
7. The blower discharge boot is made to accept only
straight sections of 2” or 3” pipe. To start off with an
elbow, a short section of the straight pipe must be cut
and glued into the end of the elbow that will mount on
the discharge boot.
INSTALLATION OF VENT SYSTEM
Before beginning installation of piping system, thoroughly
read the “Vent Pipe Preparation” section of this manual.
PLANNING THE VENT SYSTEM
Plan the layout of the vent system from the vent termination
to the water heater considering all of the 90° and 45°
elbows plus the number of feet of pipe that would be
needed to install the total vent system. The water heater
must be vented to the outdoors as described in these
instructions. This water heater must be vented separately
from all other appliances.
The unit may be vented horizontally through a wall or
vertically through the roof. Pipe runs must be adequately
supported along both vertical and horizontal runs
according to local codes or the venting manufacturer’s
instructions such as IPEX (www.ipexna.com/resources/
technical-library).
Note: Do not use an elbow as a support point. Elbows are
not designed to carry the load or stresses of the venting
system if they are rigidly held.
It is imperative that the first hanger (or support) be located
on the horizontal run immediately adjacent to the first
90° elbow from the vertical rise. Support method used
should isolate the vent pipe from the floor joists or other
structural members to prevent the transmission of noise
and vibration. Do not support, pin, or otherwise secure the
venting system in a way that restricts the normal thermal
expansion and contraction of the chosen venting material.
If the water heater is being installed as a replacement for
an existing power vented heater in pre-existing venting,
a thorough inspection of existing venting system must be
performed prior to any installation work. Verify that correct
material, as detailed in below, has been used, and that the
minimum or maximum vent lengths and terminal location
as detailed in this manual have been met.
29
HIGH AMBIENT TEMPERATURE INSTALLATIONS
This heater requires room air to lower the flue gas
temperatures before the gases pass through the vent
system. The dilution air inlets are located on the rear of
the blower assembly (see Figure 2 and Figure 28).
As the room temperature rises, the ability to lower the
flue gases temperature lessens so special attention to
the choice of venting material is required. Establishing
the ambient temperatures where the heater and the
venting is installed is very important, especially in regions
with warmer climates or any region that experiences hot
summers. Ambient conditions between 110°F and 140°F
require that the venting material be either CPVC or
polypropylene. Areas that can experience high ambient
environments include closets, alcoves, areas under
staircases, attics-especially in metal roofed buildings,
areas with restricted air movement, rooms with large solar
gains, metal sheds, industrial or commercial enterprises
and venting systems exposed to direct sunlight. For
high temperature environments, obtain high limit switch
upgrade Kit #100112696 and use the higher rated vent
piping. Use of cellular core PVC (ASTM F891), cellular
core CPVC, or Radel
®
(polyphenylsulfone) in non-metallic
venting systems is prohibited.
,
Vent Pipe
Material
Pipe and fitting
nomenclature
Applicable
Standard
PVC DWV
ASTM D2665 or
CSA B181.2
PVC Sch 40, 80, 120
ASTM D1785 or
CSA B137.3
PVC SDR series
ASTM D2241 or
CSA B137.3
PVC BH
ULC S636‡
UL 1738§
CPVC CPVC 41
ASTM D2846 or
CSA B137.6
CPVC Sch 40, 80
ASTM F441 or
CSA B137.6
CPVC SDR series ASTM-F442
CPVC BH
ULC S636‡
UL 1738§
ABS Sch 40 DWV
ASTM D2661§,
CSA B181.1§ or
ULC S636‡
Polypropylene n/a
ULC S636‡
UL 1738§
‡ Applicable to Canada only.
§ Applicable to the United States only.
Note: Use of cellular core PVC (ASTM F891), cellular
core CPVC, or Radel®(polyphenysulfone) in non-
metallic venting systems is prohibited.
Table 2.
Note: Using schedule 80 or 120 significantly reduces the
equivalent feet of vent length.
Note: This unit can be vented with the following piping:
PVC pipe
materials
(solid pipe)
DWV ASTM-D2665
Schedule 40, 80* & 120* ASTM-D1785,
SDR Series ASTM-D2241
CPVC pipe
materials
CPVC 41 ASTM-D2846
Schedule 40, 80* & 120* ASTM-F441
SDR Series ASTM-F442,
ABS pipe
materials
DWV ASTM-D2661
Schedule 40
Polypropylene
vent system
UL-1738
* NOTE: USING SCHEDULE 80 OR 120
SIGNIFICANTLY REDUCES THE VENT LENGTH.
Note: If local codes require venting to be marked suitable
for use as gas venting, type BH venting may be used.
The fittings, other than the Termination should be
equivalent to:
PVC pipe
PVC DWV ASTM D-2665
CPVC pipe CPVC ASTM F-438
ABS pipe ABS ASTM D-2661/3311
Polypropylene
vent system
UL-1738
If CPVC or ABS pipe and fittings are used, the proper
cement must be used for all joints, including joining the
pipe to Termination (PVC Material). If local codes do not
allow the use of the PVC termination when a material
other than PVC is used for venting, an equivalent fitting
of that material may be substituted if the screen in the
PVC terminal is removed and inserted into the new fitting.
This water heater is supplied with a 45° PVC termination
elbow and the applicable vent screens. A 90° termination
elbow is optional.
ASTM D-2564 Grade Cement should be used on PVC
Materials and ASTM F-493 Grade Cement on CPVC
Materials.
Note: Polypropylene vent systems require separate
adaptor, termination, and elbows (field supplied). It is
recommended to use InnoFlue® SW Residential products
from Centrotherm (www.centrotherm.us.com).
POLYPROPYLENE VENT SYSTEMS
Polypropylene vent systems do not use cement to connect
the pipe and elbow sections but use a push together
gasket seal method. Do not cement the venting system
to the heater. For polypropylene vent systems follow the
manufacturer’s instructions.
Polypropylene vent systems are designed to use specific
adaptors to connect into the rubber coupling on the top
of the blower. These are available through your venting
supplier.
The PVC vent termination elbow supplied with this heater
has been certified to be used with polypropylene vent
systems. A polypropylene to PVC end connection is
required and is available through your supplier.
30
Optional wall plates that fit the polypropylene venting are
also available through your supplier.
Note: This heater is certified to use solid wall polypropylene
venting. Do not install with the corrugated type flex venting.
Carefully inspect the entire venting system for any signs of
cracks or fractures, particularly at joints between elbows
and other fittings and straight runs of vent pipe. Check
system for signs of sagging or other stresses in joints as
a result of misalignment of any components in the system.
If any of these conditions are found, they must be corrected
in accordance with the venting instructions in this manual
before completing installation and putting the water heater
into service.
The vent piping shall be connected to the blower with
the rubber coupling and secured with gear clamps. The
coupling and clamps are provided with the heater.
Even though the flue gas temperature leaving the blower
is hot, some installations will have water condense in
the vent piping. If this occurs, then adequate means of
draining and disposing of the condensate shall be made
by the installer.
CONDENSATE
Condensate formation does not occur in all installations
of power vented water heaters, but should be drained
on installations where it can form in the venting system.
Condensation in the venting system of power vented
water heaters is dependent upon installation conditions
including, but not limited to, ambient temperature and
humidity of installation location, ambient temperature
and humidity of venting space, vent discharge and slope,
and product usage. In certain conditions, installations in
unconditioned space or having long horizontal or vertical
vent runs can accumulate condensate. Long lengths of
venting that pass through cool/cold areas will experience
condensation. The vent pipe should be sloped upwards
away from the blower assembly, then adequate means
for draining and disposing of the condensate needs to
be made by the installer. If installation conditions cause
condensation, install a condensate trap loop approximately
8” in diameter using 3/8” plastic hose. Connect the hose to
the built-in drain port of the rubber coupling of the blower
assembly (see Figure 28). Loop the hose in a vertical
position as shown. The tube loop must be filled with water
at least half way prior to operating the heater. Ensure the
end of the tube has access to a drain as condensate will
flow from the end. Secure the tubing to the side of the
heater. Prior to operating the water heater, make sure
the removable cap is installed on the drain port (if a drain
hose is not needed).
Note: This cap must remain in place if a drain hose is not
installed.
EXHAUST VENTING
This heater is designed to exhaust the products of
combustion (flue gases) to the outdoors using a sealed
piping system. Table 3 lists the allowable vent materials and
sizing information. Figure 32 shows the general venting
layout while Figure 36 through Figure 40 show various
end termination details and clearances. Connection of
the venting piping to the blower is shown in Figure 36
through Figure 40.
Correct installation of the venting system is essential to
the safe and efficient operation of this water heater. Vent
piping must be installed in accordance with all applicable
codes. All installations shall meet the requirements as
stated in the current edition of the “National Fuel Gas
Code”, ANSI Z223.1/NFPA 54.
Note: The information provided in Figure 29 is intended
as a guideline for good vent installation practices only
and is not intended to restrict venting options beyond
those restrictions established by the current edition of the
“National Fuel Gas Code”, ANSI Z223.1/NFPA 54 or any
applicable local and state codes.
6”
min.
BACK TO BACK ELBOWS
NORMAL ELBOW
90° LONG SWEEP ELBOW
(LESS RESTRICTIVE)
90° SHORT SWEEP ELBOW
(MORE RESTRICTIVE)
STREET ELBOW
PREFERRED PRACTICE
Figure 29.
31
Important Notes and Warnings
• This heater is certified to be installed using Schedule
40 PVC, CPVC, ABS or polypropylene plastic vent
material. Only use approved material. All venting
material and components must be joined with the
approved primer/cleaner and solvent cement. Check
with your local authorities to determine which materials
are allowed in your area.
• Do not common vent this heater with any other
appliance.
• Covering non-metalic vent piping with thermal insulation
is prohibited.
• During operation the plastic piping will expand as it
heats up and contract as it cools down. This is normal
for this type of venting. Rigidly fastening the vent piping
can cause undue stress that may result in the cracking
or fracturing the vent piping material. A fracture of the
venting pipe may pose a serious safety hazard. To
prevent stressing of the vent system, all hangers and
supports must allow the vent piping freedom to move.
• Use long sweep elbows wherever possible. Closely-
coupled elbows and short radius elbows can reduce
the venting capacity.
• All power vented water heaters generate a certain
amount of operational noise. In order to minimize noise
transmission to the support structure, use isolation pads
between the pipe hangers and the vent pipe.
• Most power vent installations develop some
condensation in the vent piping. When using long runs
of venting or when the venting passes through cold or
unheated areas, considerable amounts of condensate
from the flue gases can develop. Provision must be
made for the condensate to drain freely from the
system or to be collected in a condensate trap(s) that
can be drained. Damage or fracture of the vent piping
may occur if the condensate is allowed to collect and
freeze. Pooling of condensate can restrict airflow and
can cause nuisance failures of the system.
• In regions that experience freezing conditions, slope the
venting back towards the heater so that the condensate
will drain back to the blower and be collected in the
condensate trap. Draining condensate out through the
termination can result in vent freeze up resulting in a
nuisance shut down situation. Ice formed from frozen
condensate can cause a safety hazard. See also notes
in the “Venting” section.
Venting Terminations and Sizing
• Refer to Figure 32 and Table 3 for vent pipe materials
and sizing. Examples of the vent terminations are
shown in Figure 33 and Figure 34. If the installation
requires a vent riser, suitable drainage must be
provided to ensure condensation does not accumulate.
Termination through a roof is shown Figure 35.
• 40 and 50-gallon heaters with rated inputs of 50k
Btu/hr or less are supplied with a 2”-3” rubber coupling
to attach the venting to the blower and a 2”, 45° vent
termination elbow.
• 50-gallon heaters with a rated input of 60k Btu/hr or
more are supplied with a 3”-3” rubber coupling to attach
the venting to the blower and a 3”, 45° vent termination
elbow.
• Supplied with this heater are several vent termination
screens (see Figure 30 and Figure 31).
Installed in the vent termination elbow, the vent screen
is required to keep foreign objects, rodents and small
birds from entering the venting system. These screens
have been sized to ensure maximum energy efficiency of
the vent system based on the “equivalent length” of the
vent piping. CHOOSE ONLY the ONE SCREEN THAT
MATCHES YOUR VENTING CONFIGURATION (see
Figure 30 and Figure 31). How to determine the “equivalent
length” is shown in Figure 32 and in Table 3.
Vent Screen Installation
Note: The correct vent screen is required for proper
operation of this water heater. Failure to install and secure
the correct screen can result in improper vent operation
which can result in the water heater overheating or
nuisance shut down.
• Install the appropriate vent screen into the vent
termination elbow.
• Gently push the screen into the termination elbow until
it sits against the inside shoulder.
• The metal wire screens are self-securing.
• Plastic screens must be secured with (2) rustproof
screws. This will allow for easy removal for inspection
and cleaning.
32
with 2” venting (short) with 2” venting (long)
For heaters with rated inputs of 50k Btu/hr or less:
VENT LENGTH LESS THAN OR
EQUAL TO 20 EQUIVALENT FT. USE
THIS SCREEN (SUPPLIED).
VENT LENGTH GREATER THAN
20 EQUIVALENT FT. USE THIS
SCREEN (SUPPLIED).
with 3” venting
VENT LENGTH GREATER THAN
50 EQUIVALENT FT. USE THIS
SCREEN (FIELD SUPPLIED).
with 3” venting
VENT LENGTH LESS THAN OR
EQUAL TO 50 EQUIVALENT FT. USE
THIS SCREEN (SUPPLIED).
with 4” venting
VENT LENGTH GREATER THAN
125 EQUIVALENT FT. USE
THIS SCREEN (ORDER KIT
#9008310015).
ELBOW
#6 SHEET METAL
SCREW (FIELD
SUPPLIED)
OPEN
POCKET
SHOULDER
PLASTIC
SCREEN
CLOSED
POCKET
POCKETS
FACING OUT
Figure 30.
with 4” venting
VENT LENGTH GREATER THAN
50 EQUIVALENT FT. USE THIS
SCREEN (FIELD SUPPLIED).
with 3” venting (short) with 3” venting (long)
For heaters with rated inputs of 60k Btu/hr or more:
VENT LENGTH LESS THAN OR
EQUAL TO 20 EQUIVALENT FT. USE
THIS SCREEN (SUPPLIED).
VENT LENGTH GREATER THAN
20 EQUIVALENT FT. USE THIS
SCREEN (SUPPLIED).
Figure 31.
33
Calculating Equivalent Feet
WATER
HEATER
MODEL
HEATER
INPUT
(Btu/hr)
VENT SIZE
(Inside
Diam.)
PRESSURE
SWITCH
SETTING
MAXIMUM EQUIVALENT
VENT LENGTH
MINIMUM EQUIVALENT
VENT LENGTH
40 & 50 gal. 40,000
2”
- 0.27 in. w.c.
50 ft. + termination elbow 7 ft. + termination elbow
40 & 50 gal. 50,000 - 0.37 in. w.c
40 & 50 gal. 40,000
3”
- 0.27 in. w.c.
125 ft. + termination elbow 50 ft. + termination elbow
40 & 50 gal. 50,000 - 0.37 in. w.c.
50 gal. (short) 62,000
3”
- 0.99 in. w.c.
50 ft. + termination elbow 7 ft. + termination elbow
40 & 50 gal. 40,000
4”
- 0.27 in. w.c.
180 ft. + termination elbow 125 ft. + termination elbow
40 & 50 gal. 50,000 - 0.37 in. w.c.
50 gal. (short) 62,000
4”
- 0.99 in. w.c.
125 ft. + termination elbow 50 ft. + termination elbow
Equivalent lengths of straight pipe for various elbows using Schedule 40 PVC, CPVC and polypropylene.
Vent Pipe
Size
Elbow
Type
Short Sweep/
Short Radius
Long Sweep/
Long Radius
Notes:
1. Use long radius elbows where possible.
Minimum distance between 90º elbows
should be 6” wherever possible.
2. Venting systems may use a maximum of
five (5) 90° elbows.
3. Use proper screen termination (see
Figure 30 and Figure 31).
2”
3"
4"
90° 8 ft. 5 ft.
2”
3"
4"
45° 4 ft. 2.5 ft.
Table 3.
Example for calculating equivalent feet.
Section “A” 0.5 ft.
90° elbow 8.0 ft.
Section B 1.0 ft.
45° elbow 4.0 ft.
Section C 1.5 ft.
45° elbow 4.0 ft.
Section D 15.0 ft.
Total Equivalent 34.0 ft.
Based on this example use the (fully open) rodent
screen for vent length greater than 20 equivalent ft.
(see Figure 30 and Figure 31).
Note: The vent pipe must be supported every 4 ft.. To prevent vibration and sagging, it is recommended to use
isolation pads when attaching straps to floor joists, walls or ceilings. PVC and CPVC vent pipe should be sloped
upwards away from the blower assembly at a pitch of 1/8 in. rise per 4 ft.. Polypropylene vent systems require a
1/4 in. per 1 ft. upward slope to ensure proper drainage.
STRAP
45° SHORT
ELBOW
90° SHORT
ELBOW
RODENT
SCREEN
(INSTALL INTO
ELBOW)
TERMINATION
ELBOW
GROUND LEVEL
12” MIN. OR ABOVE
ANTICIPATED
SNOW LEVEL.
COVER PLATE
(OPTIONAL)
RUBBER
COUPLING
Figure 32.
Important: The exhaust vent piping must be connected to the blower using the rubber coupling supplied with this heater.
This coupling contains the condensate trap and is sized for the efficient flow of the exhaust gases. Failure to use the
coupling can result in an unsafe operating condition and poor heater performance.
34
Venting Instructions
1. Plan the venting layout starting at the vent termination
and work back toward the heater. Take into consideration
the style and position of the vent termination, the vent
pipe routing, elbows and connectors required and the
necessary support hangers.
2. Venting should be as direct as possible with the fewest
number of fittings. Use long radius 45° and long radius
90° elbows wherever possible.
3. Avoid using 90° elbows “back to back” and do not use
street elbows. Maintain a minimum 6” straight section
between elbows. Closely coupled and short radius
elbows reduce the venting capacity. Figure 29 shows
examples of vent pipe connections.
4. DO NOT USE AN ELBOW AS A SUPPORT POINT.
Elbows are not designed to carry the weight of the
venting system.
5. Calculate “Equivalent Vent Length” before starting. Do
not exceed the values shown in Table 3. An example
of how this length is determined is shown in Figure 32.
The value from your calculations should also be used
to determine which rodent screen to install into the
vent termination elbow.
6. Measure the vent piping and cut to required lengths.
Pipes must be cut at right angles and deburred to
ensure a good smooth fit with sufficient overlap for
the glue joints. Correct any interference conditions.
7. Provide support hangers for horizontal vent piping
every 4’ to prevent sagging and stress.(IS THIS
AS PER THE MANUFACTURER??? WHO IS THE
MANUFACTURER???) Provide a minimum of 1/8”
rise per 4’ of vent piping to ensure adequate drainage
(polypropylene vent systems require a 1/4” rise per 1’
of vent pipe). Horizontal vent piping must not sag to
form valleys where condensate can collect. Vertical
venting shall be supported every 5’. Use appropriate
support straps and vibration isolators (foam pads)
on straight sections only. Allow sufficient clearance
for expansion and contraction of the venting system.
8. At the point where the venting exits the building, cut a
2-1/2” hole for 2” venting, a 3-1/2” hole for 3” venting or
a 4-1/2” hole for 4” venting. For sidewall applications,
use the appropriate metal cover plate as a template
to mark the hole for the vent pipe to pass through
the wall. BEWARE OF CONCEALED WIRING AND
PIPING INSIDE THE WALL.
9. Insert the vent piping through this hole and secure into
position. Connect the vent pipe to the end termination
elbow as shown in Figure 33 through Figure 35.
10. Dry fit all vent pipes, elbows, connectors and fittings
before joining any parts with solvent cement. PARTS
MUST FIT WITHOUT STRESS OR BENDING OF
ANY SECTION and each connection must overlap
a minimum of 1/2”. Do not force fit any of the
connections. Use only the appropriate solvent cement.
Caution: Solvent cements may produce flammable
vapors. Use only in well-ventilated areas and keep
away from all sources of ignition.
Note: DO NOT use solvent cement on polypropylene
vent systems.
11. Install the properly sized rodent screen into the outlet
elbow and secure with a small quantity of silicone
sealant. Refer to Figure 30 and Figure 31 to determine
the proper screen.
12. Do not seal the vent piping to the wall until the venting
is properly connected to the blower assembly.
13. Complete the venting installation by sealing around
the termination assembly where it passes through
the outside wall, inside and out, with silicone or other
suitable sealant. Apply enough sealant to secure the
(optional) cover plate to the wall.
• Use only in well-ventilated areas.
• Do not use near flame or open fire.
• Use only the Solvent Cement and Primer appropriate for
the venting material being used.
• Solvent cements for plastic pipe are flammable liquids and
must be kept away from all sources of ignition.
Use of Solvent Cement and Primer
CAUTION
SEALANT
SEALANT
(UNDER
PLATE)
GROUND
LEVEL*
RODENT
SCREEN
(INSTALL
INTO
ELBOW)
* WHERE SNOW COVER IS NORMAL DURING
WINTER, ENSURE OUTLET IS INSTALLED
ABOVE ANTICIPATED SNOW LEVEL.
12”
MIN.*
ATTACH
TERMINATION
ELBOW (MAY
ALSO BE 90°)
6”
VENT PIPING MAY
BE SLOPED IN ANY
DIRECTION, AS
LONG AS A WATER
TRAP IS NOT
CREATED IN THE
VENTING SYSTEM.
THE SLOPE
SHOULD BE KEPT
TO A MINIMUM
SO AS NOT TO
EXERT ANY UNDUE
STRESS ON THE
PIPE.
COVER PLATE
(OPTIONAL)
Figure 33.
BRACKET
VENT
RISER
SEALANT
SEALANT
(UNDER
PLATE)
ATTACH
TERMINATION
ELBOW (MAY
ALSO BE 90°)
GROUND
LEVEL*
RODENT
SCREEN
(INSTALL
INTO
ELBOW)
VENT PIPING TO BE
SLOPED (DOWN)
TOWARD HEATER
TO PREVENT
WATER FROM
COLLECTING
(MAY REQUIRE
A CONDENSATE
TEE).
EQUIVALENT
VENT LENGTH
MEASURED
FROM THIS
POSITION
* WHERE SNOW COVER IS NORMAL DURING
WINTER, ENSURE OUTLET IS INSTALLED ABOVE
ANTICIPATED SNOW LEVEL.
12”
MIN.*
COVER PLATE
(OPTIONAL)
Figure 34.
35
TERMINATION
MAY BE 90°
ELBOW
3” MIN.
LENGTH
ROOF
LINE
A VENT USED IN A
SPECIAL VENTING
SYSTEM WITH POSITIVE
VENT PRESSURE AND
PASSING THROUGH A
ROOF SHALL EXTEND AT
LEAST 18” ABOVE THE
HIGHEST POINT WHERE
IT PASSES THROUGH THE
ROOF SURFACE AND ANY
OTHER OBSTRUCTION
WITHIN A HORIZONTAL
DISTANCE OF 18”. A
VERTICAL VENTING
SYSTEM MUST BE
SUPPORTED EVERY 5’.
18” OR
ABOVE
ANTICIPATED
SNOW LEVEL
RODENT
SCREEN
(INSTALL
INTO
ELBOW)
Figure 35.
Vent Pipe Connection to Blower
1. The plastic vent piping connects into the rubber
coupling located on the top of the blower assembly.
This coupling includes gear clamps to connect the
venting to the blower. These connections must be
properly seated and tightened to prevent the leakage
of flue gases into the area. See Figure 36 through
Figure 40.
2. The 40 and 50-gallon heaters with rated inputs of 50k
Btu/hr or less are designed and supplied with a 2”
rubber coupling to accept the vent pipe.
3. The 50-gallon models with rated inputs of 60k Btu/
hr or more are supplied with a 3” rubber coupling to
accept the vent pipe.
Note: Polypropylene vent systems require separate
adaptor.
4. Before installing, clean and lightly sand the end of the
PVC/CPVC plastic vent piping that will connect into
the rubber coupling. For polypropylene vent systems
follow manufacturer’s instructions.
5. Loosen the upper clamp on the rubber coupling and
insert the sanded end of the vent piping a full 1-1/4”.
Do not use glue or sealant in the rubber coupling.
Check that there is no stress on the connection or the
vent piping that may be caused by twisting or bending.
6. Tighten the upper clamp so that the vent piping is
firmly secured in the coupling and is gas tight. Do not
over tighten or cause distortion of any of the parts.
Ensure the bottom of the rubber coupling is firmly
seated on the blower outlet and that the lower gear
clamp is also secure. Check to ensure there is no
distortion or movement of the clamped assembly once
it is completed.
• Do not overtighten the top and bottom gear clamps of the
rubber coupling.
• Do not apply solvent cement or silicone to the rubber
coupling connection.
Property Damage Hazard
CAUTION
Coupling Installations According to Vent Sizes
BLOWER
2” VENT
PIPE
2” RUBBER
COUPLING
(SUPPLIED)
CONFIGURATION
FOR 40 AND
50-GALLON (LO-
INPUT) HEATERS
CONNECTED TO
2" VENTING.
Figure 36.
2” RUBBER
COUPLING
(SUPPLIED)
BLOWER
3” VENT
PIPE
2”-3”
ADAPTER*
(FIELD
SUPPLIED)
2” VENT
PIPE, 3” MAX
LENGTH
CONFIGURATION
FOR 40 AND
50-GALLON (LO-
INPUT) HEATERS
CONNECTED TO
3” VENTING.
* FOR 3” DIRECT
CONNECTION TO
THE BLOWER,
ORDER
COUPLING Kit #
9008311005
(SEE ALSO
Figure 39 AND
Figure 40).
Figure 37.
4” VENT
PIPE
3” RUBBER
COUPLING
(ORDER COUPLING
Kit # 9008311005
TO REPLACE 2”
RUBBER COUPLING
SUPPLIED.)
3” VENT
PIPE, 3” MAX
LENGTH
3”-4”
ADAPTER
(FIELD
SUPPLIED)
BLOWER
CONFIGURATION
FOR LO-INPUT
HEATERS
CONNECTED TO
4” VENTING.
LOW-INPUT
HEATERS ARE
SUPPLIED WITH
A 2” RUBBER
COUPLING.
Figure 38.
3” VENT
PIPE
3” RUBBER
COUPLING
(SUPPLIED)
BLOWER
CONFIGURATION
FOR HI-INPUT
HEATERS
CONNECTED TO
3” VENTING.
(OPTIONAL
CONFIGURATION
FOR LO-INPUT
HEATERS
CONNECTED TO
3” VENTING.)
Figure 39.
36
4” VENT
PIPE
3” RUBBER
COUPLING
(SUPPLIED)
3” VENT
PIPE, 3” MAX
LENGTH
3”-4”
ADAPTER
(FIELD
SUPPLIED)
BLOWER
CONFIGURATION
FOR HI-INPUT
HEATER
CONNECTED TO
4” VENTING.
Figure 40.
BLOWER EXHAUST DIRECTION
The blower assembly may be rotated 90° clockwise or
counterclockwise to allow horizontal venting in areas
having restricted space above the water heater. To rotate
the blower outlet, remove the four nuts (with 11/32” nut
driver) (see Figure 41) securing the flue collector to the
blower housing. Pull the blower assembly forward to free
it from the mounting studs. Rotate the blower housing
clockwise or counter-clockwise and align the four holes
and screws together. Reattach the blower housing to the
flue collector.
11/32” nut
Note: Coupling to vent system
not shown for clarity.
Figure 41.
VENT PIPE PREPARATION
1. INITIAL PREPARATION
• Make sure the solvent cement you are planning to
use is designed for the specific application you are
attempting.
• Know the physical and chemical characteristics and
limitations of the PVC and CPVC piping materials
that you are about to use.
• Know the reputation of your manufacturer and their
products.
• Know your own qualifications or those of your
contractor. The solvent welding technique of joining
PVC and CPVC pipe is a specialized skill just as any
other pipe fitting technique.
• Closely supervise the installation and inspect the
finished job before start-up.
• Contact the manufacturer, supplier, or competent
consulting agency if you have any questions about
the application or installation of PVC and CPVC
pipe.
• Take the time and effort to do a professional job.
Shortcuts will only cause you problems and delays
in start-up. By far, the majority of failures in PVC
and CPVC systems are the result of shortcuts and/
or improper joining techniques.
2. SELECTION OF MATERIALS (PCV and CPVC
VENTING)
• Cutting Device - Saw or Pipe Cutter
• Deburring Tool, Knife, File, or Beveling Machine (2”
and above)
• Brush - Pure Bristle
• Rag - Cotton (Not Synthetic)
• Primer and Cleaner
• Solvent Cement - PVC for PVC Components and
CPVC for CPVC Components only
• Containers - Metal or Glass to hold Primer and
Cement. Select the type of PVC or CPVC materials
to be used on the basis of their application with
respect to chemical resistance, pressure rating,
temperature characteristics, etc.
• Insertion Tool - Helpful for larger diameter pipe and
fittings 6” and above.
Read instruction manual before
installing, using or servicing
water heater.
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
Fire or Explosion Hazard
WARNING
Primer:
It is recommended that Tetrahydrofuran (THF) be
used to prepare the surfaces of pipe and fittings for
solvent welding. Do not use water, rags, gasoline
or any other substitutes for cleaning PVC or CPVC
surfaces. A chemical cleaner such as MEK may
be used.
37
Cement:
The cement should be a bodied cement of
approximately 500 to 1600 centipoise viscosity
containing 10-20% (by weight) virgin PVC material
solvated with Tetrahydrofuran (THF). Small
quantities of Dimethyl Formamide (DMF) may
be included to act as a retarding agent to extend
curing time. Select the proper cement; Schedule
40 cement should be used for Schedule 40 pipe.
Never use all-purpose cements, commercial
glues and adhesives or ABS cement to join PVC
or CPVC pipe and fittings.
• Primers and cements are
extremely flammable, and must
not be stored or used near heat
or open flame.
• Also, use only in a well venti-
lated area.
Fire Hazard
WARNING
Applicators:
Select a suitable pure bristle type paint brush.
Use a proper width brush or roller to apply the
primer and cement (see chart below). Speedy
application of cement is important due to its fast
drying characteristics. IMPORTANT NOTE: A
dauber type applicator should only be used on
pipe sizes 2” and below. For larger diameter pipe,
a brush or roller must be used.
RECOMMENDED BRUSH* SIZE FOR
PRIMER AND CEMENT APPLICATIONS
Nominal
Pipe (IPS)
Brush Size
2 1.5”
3 1.5” - 2.5”
*USE ONLY NATURAL BRISTLE
Table 4.
3. MAKING THE JOINT
A. Cutting
Pipe must be squarely cut to allow for the proper
interfacing of the pipe end and the fitting socket
bottom. This can be accomplished with a miter box
saw or wheel type cutter. Wheel type cutters are
not generally recommended for larger diameters
since they tend to flare the corner of the pipe end.
If this type of cutter is used, the flare on the end
must be completely removed.
Note: Power saws, if used, should be specifically
designed to cut plastic pipe.
Figure 42.
B. Deburring
Use a knife, plastic pipe deburring tool, or file to
remove burrs from the end of small diameter pipe.
Be sure to remove all burrs from around the inside
as well as the outside of the pipe. A slight chamfer
(bevel) of about 10°-15° should be added to the
end to permit easier insertion of the pipe into the
end of the fitting. Failure to chamfer the edge of the
pipe may remove cement from the fitting socket,
causing the joint to leak.
Figure 43.
C. Test dry fit of the joint
Tapered fitting sockets are designed so that
an interfaced fit should occur when the pipe is
inserted about 1/3 to 2/3 of the way into the socket.
Occasionally, when pipe fitting dimensions are at
the tolerance extremes, it will be possible to fully
insert dry pipe to the bottom of the fitting socket.
When this happens, a sufficient quantity of cement
must be applied to the joint to fill the gap between
the pipe and fitting. The gap must be filled to obtain
a strong, leak-free joint.
38
D. Inspection, cleaning, priming
Visually inspect the inside of the pipe and fitting
sockets and remove all dirt, grease or moisture
with a clean dry rag. If wiping fails to clean the
surfaces, a chemical cleaner must be used. Check
for possible damage such as splits or cracks and
replace if necessary.
Depth-of-entry
Marking the depth of entry is a way to check if the
pipe has reached the bottom of the fitting socket
in Step F. Measure the fitting depth and mark this
distance on the pipe O.D. You may want to add
several inches to the distance and make a second
mark as the primer and cement will most likely
destroy your first one.
Apply primer to the surface of the pipe and fitting
socket with a natural bristle brush. This process
softens and prepares the PVC or CPVC for the
solvent cementing step. Move quickly and without
hesitation to the cementing procedure while the
surfaces are still wet with primer.
E. Application of solvent cement
• Apply solvent cement evenly and quickly
around outside of pipe at a width a little
greater than the depth of the fitting socket.
• Apply a light coat of cement evenly around
the inside of the fitting socket. Avoid puddling.
• Apply a second coat of cement to the pipe
end.
• Cans of cement and primer should
be closed at all times when not in
use to prevent evaporation of
chemicals and hardening of cement.
• They are also very flammable and
should be kept away from heat or
flame.
Fire Hazard
WARNING
Figure 44.
F. Joint assembly
Working quickly, insert the pipe into the fitting
socket bottom and give the pipe or fitting a 1/4 turn
to evenly distribute the cement. Do not continue
to rotate the pipe after it has hit the bottom of
the fitting socket. A good joint will have sufficient
cement to make a bead all the way around the
outside of the fitting hub. The fitting will have a
tendency to slide back while the cement is still wet
so hold the joint together for about 15 seconds.
Figure 45.
G. Cleanup and joint movement
Remove all excess cement from around the pipe
and fitting with a dry cotton rag. This must be done
while the cement is still soft.
The joint should not be disturbed immediately
after the cementing procedure, and sufficient time
should be allowed for proper curing of the joint.
Exact drying time is difficult to predict because
it depends on variables such as temperature,
humidity and cement integrity. For more specific
information, you should contact your solvent
cement manufacturer.
Figure 46.
39
INSTALLATION CHECKLIST
Note: Use and complete this checklist before lighting the
heater. Correct any conditions that do not meet these
instructions.
Water Heater Location
Centrally located with the water piping system.
Located as close to gas piping and vent pipe system
as possible.
Located indoors and in a vertical position. Protected
from freezing temperatures.
Proper clearances from combustible surfaces main-
tained and not installed directly on a carpeted floor.
Provisions made to protect the area from water
damage. Metal drain pan installed and piped to an
adequate drain.
Installation area free of corrosive elements and flam-
mable material.
Sufficient room to service the water heater.
Gas Supply and Piping
Gas supply is the same type as listed on the water
heater data plate.
Gas line equipped with shut-off valve, union and
sediment trap.
Approved pipe joint compound used.
Adequate pipe size and of approved material.
Chloride-free soap and water solution or other
approved means used to check all connections and
fittings for possible gas leaks.
Vent Pipe System
Vent pipe and fittings of approved material.
Acceptable size, length and number of elbows on
exhaust vent system.
Installed in accordance with prevailing provisions of
local codes, or in the absence of such, the current
edition of “National Fuel Gas Code” ANSI Z223.1/
NFPA 54.
Horizontal piping slopes at an upward pitch of 1/8”
rise per 4’ away from the water heater.
Not obstructed in any way.
Venting properly supported and able to move freely
for expansion and contraction.
Condensate drain connected as required.
Vent Termination
Horizontal
12” min. above grade/snow level.
Away from corners, other vents, windows etc.
Correct termination screen installed and secured.
Vertical
Exhaust vent termination 18” min. above roof/snow
level.
Correct termination screen installed and secured.
Water System Piping
Temperature and Pressure relief valve properly
installed with a discharge line run to an open drain
and protected from freezing.
All piping properly installed and free of leaks.
Heater completely filled with water.
Closed system pressure build-up precautions
installed.
All components used in combo heating systems or
recirculation loop systems suitable for potable water.
Check valves installed in combo heating and recircu-
lation loop systems.
Thermostatic Mixing Valves installed at each point-
of-use.
Electrical Connections
Unit connected to a (preferably dedicated) 120VAC
electrical supply.
Proper polarity.
Water heater properly grounded.
Electrical outlet is NOT a GFI outlet.
Installed in accordance with prevailing provisions of
local codes, or in the absence of such, the current
edition of “National Electrical Code”, NFPA 70.
After all actions on checklist are checked/
completed, read the Lighting Instructions and
proceed with lighting the heater.
40
LIGHTING INSTRUCTIONS
Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner
viewport is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater.
The gas control valve/thermostat has an “On/Off Switch” and must be turned on before the water heater is operational.
Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas. Do not start
this water heater with any gas other than the one listed on the label. If you have any questions or doubts, consult the
gas supplier or gas utility company. The following Lighting Instruction label appears on the front of the water heater.
This heater is equipped with a Honeywell gas control/thermostat and a hot-surface igniter. This control is a combination
gas valve, thermostat and ignition controller for use on this power vented water heater. The valve contains a micro-
controller that supervises the ignition sequence and monitors the temperature settings and operation of the heater. The
controller also monitors the flammable vapor safety features of this heater.
This heater is equipped with a hot-surface ignition system that automatically ignites the burner. Do not attempt
to light this heater manually with a match or flame-producing device.
323546-000
1. Turn the thermostat counter-clockwise to the lowest setting.
2. Set the gas control switch to the “OFF” position.
3. Turn off electrical power to the appliance if service is to be performed.
TO TURN OFF GAS TO APPLIANCE
1. STOP! Read the safety
information above on this
label.
2. Turn off all electric power to the
appliance.
3. Turn the thermostat
counter-clockwise to the
lowest setting.
4. Set the switch on the control to
the “OFF” position.
5. Do not attempt to light manually.
6. Wait five (5) minutes to clear out
any gas. If you then smell gas, STOP!
Follow “B” in the safety information above on
this label. If you don't smell gas, go the next
step.
7. Turn on all electric power to
the appliance.
8. Set the switch on the control
to the “ON” position.
9. Turn thermostat to desired
setting.
DANGER Hotter water
increases the risk of
scald injury. Consult the
instruction manual before
changing temperature.
10. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
DANGER
A. This appliance does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do NOT try
to light the burner by hand.
B. BEFORE OPERATING smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier
than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; Do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to turn the gas control
buttons. Never use tools. If the control
buttons will not turn, don't try to repair them,
call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has
been under water. Immediately contact a
qualified installer or service agency to
replace a flooded water heater. Do not
attempt to repair the unit. It must be
replaced!
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
FLAMMABLE
FLAMMABLE
WARNING: If you do not follow these instructions exactly, a fire
or explosion may result causing property damage, personal
injury or loss of life.
FOR YOUR SAFETY READ BEFORE LIGHTING
Read and follow water heater warnings and instructions in furnished manual.
If manual is missing, you may obtain one free of charge by calling 1-800-821-2017.
Si Ud. no puede ni leer ni entender el inglés y si necesita manuales, etiquetas
o rótulos en español, Ud. los puede obtener si al llama 1-800-821-2017.
WARNING / ADVERTENCIA
HOT
BURN
Water temperature over 125°F can
cause severe burns instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See instruction manual before
setting temperature at water heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
DANGER
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance. Storage or
use of gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in serious injury
or death.
Can result in serious injury or death
FIRE AND EXPLOSION HAZARD
Flammable Vapors
FLAMMABLES
WARNING
41
OPERATING THE TEMPERATURE CONTROL SYSTEM
Install Thermostatic Mixing Valves (see Figure 8) to
regulate the temperature of the water supplied to each
point-of-use (for example, kitchen sink, bathroom sink,
bath, shower). Install and adjust the mixing valve according
to its manufacturer’s instructions.
It is recommended that lower water temperatures be used
to avoid the risk of scalding. It is further recommended,
in all cases, that the water temperature be set for the
lowest temperature which satisfies your hot-water needs.
This will also provide the most energy efficient operation
of the water heater.
Short repeated heating cycles caused by small hot-water
uses can cause a temperature increase of the hot water
by 30F° higher than the heater’s temperature settings. If
you experience this type of use you should consider using
lower temperature settings to reduce scald hazards.
WARNING! Even if the water heater’s thermostat is set
to a relatively low temperature, hot water can scald.
Install Thermostatic Mixing Valves (see Figure 8) at
each point-of-use to reduce the risk of scalding.
Should overheating occur or the gas supply fails to shut
off, turn off the main manual gas shut off valve to the
appliance (see Figure 1).
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled are at highest risk
of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing valves must
be installed when required
by codes and to ensure safe
temperatures at fixtures.
BURN
HOT
HOT
DANGER
HOT WATER CAN SCALD:
Water heaters are intended to produce hot water. Water
heated to a temperature which will satisfy space heating,
clothes washing, dish washing, and other sanitizing needs
can scald and permanently injure you upon contact. Some
people are more likely to be permanently injured by hot
water than others. These include the elderly, children, the
infirm or physically/mentally handicapped. If anyone using
hot water fits into one of these groups or if there is a local
code or state law requiring certain temperature water at
the hot-water tap, then you must take special precautions.
In addition to using lowest possible temperature setting
that satisfies demand of application, to reduce the risk of
scalding, install Thermostatic Mixing Valves (temperature
limiting valves) (see Figure 8) at each point-of-use. These
valves automatically mix hot and cold water to limit the
temperature at the tap. Before changing the factory setting
on the thermostat, in this manual, see Table 5.
The water heater should be located in an area where
the general public does not have access. If a suitable
area is not available, a cover should be installed over the
thermostat to prevent tampering.
This water heater is equipped with an adjustable
thermostat to control water temperature (see Figure 47).
Hot water temperatures required for automatic dishwasher
and laundry use can cause scald burns resulting in serious
personal injury and/or death. The temperature at which
injury occurs varies with the person’s age and time of the
exposure. The slower response time of children, aged or
disabled persons increases the hazards to them. Never
allow small children to use a hot-water tap, or to draw their
own bath water. Never leave a child or disabled person
unattended in a bathtub or shower.
The hot setting shown on the dial is approximately 120°F.
This is a good starting point to set the temperature.
Setting the water heater temperature at 120°F will reduce
the risk of scalds.
The thermostat settings on the gas control valve are shown
in Figure 47.
The water temperature setting was factory set at the lowest
(VAC) temperature setting.
WARNING! Higher temperatures increase the risk of
scalding, but even at 120°F, hot water can scald. (See
Table 5). Install Thermostatic Mixing Valve(s) (see
Figure 8) at each point-of-use to reduce the risk of
scalding.
42
GAS CONTROL VALVE/THERMOSTAT
ON/OFF
SWITCH
TEMPERATURE
SETTING DIAL
155°F
70°F
130°F 140°F 150°F
120°F
110°F
Figure 47.
Temperature
Dial Setting
Approximate
Temperature
°F
Time to induce a 2nd
and 3rd Degree burn
to adult skin
VERY HOT 155 Less than 1 second
C 150 About 1.5 seconds
B 140 Less than 5 seconds
A 130 More than 30 seconds
HOT 120 More than 5 minutes
LOW 110 Normal shower temp
VAC 70 N/A
Table 5.
WARNING! Higher temperatures increase the risk of
scalding, but even at 120°F, hot water can scald. (See
Table 5). Install Thermostatic Mixing Valve(s) (see
Figure 8) at each point-of-use to reduce the risk of
scalding.
Note: The temperatures indicated are approximate. The
actual temperature of the heated water may vary. In some
cases, repeated small draws of water can cause the
hot and cold water in the tank to “stack” in layers. If this
happens, the water can be as much as 30F° hotter than
the gas control valve setting. This temperature variation is
the result of your usage pattern and is not a malfunction.
Check water temperature at several points of use in your
home (for example, bathtub faucet, shower, or lavatory
sink) and adjust the Thermostatic Mixing Valves (see
Figure 8) as needed.
The Vacation Setting (VAC) sets the controller at
approximately 70°F. This setting is recommended when
the water heater is not in use for a long period of time. This
effectively turns the controller temperature setting down to
a temperature that prevents the water in the water heater
from freezing while still conserving energy.
43
FOR YOUR INFORMATION
START UP CONDITIONS
Condensate
Whenever the water heater is filled with cold water, some
condensate will form while the burner is ON. A water
heater may appear to be leaking when in fact the water is
condensate. This usually happens when:
a. A new water heater is filled with cold water for the
first time.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue
temperatures are lower.
c. Large amounts of hot water are used in a short time
and the refill water in the tank is very cold.
Moisture from the products of combustion condense on
the cooler tank surfaces and form drops of water which
may fall onto the burner or other hot surfaces to produce
a “sizzling” or “frying” noise.
Because of the suddenness and amount of water,
condensate water maybe diagnosed as a “tank leak”.
After the water in the tank warms up (about 1-2 hours),
the condition should disappear.
Do not assume the water heater is leaking until there has
been enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the
family’s demands for hot water including dishwashers,
washing machines and shower heads.
Excessive condensate maybe noticed during the
winter and early spring months when incoming water
temperatures are at their lowest.
Good venting is essential for a gas fired water heater
to operate properly as well as to carry away products
of combustion and water vapor (see also “Condensate”
section).
Smoke/Odor
It is not uncommon to experience a small amount of smoke
and odor during the initial start-up. This is due to burning off
of oil from metal parts, and will disappear in a short while.
Strange Sounds
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do
not necessarily represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the
burner area during heating and cooling periods and should
be considered normal. See “Condensate” section in this
manual.
OPERATIONAL CONDITIONS
Smelly Water
Each water heater contains at least one anode rod for
corrosion protection of the tank. Certain water conditions
will cause a reaction between this rod and the water. The
most common complaint associated with the anode rod
is one of a “rotten egg smell” in the hot water. The smell
is a result of four factors which must all be present for the
odor to develop:
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
d. An excess of active hydrogen in the tank. This is
caused by the corrosion protective action of the anode.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less
active material, and then chlorinating the water heater tank
and all water lines. Contact the local water heater supplier
or service agency for further information concerning an
Anode Replacement Kit and this chlorination treatment.
If the smelly water persists after the anode replacement
and chlorination treatment, we can only suggest that
chlorination or aeration of the water supply be considered
to eliminate the water problem.
Do not remove the anode leaving the tank unprotected.
By doing so, all warranty on the water heater tank is
voided.
“AIR” IN HOT-WATER FAUCETS
• Flammable hydrogen gases may
be present.
• Keep all ignition sources away
from faucet when turning on hot
water.
Explosion Hazard
WARNING
HYDROGEN GAS: Hydrogen gas can be produced in
a hot-water system that has not been used for a long
period of time (generally two weeks or more). Hydrogen
gas is extremely flammable and explosive. To prevent
the possibility of injury under these conditions, it is
recommended that the hot-water faucet, located farthest
away, be opened for several minutes before any electrical
appliances which are connected to the hot-water system
are used (such as a dishwasher or washing machine). If
hydrogen gas is present, there will probably be an unusual
sound similar to air escaping through the pipe as the hot-
water faucet is opened. There must be no smoking or open
flame near the faucet at the time it is open.
44
PERIODIC MAINTENANCE
GENERAL UPKEEP
Make it a habit to look around the heater, the vent piping,
and the hot and cold water pipes. Do not allow any material
to be piled up against the heater. Do not place any object
on top of the vent pipes.
Every 3 - 6 months or as necessary:
• Clean lint from blower, top of heater.
Once per year:
• Inspect the Vent System.
• Burner Operation and Inspection.
• Combustion Chamber for scaling or sooting.
• Temperature-Pressure Relief Valve Test.
• Anode Rod Inspection.
• Flush a pail of water from the heater drain valve, once
per year.
If any deficiencies or abnormalities are encountered during
these inspections call a qualified service technician.
VENTING SYSTEM INSPECTION
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Flue gases may escape if vent pipe is not properly
connected.
• Be alert for obstructed, sooted or deteriorated vent
system to avoid serious injury or death.
• Do not store corrosive chemicals in vicinity of water
heater.
• Chemical corrosion of flue and vent system can
cause serious injury or death.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing Hazard - Carbon Monoxide Gas
WARNING
At least once a year a visual inspection should be made
of the venting system. You should:
• Check for obstructions and/or deterioration of the
intake air and/or vent piping and the intake air and
vent terminations. The combustion and ventilation air
flow must not be obstructed. Repair and/or replace
immediately as necessary.
Note: Do not reach inside the vent termination while the
heater is in operation.
• Remove any debris that may have accumulated on the
screen in the vent terminations.
• Check all vent system connections for damage or
deterioration which could cause improper venting or
leakage of combustion products. Repair or reseal as
necessary.
Be sure the vent piping is properly connected to prevent
escape of dangerous flue gasses which could cause
deadly asphyxiation.
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chemical
vapors. Spray can propellants, cleaning solvents,
refrigerator and air conditioner refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes, bleach
and process chemicals are typical compounds which are
potentially corrosive.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility
to correct the problem and clean or replace the flue and
venting before resuming operation of the water heater.
BLOWER MAINTENANCE
Inspect the top of the heater and around the ventilation
openings of the blower motor and the rear blower dilution
air intakes for any lint and dust that may have accumulated.
Depending on the location of the heater, significant
quantities of lint may accumulate. The lint may obstruct
the free flow of air to the motor, and cause the motor and
blower to run hotter than normal (see Figure 48).
To clean any dust and lint, proceed as follows:
1. Unplug the water heater.
2. Using a nylon bristled paint or toothbrush, brush away
any lint. Pick up the lint with a cloth.
Better results can be achieved by using the small brush
on a vacuum cleaner to remove all lint and dust which
have accumulated on top of the heater, the louvres of the
air intake snorkel, the motor ventilation openings and the
rear blower dilution air intakes.
Important: Do not insert any foreign object into the
ventilation openings of the motor.
CLEANING THE BLOWER.
In dusty and contaminated air conditions, the interior of
the blower and the blower wheel may require periodic
cleaning. This is often indicated by nuisance failures of the
air pressure switch or the high limit temperature control.
A collection of dust or debris on the rear blower dilution
air intakes can also indicate reduced blower capacity. To
clean the inside of the blower assembly and the blower
wheel requires the removal of the blower/motor from the
mounting plate located on the top of the heater. Tools
required include an 11/32” nut driver, small (1”) paint brush,
toothbrush and vacuum cleaner.
1. Turn the thermostat on the gas control to the lowest
setting. If the heater is running, wait for it to shut down
(see Figure 47).
2. Turn the gas control switch to the “OFF” position.
3. Disconnect the electrical power to the water heater
from the wall outlet.
4. Disconnect the vent piping from the top of the blower.
Loosen the lower gear clamp that holds the rubber
coupling to the blower (see Figure 48).
45
5. Remove and retain the (4) 11/32” nuts located on the
back of the blower with the nutdriver (see Figure 41
and Figure 48).
6. Holding the blower motor and the blower housing,
pull the assembly forward to disengage it from the
mounting plate. The blower will still be connected to
the junction box so exercise care not to stress the
wiring.
7. Accessing the blower wheel through the outlet, use
the paint brush to brush off the outer edge of the
blower wheel to dislodge the dirt stuck on the blades
and the inside of the housing. Rotate the wheel until
all blades are clear. Note: The wheel is a balanced
component. Do not bend, dent or distort the blades as
this can upset the wheel balance and affect the blower
operation. Vacuum out the loosened dirt.
8. Accessing the inside of the blower wheel through the
rear of the housing, gently brush off the inside of the
blades using the toothbrush. Again, take care not to
distort the blades. Rotate the wheel until all blades are
cleaned and vacuum the debris. Do not remove any
of the balancing chips attached to the blades.
9. Inspect the flue collector hood (still attached to the
heater) and vacuum out the dust and debris that may
have accumulated.
10. With all parts cleaned and the blower wheel turning
freely, reinstall the blower to the mounting plate
aligning the (4) studs and pushing tight against the
mounting plate.
11. Reinstall the (4) 11/32” nuts and tighten securely. All
(4) nuts must be in place and secure to safely operate
the blower.
12. Reattach the vent piping and coupling to the top of the
blower, tighten the bottom gear clamp and ensure the
piping is secure.
13. With all components clean and secure, reconnect the
electrical power to the heater.
14. Reset the thermostat to the desired temperature
setting and turn the gas control switch back to the
“ON” position. Note: If the water in the heater is hot,
the unit will wait to operate until there is a need for
more hot water.
BLOWER
DILUTION
AIR INTAKES
COUPLING
BLOWER
FLUE
COLLECTOR
HOOD
11/32”
NUTS
MOUNTING
PLATE
GEAR
CLAMP
VENT
PIPE
MOTOR
DRAIN
PORT
Figure 48.
BURNER OPERATION AND INSPECTION
Flood damage to a water heater may not be readily visible
or immediately detectable. However, over a period of time
a flooded water heater will create dangerous conditions
which can cause death, serious bodily injury, or property
damage. Contact a qualified installer or service agency to
replace a flooded water heater. Do not attempt to repair
the unit! It must be replaced!
At least once a year a visual inspection should be made of
the main burner and the hot surface igniter assembly for
proper flame characteristics and ignition sequences. This
can be done by removing the outer door and viewing the
main burner operation through the viewport on the inner
door (see Figure 49). The main burner should provide
complete combustion of gas, ignite rapidly, give reasonably
quiet operation, and cause no excessive flame lifting from
the burner ports. If the proper flame characteristics are
not evident (see Figure 50), make sure that the flow of
combustion and ventilation air is not blocked.
You should also check for sooting. Soot is not normal and
will impair proper combustion. A visual inspection of the
main burner and hot surface igniter should also be done
at least once a year (see Figure 49).
Soot build-up indicates a problem that requires correction
before further use. Turn “OFF” gas to water heater by
unplugging the power cord and leave off until repairs are
made. Failure to correct the cause of the sooting can result
in a fire causing death, serious injury, or property damage.
46
VIEWPORT
MAIN
BURNER
IGNITER
AND FLAME
ROD
IGNITER
AND
FLAME
ROD
Figure 49.
CORRECT FLAME
SOFT BLUE
INCORRECT
FLAME LAZY
YELLOW
BLUE TIPS
LIGHT BLUE INNER
CONES ARE
SATISFACTORY
Figure 50.
COMBUSTION CHAMBER AND BURNER CLEANING
In the event your burner or burner air openings require
cleaning, Call your service agency to remove and clean
the burner and correct the problem that required the burner
to be cleaned.
HOUSEKEEPING
• Do not obstruct combustion air
openings at the rear of the water
heater.
• Do not use or store flammable
vapor products such as gaso-
line, solvents or adhesives in the
same room or area near water
heater or other appliance.
• Can cause serious injury or
death.
Fire and Explosion Hazard
DANGER
INSTALLED IN SUITABLE AREA:
To ensure sufficient ventilation and combustion air
supply, proper clearances from the water heater must
be maintained. See “Locating The New Water Heater”
section. Combustible materials such as clothing, cleaning
materials, or flammable liquids, etc. must not be placed
against or adjacent to the water heater which can cause
a fire.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
• Burn hazard.
• Hot water discharge.
• Keep clear of
temperature-pressure
relief valve discharge.
BURN
HOT
HOT
DANGER
It is recommended that the temperature-pressure relief
valve be checked to ensure it is in operating condition at
least once a year.
When checking the temperature-pressure relief valve
operation, make sure that (1) no one is in front of or around
the outlet of the T&P valve discharge line, and (2) that
water discharge will not cause any property damage, as
water may be extremely hot. Use care when operating
valve as the valve may be hot.
To check the relief valve, lift lever at the end of valve
several times (see Figure 51). The valve should seat
properly and operate freely.
If after manually operating the valve, it fails to completely
reset and continues to release water, immediately close
the cold-water inlet to the water heater and drain the water
heater, see “Draining And Flushing” section. Replace
the T&P valve with a properly rated/sized new one, see
“Temperature-Pressure Relief Valve” for instructions on
replacement.
Figure 51.
If the Temperature-Pressure Relief Valve on the water
heater weeps or discharges periodically, it may be due to
thermal expansion.
Note: Excessive water pressure is the most common
cause of temperature-pressure relief valve leakage.
Excessive water system pressure is most often caused
by “thermal expansion” in a “closed system.” See
“Closed Water Systems” and ““Thermal Expansion”
sections of this manual. The T&P valve is not intended
for the constant relief of thermal expansion.
47
Temperature-pressure relief valve leakage due to pressure
build up in a closed system that does not have a thermal
expansion tank installed is not covered under the Limited
Warranty. Thermal expansion tanks must be installed on
all closed water systems.
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperature-
pressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
Explosion Hazard
WARNING
DRAINING AND FLUSHING
Periodic draining and cleaning of sediment from the tank
may be necessary. It is recommended that the tank be
drained and flushed every 6 months to remove sediment
which may build up during operation. The water heater
should be drained if being shut down during freezing
temperatures. See “Typical Installation” section in this
manual for location of the water heater components
described below.
• Burn hazard.
• Hot water discharge.
• Keep hands clear of drain
valve discharge.
BURN
HOT
HOT
DANGER
To Drain the Water Heater Storage Tank
1. Turn “OFF” the electrical supply to the water heater.
2. Turn “OFF” the gas supply at the Main Gas shut-off
Valve.
3. Open a hot water faucet and let the hot water run until
it is cool (This may take 10 minutes or longer).
Warning: Be sure the water runs cool before draining the
tank to reduce the risk of scalding.
4. Connect a garden hose to the drain valve and place
the other end of the hose in an adequate drain,
outside, or in buckets. Note that sediment in the bottom
of the tank may clog the valve and prevent it from
draining. If you can’t get the tank to drain, contact a
qualified person.
5. CLOSE the cold-water inlet valve to the water heater.
6. Open the drain valve on the water heater.
7. If not already done, open a hot water faucet to help
the water in the tank drain faster.
8. If a large amount of sediment was present when
the tank was drained, follow instructions in the
“To Flush the Water Heater Storage Tank” section.
9. Close the water heater drain valve when all water in
the storage tank has drained and remove the hose.
10. Follow instructions in the “Filling The Water Heater”
section.
11. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
Note: If the water heater is going to remain shut down and
empty for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
To Flush the Water Heater Storage Tank
Follow Step 1 through Step 7 in the
“To Drain the Water Heater Storage Tank” section.
1. Flush the tank by opening the cold water supply valve
and letting the water run until no more sediment drains
from the tank.
2. Close the water heater drain valve when flushing is
completed and remove the drain hose.
3. Ensure the heater is full of water.
4. Follow instructions in the “Filling The Water Heater”
section.
5. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
Caution: Do not turn on power to the water heater unless
the tank is full. Open a hot-water faucet and allow the
water to run until the air is purged and the water flows
uninterrupted from the faucet.
Important: When operating a cold tank, condensation can
occur and drip on the burner. This should not be confused
with a tank leak.
48
ANODE ROD MAINTENANCE
• Avoid water heater damage.
• Inspection and replacement of anode rod required.
Property Damage Hazard
CAUTION
Anode Rod. The anode rod is a sacrificial metal rod that
helps avoid corrosion and premature failure (leaks) in the
tank. The anode rod is a consumable item. Inspect the
anode rod after the first six months of operation when
you drain and flush the tank. Replace the anode rod if
it is substantially worn out or depleted (see Figure 52).
Thereafter, inspect the anode rod annually or more
frequently if needed. If you use a water softener, your
anode rod will deplete faster than normal. Inspect the
anode rod more frequently, replacing the anode rod if it
is depleted. Once the anode rod is depleted, the tank will
start to corrode, eventually developing a leak. Obtain a
new anode rod from your local plumbing supplier or have a
qualified person replace it. (Anode rods are a consumable
item and are not covered under warranty).
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water. The removal of the anode rod
requires a 1-1/16” socket.
Important: Do not operate the water heater without a
functioning anode rod as this will void any warranties.
A special anode rod may be available if water odor or
discoloration occurs.
Note: This rod may reduce but not eliminate water odor
problems. The water supply system may require special
filtration equipment from a water conditioning company to
successfully eliminate all water odor problems.
To replace the anode:
1. Turn “OFF” the electrical supply to the water heater.
2. Turn “OFF” the gas supply at the Main Gas shut-off
Valve.
3. CLOSE the cold-water inlet valve to the water heater.
4. OPEN a nearby hot-water faucet and leave open to
allow for draining.
5. Drain approximately 5 gallons of water from tank. (Refer
to “Draining And Flushing” for proper procedures).
Close drain valve.
6. Remove old anode rod.
7. Use Teflon
®
tape or approved pipe sealant on threads
and install new anode rod.
8. Remove the hose and follow instructions in the
“Filling The Water Heater” section.
9. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
See Figure 53 for anode rod location.
NEW
PARTIALLY DEPLETED
FULLY DEPLETED
Figure 52.
CAP
ANODE ROD *
* THE ANODE ROD IS COVERED
BY URETHANE FOAM LOCATED
UNDER THE CAP. CHIP AWAY
THE FOAM TO EXPOSE THE
TOP OF THE ANODE ROD
Figure 53.
49
LEAKAGE CHECKPOINTS
SERVICE
If a condition persists or you are uncertain about the
operation of the water heater contact a service agency.
Use this guide to check a “leaking” water heater. Many
suspected “leakers” are not leaking tanks. Often the source
of the water can be found and corrected.
If you are not thoroughly familiar with gas codes, your
water heater and safety practices, contact your gas
supplier or qualified installer to check the water heater.
Ensure the venting is properly attached and secured.
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot-water
faucet before turning “ON” gas to the water heater.
A. Water at the blower assembly is water vapor which
has condensed out of the combustion products. This
is caused by a problem in the vent. A drainage port
is included at the vent pipe connection. Contact the
gas utility.
B. *Condensation may be seen on pipes in humid
weather or pipe connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure
relief valve may be due to thermal expansion or high
water pressure in your area.
E. *The temperature-pressure relief valve may be leaking
at the tank fitting.
F. Water from a drain valve may be due to the valve
being slightly opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets
form and drip onto the burner. This is common at the
time of start-up after installation and when incoming
water is cold.
I. Water in the water heater bottom may be from
condensation, loose connections, or the relief valve.
DO NOT replace the water heater until a full inspection
of all possible water sources is made and necessary
corrective steps taken.
Leakage from other appliances, water lines, or ground
seepage should also be checked.
* To check where threaded portion enters tank,
insert cotton swab between jacket opening and
fitting. If cotton is wet, follow the instructions in the
“To Drain the Water Heater Storage Tank” section and
remove fitting. Put pipe dope or Teflon tape on the
threads and replace. Then follow the instructions in the
“Filling The Water Heater” section.
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
WARNING
C
B
D
E
F
G
H
I
A
Figure 54.
50
REFERENCE PARTS LISTING
Replacement parts may be ordered
through your plumber or the local
distributor. When ordering replacement
parts, always have the following
information ready:
1. Model, Serial and Product number
2. Type of gas
3. Item number
4. Parts description
1 Vent Termination Elbow with Rodent
Screen
2 *Vent Pipe
3 *Vent Pipe Coupling (if required)
4 *Vent Pipe Elbow (long radius)
5 Blower High Limit Switch (see Figure 6)
(see also Figure 60)
6 T&P Valve
7 Cold-Water Inlet Nipple/Diptube
8 Baffle Assembly
9 * Discharge Pipe
10 Gas Control Valve/Thermostat
(Honeywell)
11 Gas Valve Electronic Control Module
And Cover (Honeywell)
12 Drain Valve
13 Outer Gas Door
14 Manifold Door Assembly (behind outer
door) (see Figure 3 and Figure 4) (see
also Figure 57 and Figure 58)
15 *Floor Drain
16 *Metal Drain Pan
17 Flammable Vapor Sensor (under
cover) (see Figure 5) (see also
Figure 59)
18 **Combo Heating System Return Inlet
(Optional)
19 Air Inlet Snorkel
20 **Combo Heating System Supply
Outlet (Optional)
21 Blower with Power Cord (see also
Figure 6) (see also Figure 60)
22 Air Switch (inside box) (see Figure 6)
(see also Figure 60)
23 Junction Box (see Figure 6) (see also
Figure 60)
24 Junction Box Cover (see Figure 6) (see
also Figure 60)
25 Air Tubing (see Figure 6) (see also
Figure 60)
26 Rubber Coupling (see also Figure 6)
(see also Figure 60)
27 Gear Clamp (see also Figure 6) (see
also Figure 60)
28 Flue Collector
29 Hot-Water Outlet Nipple
30 Anode (under cap)
32 Flexible Manifold Tube (see
Figure 3 and Figure 4) (see also
Figure 57 and Figure 58)
33 Viewport (see Figure 3 and Figure 4)
34 Flame Sensor Rod (see Figure
3 and Figure 4) (see also
Figure 57 and Figure 58)
35 Gas Orifice (see Figure 3 and Figure 4)
(see also Figure 57 and Figure 58)
36 Sheet Metal Burner (see Figure
3 and Figure 4) (see also
Figure 57 and Figure 58)
37 Gas Manifold (see Figure 3 and Figure
4) (see also Figure 57 and Figure 58)
38 Hot-Surface Igniter (see
Figure 3 and Figure 4) (see also
Figure 57 and Figure 58)
39 Manifold Door Gasket (see
Figure 3 and Figure 4) (see also
Figure 57 and Figure 58)
40 Manifold Door (see Figure 3 and Figure
4) (see also Figure 57 and Figure 58)
41 Two Piece Grommet With Clip (see
Figure 3 and Figure 4) (see also
Figure 57 and Figure 58)
** parts not supplied with the
water heater
1
2
3
4
6
20
7
9
10
18
12
13
15
16
17
8
21
21
26
11
14
27
Front View
Figure 55.
Combustion
Air Inlets
Blower
Dilution Air
Inlets
27
29
30
19
7
28
Rear View
Figure 56.
51
Natural gas and Propane main
burner with igniter assembly for
40k to 50k Btu/hr models (item
14 in Figure 1).
Flare Nut**
*
34
35
36
37
38
39
4041
33
32
Figure 57.
Natural gas and Propane
main burner with igniter
assembly for 60k to 75k
Btu/hr models (item 14 in
Figure 1).
Flare
Nut**
*
32
34
35
33
41
40
39
38
37
36
Figure 58.
17
Figure 59.
26
27
2522
23
24
5
21
Figure 60.
Notes: * Natural gas models have Right-hand thread,
Propane models have Left-hand thread.
** For Natural gas models the Flare Nut has Right-
hand thread. For Propane models the Flare Nut
has Left-hand thread.
52
TROUBLESHOOTING GUIDELINES
WARNING! Because of the increased risk from scalding, if you set the water heater’s gas control knob higher
than 120°F, install Thermostatic Mixing Valves (see Figure 8) at each point-of-use. Due to the increased risk of
scalding, do not set the temperature of the Thermostatic Mixing Valves above 120°F.
These guidelines should be utilized by a qualified service agent.
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Burner Flame
Too High
1. Air inlets blocked
2. Insufficient secondary air
3. Orifice too large
1. Unblock inlet air openings
2. Provide ventilation to water heater
3. Replace with correct orifice
Flame Burns
At Orifice
1. Low gas pressure
2. Defective gas control valve/thermostat
1. Check with gas utility company
2. Replace gas control valve/thermostat
Insufficient
Hot Water
1. Low gas pressure
2. Orifice too small
3. Thermostat set too low
4. Gas control error codes
5. Sediment or lime in tank
6. Water heater too small
7. Wrong piping connections
8. Leaking faucets
9. Wasted hot water
10. Long runs of exposed piping
11. Hot-water piping in outside wall
1. Check with gas utility company
2. Replace with correct orifice (see rating
plate)
3. Turn temperature knob to higher setting
4. Refer to gas control error codes
5. Drain/flush-provide water treatment if
needed
6. Install adequate heater
7. Correct piping: dip tube must be in cold
inlet
8. Repair faucets
9. Advise customer
10. Insulate piping
11. Insulate piping
Water Is Too Hot
1. Thermostat is too high
2. Incorrect or missing vent screen in vent
termination
3. Defective gas control valve/thermostat
1. Turn temperature knob to lower setting.
Install or adjust Thermostatic Mixing Valves
(see Figure 8) for each point-of-use (see
the valve manufacturer’s instructions).
2. Check venting for correct screen
3. Replace the gas control valve/thermostat
Slow Hot Water
Recovery
1. Insufficient air/flue blockage
2. Low gas pressure
3. Orifice too small
4. Thermostat set too low
5. Heater too small
6. Wrong piping connection
7. Wasted hot water
8. Flue clogged
9. Air inlets blocked
1. Provide ventilation to water heater.
Check flue way, flue baffle and burner
2. Check with gas utility company
3. Replace with correct orifice (see rating
plate)
4. Turn temperature knob to higher setting.
You may be able to meet your family’s hot
water needs by installing Thermostatic
Mixing Valves (see Figure 8) at each point-
of-use and then turning the gas control
knob to a higher setting.
5. Install adequate heater. If the water heater
is in good condition, you may be able to
meet your family’s hot water needs with
the existing water heater by installing
Thermostatic Mixing Valves (see Figure 8)
at each point-of-use and then turning the
gas control knob to a higher setting.
6. Correct piping-dip tube must be in cold
inlet
7. Advise customer
8. Clean flue, locate source and correct
9. Unblock inlet air openings
53
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Drip From
Relief Valve
1. Pressure build-up
2. Heater stacking
3. Closed water system
4. Improperly seated valve
5. Water overheating
1. Use a pressure-reducing valve and relief
valve
2. Lower the thermostat setting
3. See “Thermal Expansion” section
4. Check Relief valve for proper operation
(Do Not plug T&P valve)
5. Check venting for proper vent termination
screen. Check valves in loop system stuck
or missing.
Gas Control Valve/
Thermostat Fails To
Shut Off
1. Defective gas control valve/thermostat 1. Replace gas control valve/thermostat
Smelly Water
1. Sulfides in water supply
2. Bacteria in water supply
3. Incompatible anode
1. Chlorination procedure
2. Chlorination procedure
3. Replace with anode appropriate for water
conditions
Condensation
1. Filling the new water heater for the first
time
2. Moisture from the products of
combustion
3. Water dripping from blower assembly
4. Undersized water heater
1. Normal operation: the condensation should
disappear after heater warms up
2. Normal operation: the condensation should
disappear in time
3. Install condensate hose to drain port on the
rubber coupling
4. Install adequately sized heater
Combustion Odors
1. Air inlets blocked
2. Insufficient air
3. Flue clogged
4. Heater installed in a confined area
5. House too tight
1. Unblock inlet air openings
2. Provide fresh air ventilation to the water
heater
3. Clean, locate source and correct
4. Provide fresh air ventilation to the water
heater
5. Provide fresh air ventilation to the water
heater
Smoking And Carbon
Formation
1. Air inlets blocked
2. Insufficient air
3. Low gas pressure
4. Orifice too large
5. Flue clogged
6. Defective gas control valve/thermostat
7. Heater installed in a confined area
1. Unblock inlet air openings
2. Provide ventilation to water heater.
Check flue way, flue baffle and burner
3. Check with gas utility company
4. Replace with correct orifice (see rating
plate)
5. Clean, locate source and correct
6. Replace gas control valve/thermostat
7. Provide fresh air ventilation
Unable To Light
The Burner
1. Air in gas line
2. Pressure switch
3. Blocked exhaust
4. Wire connection
5. Defective gas control valve/thermostat
1. Purge the air from gas line
2. Check the pressure switch, make sure the
pressure switch hose is not kinked
3. Check vent pipe for blockage
4. Check wire connections
5. Replace the gas control valve/thermostat
Sizzling, Rumbling
Noise
1. Scale and sediment
2. Condensation dripping on burner
1. Drain/flush-provide water treatment if
needed
2. Refer to “Condensate” section
Water Leakage
1. Condensation
2. Dripping Temperature & Pressure
Relief Valve
3. Drain valve dripping/leaking
4. Tank Leak
1. Refer to “Condensate” section
2. Refer to
“Temperature-Pressure Relief Valve”
section
3. Back flush to clean- out sediment, replace
if necessary.
4. Check “Leakage Checkpoints”
54
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Blower Will
Not Start
1. No power to unit
2. Thermostat set too low
3. Defective air pressure switch
4. Defective blower
5. Disconnected or loose wire
6. Control locked out
1. Plug in power cord, check fuses and/or
supply voltage
2. Turn temperature knob to higher setting
3. Replace air pressure switch
4. Replace blower
5. Repair and reconnect wires
6. Refer to “Resetting The Heater Control” –
determine cause of lockout
Blower Runs
Continuously
1. Air pressure switch not closing due to
insufficient dRaFt – check for:
a. Vent piping blocked
b. Piping length too long
c. Clogged/dirty blower
2. Disconnected, torn or blocked pressure
switch hose from air pressure switch to
blower housing
3. Defective pressure switch
4. High limit switch open due to excessive
vent temperature or defective switch
1. Determine cause of insufficient dRaFt.
Check dRaFt with manometer at pressure
switch
a. Remove blockage
b. Reduce vent length/increase vent size
c. Clean blower wheel
2. Reconnect or replace pressure switch hose
3. Replace defective pressure switch
4. Determine cause of overheating check
for: overfiring, insufficient air supply, high
ambient air temperature
Hot Surface Igniter
Not Glowing
Following Warm-Up
Period
1. 120VAC polarity reversed at 120VAC
outlet receptacle
2. Defective hot surface igniter
3. Defective gas control valve/thermostat
1. Reverse polarity at 120VAC outlet
receptacle
2. Replace igniter
3. Replace gas control valve/thermostat
Vent Pipe Too Hot
1. Blower high limit switch fails to open -
switch defective
2. Not enough dilution air to mix with flue
gases
3. Air in room too hot for mixing with flue
gases
4. Wrong burner orifice
5. Wrong or missing vent termination
screen
1. Replace blower high limit switch Replace
blower high limit switch
2. Proper air circulation must be provided for
combustion and dilution of flue temp
3. Increase ventilation to lower room
temperature
4. Install correct orifice
5. Install and secure proper vent termination
screen
WARNING! Because higher temperatures increase the risk of scalding, if you set the thermostat(s) higher than
120°F, Thermostatic Mixing Valves (see Figure 8) at each point-of-use are particularly important.
RESETTING THE HEATER CONTROL
• Soft lockouts as diagnosed by the system error codes require the gas control to be reset.
• To reset the control, slide the “ON/OFF” switch to the “OFF” position. Wait for 10 seconds and move the switch back
to the “ON” position.
• If the problem that caused the control to lock out has not been corrected, the control will remain or again go back
into lockout.
LOCKOUTS
Soft Lockout
• occurs when a system safety device trips to break the sequence of operation. The control will retry the system in a
timed basis but will not reinstate operation until the failure is corrected.
Hard Lockout
• occurs when the main controller fails and must be replaced.
The gas control valve\thermostat includes a temperature limiting ECO (Energy Cut Off) system that will shut off the water
heater if the water temperature is too high.
Should the water temperature get too high, the diagnostic status light will indicate a code (4 flashes), indicating an over-
temperature condition and the main burner will be shut off. If a high temperature condition occurs, turn the main gas
supply OFF and have the water heater repaired by a qualified service technician. Contact your local dealer for service
information.
55
Note: Should an over-temperature condition occur, restart
the water heater and verify the LED flash sequence. If the
4 flash sequence is observed, slide the “ON/OFF” switch to
the “OFF” position. Turn Main Gas Supply “OFF”. Replace
the gas control valve\thermostat.
IGNITION STATE AND TIMING
IGNITION STATE TIMING
Pre-purge
5 seconds (NG models)
15 seconds (LP models)
Hot Surface Igniter
(HSI) Warmup
10 seconds
Ignition Activation
Period (IAP)
3.5 seconds maximum
Flame Recognition
Period (FRP)
0.5 second
Trial For Ignition IAP + FRP
Flame Stabilization
Period
Not Applicable
Inter-purge 30 seconds
Flame Failure
Response Time
2 seconds max
(@ 1uA flame current)
Post-purge 30 seconds
Pressure Switch (PS)
Prove Period
2 minutes
Pressure Switch (PS)
Fault Delay (failed
open/closed)
2 minutes
Soft Lockout 20 minutes
Energy Cut Off
(ECO) Limit Lockout
Indefinite
Flammable Vapor
(FV) Sensor Lockout
Indefinite (see
“Resetting The Heater Control”)
SYSTEM STATUS AND ERROR CODES
The micro-controller inside the gas control monitors the
flammable vapor safety features, the ignition sequence,
temperature settings and overall operation of the heater.
If any of these parameters does not operate properly the
controller will shut down the water heater, diagnose the
failure and flash an error code. The table below lists the
System Status Codes for the Honeywell control. Refer
to it and to the “Troubleshooting Guidelines” to diagnose
the problem before attempting corrective action. See also
“Flammable Vapor Sensor”.
LED Flash
Sequence
Control Status
Short flash
once every four
seconds
IDLE (no call for heat,
no fault conditions)
“Heartbeat”,
alternates bright/dim
Call For Heat
(no fault conditions)
One Flash,
three second pause
Low Flame Signal
(control continues to operate)
Two Flash,
three second pause
Pressure Switch Failed
Closed
Three Flash,
three second pause
Pressure Switch Failed Open
Four Flash,
three second pause
ECO (Energy Cut Off) Limit
Lockout
thermostat temperature limit
was exceeded.
Five Flash,
three second pause
Flame Out Of Sequence
Six-One Flash,
three second pause
Soft Lockout
- Retry Limit
- Failed Trial For Ignition
Six-Two Flash,
three second pause
Soft Lockout
- Recycle Limit
- Pressure Switch/High Limit
opened
Six-Three Flash,
three second pause
Soft Lockout
- Recycle Limit
- Flame Lost
Six-Four Flash, three
second pause
Soft Lockout
- Flame out of Sequence
Sensed
Seven Flash,
three second pause
Flammable Vapor Sensor
(FVS) Lockout
Eight-One Flash,
three second pause
Flammable Vapor Sensor
FVS Fault Detected
Eight-Two Flash,
three second pause
Temperature Sensor Fault
Detected
Eight-Three Flash,
three second pause
Electronics Fault Detected
Eight-Four Flash,
three second pause
Valve Fault Detected
Hardware Fault
Lockout
Indefinite
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