COMMERCIAL GAS WATER HEATERS
Installation and Operating Manual
1502 331603-000
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
POWER DIRECT VENT GAS MODELS
WITH HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
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.
MODELS BPD-80 SERIES 210, 211
- 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
Qualifi ed Installer Or Service Agency . . . . . . . . . . . . 6
Preparing For The Installation. . . . . . . . . . . . . . . . . . 6
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7
TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Get To Know Your Water Heater - Gas Models
(List Referencing Figures 1-5). . . . . . . . . . . . . . . . . . 9
Replacement Parts And Deliming Products . . . . . . 10
Combo Heating Inlet And Outlet Side Taps. . . . . . . 10
Water Piping - Mixing Valve Usage . . . . . . . . . . . . . .11
Mixing Valves
Water Heater Operation . . . . . . . . . . . . . . . . . . . . . 12
Electrical Requirements & Wiring Diagram . . . . . . . 13
SAFETY LOCKOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Limit Controls (Energy Cut Off). . . . . . . . . . . . 14
Thermostat/Water Temperature
Blower High Limit Switch
Blower Air Pressure Switches . . . . . . . . . . . . . . . . . 14
LOCATING THE NEW WATER HEATER. . . . . . . . . . . . . 15
Facts To Consider About The Location . . . . . . . . . . 15
Clearances To Combustibles
Floors With Carpeting
Clearances For Servicing
Important Notes and Warnings
Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLING THE NEW WATER HEATER . . . . . . . . . . . 18
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Space Heating And Potable Water Systems . . . . . . 18
Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Requirements
Installation
Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 20
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 20
Temperature-Pressure Relief Valve. . . . . . . . . . . . . 20
T&P Valve Discharge Pipe Requirements:
Temperature-Pressure Relief Valve And
Pipe Insulation
High Altitude Installation . . . . . . . . . . . . . . . . . . . . . 22
Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sediment Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 24
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Termination Clearances (Sidewall) . . . . . . . . . . . . . 26
Side Wall Vent Terminal Installation
Roof Vent Terminal Installation
Concentric Vent Termination Kit Installation
Multiple Concentric Vent Installations
Vent Pipe Length
Vent Pipe Termination
Venting Terminations And Sizing
Vent Screen Installation
Vent Pipe Material
Vent Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . 30
Vent Pipe Installation
Vent Pipe Runs
Vent Terminal Installations
Blower Assembly Installation. . . . . . . . . . . . . . . . . . 33
Vent/Intake Pipe Connections To Blower/Air Duct
Coupling Installations According To Vent Sizes
Sound Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 36
LIGHTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 37
OPERATING THE TEMPERATURE
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Gas Control Valve/Thermostat . . . . . . . . . . . . . . . . 39
FOR YOUR INFORMATION. . . . . . . . . . . . . . . . . . . . . . . 40
Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 40
Condensate
Smoke/Odor
Strange Sounds
Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 40
Smelly Water
“Air” In Hot-Water Faucets . . . . . . . . . . . . . . . . . . . 40
PERIODIC MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 41
General Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Venting System Inspection . . . . . . . . . . . . . . . . . . . 41
Burner Operation And Inspection . . . . . . . . . . . . . . 41
Combustion Chamber And Burner Cleaning . . . . . . 42
Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Temperature-Pressure Relief Valve Test . . . . . . . . . 42
Draining And Flushing . . . . . . . . . . . . . . . . . . . . . . . 43
To Drain The Water Heater Storage Tank:
To Flush The Water Heater Storage Tank:
Anode Rod Maintenance. . . . . . . . . . . . . . . . . . . . . 44
LEAKAGE CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . 45
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REFERENCE PARTS LISTING . . . . . . . . . . . . . . . . . . . . 46
TROUBLESHOOTING GUIDELINES. . . . . . . . . . . . . . . . 48
Resetting The Heater Control . . . . . . . . . . . . . . . . . 48
Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Soft Lockout
Hard Lockout
Ignition State And Timing . . . . . . . . . . . . . . . . . . . . 48
System Status And Error Codes . . . . . . . . . . . . . . . 49
Reading The LED Flash Sequence. . . . . . . . . . . . . 49
Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Other Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects or other reproductive harm and requires businesses to warn
of potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.
This appliance can cause low level exposure to some of the substances listed in the Act.
This product is certifi ed to comply with a maximum weighted average of 0.25% lead content as required in some areas.
IMPORTANT DEFINITIONS
Qualifi ed Installer: A qualifi ed installer must have ability equivalent to a licensed tradesman in the fi elds of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the “National Fuel Gas
Code”, ANSI Z223.1/NFPA 54 as it relates to the installation of gas fi red water heaters. The qualifi ed installer must also
be familiar with the design features and use of fl ammable vapor ignition resistant water heaters and have a thorough
understanding of this Installation and Operating manual.
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fi elds of plumbing, air
supply, venting and gas supply, including a thorough understanding of the requirements of the “National Fuel Gas Code”,
ANSI Z223.1/NFPA 54 as it relates to the installation of gas fi red water heaters. The service agency must also have a
thorough understanding of this Installation and Operating manual, and be able to perform repairs strictly in accordance
with the service guidelines provided by the manufacturer.
Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances
within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping
up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service
and inspection of appliances within the building.
4
GENERAL SAFETY
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Temperature limiting valves
are available.
Read instruction manual for
safe temperature setting.
BURN
HOT
HOT
DANGER
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
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Install vent system in accordance with codes.
• Do not operate water heater if flood damaged.
• For operation above 10,100’, a high altitude
orifice must be installed.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake with
insulating jacket.
• Do not obstruct blower air intake.
• Do not place chemical vapor emitting products
near water heater.
• Gas and carbon monoxide detectors are
available.
• No vent damper installation is compatible with
this power vented water heater.
Breathing Hazard - Carbon Monoxide Gas
WARNING
Installation: Do not install the water heater where flammable
products will be stored or used.
Vapors from flammable
liquids may explode and
catch fire causing death or
severe burns.
Do not use or store
flammable products such as
gasoline, solvents or adhe-
sives in the same room or
area near the water heater.
Keep flammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
4. out of children's reach.
Water heater has a main
burner and hot surface igniter.
The hot surface igniter:
1. can be triggered at any
time and
2. the hot surface will ignite
flammable vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the floor
and
4. can be carried from other
rooms to the the
electodes by air currents.
Flammable Vapors
FLAMMBLE
DANGER
6
INTRODUCTION
Thank You for purchasing this water heater. Properly
installed and maintained, it should give you years of trouble
free service.
Abbreviations found in this Installation and Operating
manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• UL - Underwriters Laboratories Inc.
• AHRI - Air Conditioning, Heating and Refrigeration
Institute.
This gas-fi red water heater is design certifi ed by CSA
International, under Water Heater Standard ANSI
Z21.10.3 • CSA 4.3 (current edition), as applicable.
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualifi ed Agency (as defi ned by
ANSI below) in the fi eld involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical
supply are required in addition to electrical testing skills
when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualifi ed Agency” - “Any
individual, fi rm, corporation or company that either in
person or through a representative is engaged in and is
responsible for (a) the installation, testing or replacement
of gas piping or (b) the connection, installation, testing,
repair or servicing of appliances and equipment; that
is experienced in such work; that is familiar with all
precautions required and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualifi ed (as defi ned by ANSI above) and
licensed or certified as required by authority having
jurisdiction to perform a given task, do not attempt to
perform any of the procedures described in this manual.
If you do not understand the instructions given in this
manual do not attempt to perform any procedures outlined
in this manual.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section of this manual
fi rst and then entire manual carefully. If you don’t
follow safety rules, the water heater will not operate
properly. It could cause DEATH, SERIOUS BODILY
INJURY AND/OR PROPERTY DAMAGE. This manual
contains instructions for installation, operation,
and maintenance of the gas-fi red water heater. It
also contains warnings throughout the manual that
you must read and be aware of. All warnings and
instructions are essential to proper operation of the
water heater and your safety. Since we cannot put
everything on the fi rst few pages, READ ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER. 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.
2. The water heater, when installed, must be electrically
grounded in accordance with the local codes or in
the absence of local codes: current edition of the
“National Electrical Code”, NFPA 70.
3. 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.
4. Carefully plan the place where you are going to put
the water heater. Correct combustion, vent action,
and vent pipe installation are very important in
preventing death from possible carbon monoxide
poisoning and fi res (see Figure 12). Examine the
location to ensure the water heater complies with
the “Locating The New Water Heater” section in this
manual.
5. For installation in areas subject to earthquakes, this
water heater must be braced, anchored, or strapped
to avoid falling or moving during an earthquake.
See instructions for correct installation procedures.
Instructions may be obtained from:
California Offi ce of the State Architect,
400 P Street,
Sacramento, CA 95814.
6. 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.
7. 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
fi nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall
be satisfi ed:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfi tter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the fl oor level where
the gas equipment is to be installed. In addition, the installing plumber or gasfi tter shall observe that a battery operated
or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or
structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner
to secure the services of qualifi ed licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent fl oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and
be ANSI/ UL 2034 listed and CSA certifi ed.
SIGNAGE
A metal or plastic identifi cation plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign shall read, in print size no less than one- half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with
the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS
The following equipment is exempt from 248 CMR 5.08(2) (a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from
the dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system
design or venting system components with the equipment, the instructions provided by the manufacturer for installation
of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the fl ue gases, but identifi es “special venting systems,” the following requirements shall be satisfi ed by
the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
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.
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: GAS-FIRED POTABLE
WATER HEATING/SPACE HEATING 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 1-5)
1 Termination Elbow with Rodent
Screen
2 *Vent Pipe
3 *Coupling (if required)
4 CPVC Vent Pipe ( 5 ft. supplied)
5 *Vent Pipe Elbow (long radius)
6 *CPVC Vent Pipe Elbow
7 *Union (Di-electric water connection)
8 Cold-Water Inlet Nipple/Diptube
9 **Combo Heating System Supply
Outlet (Optional)
10 T&P Valve
11 * Discharge Pipe
12 **Combo Heating System Return
Inlet (Optional)
13 Gas Control Valve/Thermostat
(Honeywell)
14 Gas Valve Electronic Control Module
And Cover (Honeywell)
15 Drain Valve
16 Outer Gas Door
17 Manifold Door Assembly (behind
outer door) (see Figure 3)
18 *Metal Drain Pan
19 *Floor Drain
20 Flexible Manifold Tube (see
Figure 3)
21 ***Control Harness
22 *Sediment Trap
23 *Ground Joint Union (gas
connection)
24 *Main Manual Gas Shut-off Valve
25 *Gas Supply*
26 Anode (under cap)
27 Baffl e Assembly
28 Hot-Water Outlet Nipple/Anode
29 Sound Suppressor (Tee fi tting)
30 *Inlet Water Shut-off Valve
31 ****Rubber Coupling (see Figure 4)
32 Gear Clamp (see Figure 4)
33 ***Blower with Power Cord (see
Figure 4)
34 Air Duct Adapter
35 Air Inlet Snorkel
36 Air Duct
37 *Thermal Expansion Tank (see
“Closed Water Systems” and
“Thermal Expansion” sections)
38 Flame Sensor Rod (see Figure 3)
39 Sheet Metal Burner (see Figure 3)
40 Gas Orifi ce (see Figure 3)
41 Gas Manifold (see Figure 3)
42 Hot-Surface Igniter (see Figure 3)
43 Manifold Door Gasket (see
Figure 3)
44 Manifold Door (see Figure 3)
45 Two Piece Grommet With Clip (see
Figure 3)
46 Viewport (see Figure 3)
47 Air Tubing (Intake) (see Figure 4)
48 Blower High Limit Switch (see
Figure 4)
49 Intake Air Pressure Switch (NC)
(inside box) (see Figure 4)
50 Capacitor (see Figure 4)
51 Air Tubing (Exhaust) (see Figure 4)
52 Exhaust Air Pressure Switch (NO)
(inside box) (see Figure 4)
*, **, ***, **** see notes on following
page
Rear View
30
37
7
32
33
36
31
AIR INLET
PIPING
EXHAUST OUTLET
PIPING
35
34
Front View
1
2
5
7
10
8
11
15
18
1920
22
23
24
25
27
7
28
29
2
13 14
16 17
26
8
21
9
12
6
3 4
Figure 1 Figure 2
10
Natural gas and Propane
(LP) main burner with
igniter assembly. NG burner
shown. LP burner similar
but with drain hole (item 17
in Figure 1).
Flare
Nut
††
44
46
42
39
41
43
40
38
45
20
Figure 3
31
32
47
49
33
52
Shown with
Junction Box Cover
removed for clarity.
48
51
50
Figure 4
Vacuum relief valve
install per local
codes (not supplied
with heater).
Figure 5
Notes:
* Items not supplied with the water heater.
** The side recirculation loop connections may not be
used as the primary water inlet and outlet connections.
See “Combo Heating Inlet And Outlet Side Taps”
below.
*** Caution harness has 120 VAC In operation.
**** See “Vent Pipe Installation” for more information.
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be
ordered through authorized servicers or distributors. When
ordering parts, provide complete model and serial numbers
(see rating plate), quantity and name of part desired.
Standard hardware items may be purchased locally.
COMBO HEATING INLET AND OUTLET SIDE TAPS
Models equipped with Combo Heating capabilities are
shipped with the two side plumbing taps OPEN (item 9 and
item 12 in Figure 1 and see also Figure 6 & Figure 19). If
the heater is to be operated without using the side taps
these openings must be plugged with the two pipe plugs
supplied with the heaters.
11
WATER PIPING - MIXING VALVE USAGE
Mixing Valves
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing must be
installed when required by
codes and to ensure safe
temperatures at fixtures.
BURN
HOT
HOT
DANGER
Water heated to a temperature which satisfi es space
heating, clothes washing, dish washing, and other
sanitizing needs can scald and cause permanent injury
upon contact. Short repeated heating cycles caused by
small hot-water uses can cause a temperature increase of
the hot water by 20F° higher than the heater’s temperature
settings.
MIXING
VALVE
SHUT-OFF
VALVE
SUGGESTED PIPING ARRANGEMENT
FOR TOP CONNECTIONS
COLD-WATER
INLET
TEMPERED
POTABLE WATER
DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
TEMPERATURE-
PRESSURE
RELIEF VALVE
DRAIN
VALVE
METAL DRAIN PAN
1.75 in. MAX. DEPTH.
AT LEAST 2 in.
GREATER THAN THE
DIAMETER OF THE
WATER HEATER.
6 in.
MAX. AIR
GAP*
CERTAIN MODELS
ARE EQUIPPED WITH
SIDE PLUMBING
CONNECTIONS FOR
SPACE HEATING.
* NOTE: THE
T&P VALVE
DISCHARGE
PIPE SHALL
BE PIPED
DIRECTLY TO
THE DRAIN
OR EXTERNAL
TO THE
BUILDING
MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE
PER SECTION 19 MGL 142.
Figure 6
This appliance has been design certifi ed as complying with
ANSI/CSA Standard for water heaters and is considered
suitable for combination 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.
MIXING VALVE
SHUT-OFF
VALVE
SUGGESTED PIPING
ARRANGEMENT FOR
TOP CONNECTIONS
COLD-WATER
INLET
TEMPERED
POTABLE WATER
DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
TEMPERATURE-
PRESSURE
RELIEF VALVE
DRAIN
VALVE
METAL DRAIN
PAN 1.75 in.
MAX. DEPTH.
AT LEAST 2
in. GREATER
THAN THE
DIAMETER OF
THE WATER
HEATER.
6 in.
MAX. AIR
GAP*
* NOTE: THE
T&P VALVE
DISCHARGE PIPE
SHALL BE PIPED
DIRECTLY TO
THE DRAIN OR
EXTERNAL TO
THE BUILDING
NON-TEMPERED
WATER SUPPLY
NON-TEMPERED
WATER RETURN
MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE
PER SECTION 19 MGL 142.
Figure 7
SHUT-OFF
VALVE
COLD-
WATER
SUPPLY
TEMPERED
POTABLE
WATER
MIXING
VALVE
NON-
TEMPERED
WATER
SUPPLY
NON-
TEMPERED
WATER
RETURN
TO COLD
INLET
TO HOT
OUTLET
Figure 8
12
Some people are more likely to be permanently injured
by hot water than others. These include the elderly,
children, the infi rm and the physically/mentally disabled.
Table 1 (published by U.S. Government Memorandum,
1978) shows the approximate time-to-burn relationship
for normal adult skin. If anyone using hot water provided
by the water heater being installed fi ts into one of these
groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special
precautions must be taken.
Water
Temperature
°F
Time for 1st
Degree Burns
(Less Severe Burns)
Time for Permanent
Burns 2nd & 3rd
Degree (Most
Severe Burns)
110 (normal shower temp.)
116 (pain threshold)
116 35 minutes 45 minutes
122 1 minute 5 minutes
131 5 seconds 25 seconds
140 2 seconds 5 seconds
149 1 second 2 seconds
154 instantaneous 1 seconds
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)
Table 1
In addition to using lowest possible temperature setting
that satisfi es demand of application, a mixing valve should
be installed at water heater (see Figure 6 & Figure 7) or at
hot-water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualifi ed Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat,
read the “Operating The Temperature Control System”
section in this manual.
WATER HEATER OPERATION
Figure 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 fl ash the corresponding error code.
HEATER CONTROL
CHECKS TO ENSURE
BLOWER EXHAUST
PRESSURE SWITCH IS
OPEN
BLOWER IS
ENERGIZED
CONTROL CHECKS
TO ENSURE:
EXHAUST PRESSURE
SWITCH CLOSES AND
INTAKE PRESSURE
SWITCH REMAINS
CLOSED INDICATING
BLOWER IS
OPERATING AND
THERE ARE NO
BLOCKAGES (INTAKE
OR EXHAUST)
TEMPERATURE
SWITCH REMAINS
CLOSED INDICATING
VENT TEMPERATURE
IS NOT ABOVE THE
ALLOWABLE LIMIT
IGNITER IS ENERGIZED
AND GAS VALVE IS
OPENED
BURNER COMES ON
AND THE FLAME IS
SENSED BY CONTROL
BURNER CONTINUES
UNTILL THE WATER IN
THE TANK REACHES
THERMOSTAT SETTING
GAS VALVE IS CLOSED
AND BURNER SHUTS
OFF
HEATER
THERMOSTAT
CALLS FOR
HEAT
HEATER
REMAINS ON
STANDBY UNTIL
NEXT CALL FOR
HEAT
BLOWER CONTINUES
FOR A POST PURGE
TIME
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
specifi ed on the water heater wiring diagram.
• The electrical outlet has the proper overload fuse or
breaker protection.
1. The unit must be connected to a 120VAC power
supply. A dedicated power circuit is preferred.
2. The water heater must be properly grounded.
3. This water heater is a polarity sensitive appliance and
will not operate if the power supply polarity is reversed.
Note: Always reference the wiring diagram for the correct
electrical connections.
After making all electrical connections, completely fi ll the
tank with water and check all connections for leaks. Open
the nearest hot-water faucet and let it run for 3 minutes to
purge the water lines of air and sediment and to ensure
complete fi lling of the tank. The electrical power may then
be turned on. Verify proper operation after servicing. See
also “Installation Checklist”.
BLUE
120Vac/60Hz Wall Plug
BLACK SMOOTH - LINE
IGNITER - FLAME ROD
ASSEMBLY
PRESSURE
SWITCH
(NC)
PRESSURE
SWITCH
(NO)
CAPACITOR
BLACK RIBBED - NEUTRAL
BLACK MIDDLE - GND
GREEN
BLACK
BLACK
YELLOW
BLACK
WHITE
JUNCTION BOX
HONEYWELL GAS VALVE
HIGH LIMIT
SWITCH
IF WIRING HAS TO BE REPLACED IN THE FIELD, USE ONLY TYPE TEW 105°C WIRE.
ELECTRICAL RATING 120V, 5A, 60 HZ.
BLOWER
BLACK
WHITE
BLUE
GREEN
YELLOW
YELLOW
BLUE
WHITE
WHITE
2
3
4
5
6
2
3
4
1
2
3
4
1
1
1
4
5
6
1
2
3
4
5
6
JP
2
3
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.
POWER VENT WIRING SCHEMATIC.
NOTE: REFER TO THE “Installation Checklist”
BEFORE OPERATING THIS HEATER.
N
1
2
3
HOT SURFACE IGNITER
HIGH LIMIT SWITCH (CLOSED)
CAPACITOR
L1
EARTH GND
PRESSURE SWITCH (CLOSED)
PRESSURE SWITCH (OPEN)
PRESSURE SWITCH (CLOSED)
BLOWER
4
5
6
4
3
2
1
2
1
3
4
FLAME SENSOR
P1
P2
P3
3
5
1
4
2
4
6
Circled numbers indicate
sequence of operation.
P4
1
4
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 12) 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 4, item
48) 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
suffi ciently.
BLOWER AIR PRESSURE SWITCHES
The blower/heater is equipped with two air pressure
switches located in the junction box (see Figure 4, item
49 and item 52). These devices are connected in series
and monitor the air pressure produced by the blower. In
the event that the exhaust venting becomes blocked or
suffi ciently restricted, the normally open (NO) air pressure
switch will shut down the heater. In the event that the
intake pipe becomes suffi ciently blocked or restricted, the
normally closed (NC) air pressure switch will shut down
the heater.
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. Avoid locations that could cause the water heater to
freeze from outside air.
4. Selected location must provide access to a properly
grounded electrical branch circuit. A dedicated circuit
is preferred. Do not use a GFI outlet.
5. Avoid locations that expose the water heater to direct
sunlight.
6. 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.
• 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 fl ow of water will not cause damage to the
structure. For this reason it is not advisable to install the
water heater in an attic or upper fl oor. In all cases, a metal
drain pan should be installed under the water heater. Metal
drain pans are available at your local hardware store. Such
a metal drain pan must have a clearance of at least 1 in.
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 in. .
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.
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
FLAMMABLE
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
16
Clearances To Combustibles
Minimum clearances between water heater and
combustibles are 0 in. at the sides and rear, 5.5 in. from the
front and 12 in. 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 12).
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. in
every direction, or if the appliance is installed in an alcove
or closet, the entire fl oor must be covered by the panel.
Failure to heed this warning may result in a fi re hazard.
Clearances For Servicing
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.
Servicing this appliance, such as changing the anodes,
etc. requires clearances for accessibility and replacement
of parts. The anode could be as long as 35 in. .
Refer to the current edition of the “National Fuel Gas
Code”, ANSI Z223.1/NFPA 54 for detailed requirements.
TOP VIEW
OF CLOSET
WITHOUT DOOR
TOP VIEW OF
CLOSET WITH
DOOR
0 in.
MIN.
0in. MIN.
0 in.
MIN.
5.5 in. MIN.
Figure 12
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
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Flue gases may escape if
vent pipe is deformed,
broken, or not properly
connected.
Breathing Hazard - Carbon Monoxide Gas
WARNING
17
Important Notes and Warnings
• This heater is certifi ed to be installed using Schedule
40 PVC or CPVC 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 or mechanical seals. To join
PVC and CPVC materials, use ATSM F-493 compliant
cement.
• Do not common vent this heater with any other
appliance.
• During operation the plastic piping will expand as it
heats up and contract as it cools down. This is normal
for this type of venting. Rigidly fastening the vent piping
can cause undue stress that may result in the cracking
or fracturing the vent piping material. A fracture of the
venting pipe may pose a serious safety hazard. To
prevent stressing of the vent system, all hangers and
supports must allow the vent piping freedom to move.
• Use long sweep elbows wherever possible. Closely
coupled elbows and short radius elbows can reduce
the venting capacity.
• All power vented water heaters generate a certain
amount of operational noise. In order to minimize
noise transmission to the support structure, it is
recommended to 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 fl ue gases can develop. Provision must be
made for the condensate to drain freely from the
system or to be collected in a condensate trap(s) that
can be drained. Damage or fracture of the vent piping
may occur if the condensate is allowed to collect and
freeze. Pooling of condensate can restrict airfl ow and
can cause nuisance failures of the system.
INSULATION BLANKETS
Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary
with these products. The purpose of an insulation blanket is
to reduce standby heat loss encountered with storage tank
heaters. Your water heater meets or exceeds the current
standards with respect to insulation and standby loss
requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to
this heater, you should follow these instructions (For
identification of components mentioned below, see
Figure 1 thru Figure 5). Failure to follow these instructions
will restrict the air fl ow required for proper combustion and
dilution, potentially resulting in fi re, asphyxiation, serious
personal injury or death.
• Do not apply insulation to the top of the water heater,
as this will interfere with safe operation of the blower
assembly.
• Do not cover the outer door, thermostat or T&P relief
valve.
• 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 fl ow.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Do not obstruct water heater air intake(s) with
insulating jacket.
• Gas and carbcn monoxide detectors are available.
• Install water heater in accordance with the
instruction manual and NFPA54.
Breathing Hazard - Carbon Monoxide Gas
WARNING
AIR REQUIREMENTS
For safe operation an adequate supply of fresh,
uncontaminated air for combustion, dilution and ventilation
must be provided.
Note: Contaminated or dusty air may cause build-up on
the blower wheel resulting in nuisance shut downs.
18
INSTALLING THE NEW WATER HEATER
WATER PIPING
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing must be
installed when required by
codes and to ensure safe
temperatures at fixtures.
BURN
HOT
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 infi rm, or physically/
mentally handicapped. If anyone using hot water fi ts into
one of these groups or if there is a local code or state law
requiring certain temperature water at the hot-water tap,
then you must take special precautions. In addition to
using lowest possible temperature setting that satisfi es
your hot water needs, a means such as a mixing valve,
should be used at hot-water taps used by these people
or at the water heater (see Figure 6 & Figure 7). Valves
for reducing point of use temperature by mixing cold and
hot water are also available.
SPACE HEATING AND POTABLE WATER SYSTEMS
This appliance has been design certifi ed as complying with
ANSI/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 Qualifi ed Installer or Service Agency. Follow
manufacturer’s instructions for installation of valves.
Before changing the factory setting on thermostat, read
“Operating The Temperature Control System” section in
this manual.
• This water heater should not be connected to any
heating systems or components previously used with
a non-potable water heating appliance.
• All piping components connected to this unit for space
heating applications should be suitable for use with
potable water.
• Toxic chemicals, such as those used for boiler treatment
shall not be introduced into the potable water used for
space heating.
• When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a mixing valve must be installed. Please
refer to Figure 6 & Figure 7 for suggested piping
arrangement.
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.
If this water heater is to be used to supply both space
heating and potable water, the instructions listed below
must be followed:
• Be sure to follow the manual(s) shipped with the air
handler or other type heating system.
• This water heater is not to be used as a replacement
for an existing boiler installation.
• Do not use with piping that has been treated with
chromates, boiler seal or other chemicals and do not
add any chemicals to the water heater piping.
• If the space heating system requires water temperatures
in excess of 120°F , steps must be taken to limit
temperatures at fi xtures in the potable hot-water supply
for safety and regulatory requirements.
• Pumps, valves, piping and fi ttings must be compatible
with potable water.
• A properly installed fl ow control valve is required to
prevent thermosiphoning. Thermosiphoning is the
result of a continuous fl ow 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 fi rst signs of
thermosiphoning.
• The hot-water line from the water heater should be
vertical past any mixing valve or supply line to the
heating system to remove air bubbles from the system.
• Do not connect the water heater to any system or
components previously used with non-potable water
heating appliances when used to supply potable water.
19
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 specifi cally approved for such use.
It is written for those knowledgeable in the required trades
and professionals involved in the design and installation
of Combo Heating Systems.
It is the responsibility of the installer/designer to follow all
applicable codes to ensure the 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, fi ttings, solder and fl uxes,
pumps for circulation of water, valves, etc.
2. The water heater must not be connected to a hydronic
heating system that has been used previously.
3. No boiler treatment chemicals of any kind shall be
introduced into the system.
4. The Combo System components must be selected
and sized to meet and maintain the total calculated
demands for both domestic service hot water
and space heating requirement. The sizing and
installation must be performed in accordance with
good engineering practice such as “ASHRAE
Handbooks”, HRAI’s Unifi ed Combo Guidelines,
“Hydronics Institute Manuals”, ANSI Z223.1, CSA
F280, National/Provincial Building Codes, ANSI
and/or codes having jurisdiction.
5. The air handler (fan coil) and/or the circulating pump
in a baseboard hydronic loop will require a dedicated
120V circuit. This must be provided and identifi ed for
this purpose.
6. All piping between the water heater and the air handler
or hydronic baseboard loop must be adequately
insulated to reduce heat loss.
7. If the local jurisdiction requires a back-fl ow preventer
in the cold water line, an expansion tank of adequate
size must be installed.
8. “Combo” Heating Systems require higher water
temperatures than other applications. When the
system is used to supply water for Combo Heating
applications, a means, such as mixing valve, must be
installed to temper the water in order to reduce scald
hazard potential (see Figure 13 & Figure 14).
Installation
The heating mode may be one of the following options:
A. A fan coil/air handler (Figure 13).
B. A hydronic baseboard (finned tube) loop/In floor
heating (Figure 14).
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.
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
CHECK
VALVE
EXTERNAL
CIRCULATOR
AIR
HANDLER
HOT WATER
TO HOUSE
FIXTURE
C
H
M
INTERNAL
CIRCULATOR
DRAIN/
PURGE
VALVE
(see also
Massachusetts
code requirements
on pg 8)
Figure 13
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
CHECK
VALVE
EXTERNAL
CIRCULATOR
HOT WATER
TO HOUSE
FIXTURE
C
H
M
HYDRONIC
BASEBOARDS
(SERIES
CONNECTED
SHOWN)
(see also
Massachusetts
code requirements
on pg 8)
Figure 14
20
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 fl ow preventers. Devices such
as these cause the water system to be a closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will increase. As the
volume of water increases, there will be a corresponding
increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure
(leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause
intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure
build up. The temperature-pressure relief valve is not
intended for the constant relief of thermal expansion. This
condition is not covered under the limited warranty.
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)
6 in.
MAX. AIR
GAP
DRAIN
VALVE
SHUT-OFF VALVE
SOME
COMPONENTS
NOT SHOWN
FOR CLARITY.
Figure 15
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 fi ttings, it is recommended that di-electric unions or
couplings be installed on this water heater when connected
to copper pipe.
• Avoid water heater damage.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold water inlet.
• Contact qualified installer or service agency.
Property Damage Hazard
CAUTION
Figure 15 shows typical attachment of water piping to the
water heater. The water heater is equipped with 3/4” NPT
water connections.
Note: If using copper tubing, solder tubing to an
adapter before attaching the adapter to the water heater
connections. Do not solder the water lines directly to the
water heater connections - it will harm the dip tube and
heat traps and damage the tank.
TEMPERATURE-PRESSURE RELIEF VALVE
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperature-
pressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
Explosion Hazard
WARNING
This water heater is provided with a properly rated/sized
and certifi ed combination Temperature-Pressure Relief
Valve (T&P valve) by the manufacturer. The valve is
certifi ed by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed
equipment of materials as meeting the requirements for
Relief Valves for Hot Water Supply Systems, ANSI
Z21.22-CSA 4.4, and the code requirements of ASME.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination temperature-
pressure relief valve rated/sized and certifi ed as indicated
in the above paragraph. The new valve must be marked
with a maximum set pressure not to exceed the marked
hydrostatic working pressure of the water heater (150 psi)
and a discharge capacity not less than the water heater
Btu/hr input rate as shown on the water heater’s model
rating plate.
21
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 fi tting of the water heater designed
for the relief valve. Install discharge piping so that any
discharge will exit the pipe within 6 in. above an adequate
fl oor drain, or external to the building. In cold climates it is
recommended that it be terminated at an adequate drain
inside the building. Be certain that no contact is made with
any live electrical part.
The discharge opening must not be blocked or reduced in
size under any circumstances. Excessive length (over 30
ft. ), 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 in. 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 fl ow may cause property
damage.
• Temperature-pressure relief valve discharge pipe
must terminate at an adequate drain.
Water Damage Hazard
CAUTION
T&P Valve Discharge Pipe Requirements:
• Shall not be smaller in size than the outlet pipe size
of the valve, or have any reducing couplings or other
restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage
of both the temperature-pressure relief valve and the
discharge pipe.
• Must terminate a maximum of 6 in. above a fl oor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated
at an adequate drain inside the building
• Shall not have any valve or other obstruction between
the relief valve and the drain.
• Burn hazard.
• Hot water discharge.
• Keep clear of
temperature-pressure
relief valve discharge.
BURN
HOT
HOT
DANGER
It is recommended to manually operate the T&P valve at
least once a year. Caution should be taken to ensure (1) no
one is in front of or around the outlet of the discharge line,
and (2) the water manually discharged will not cause any
bodily injury or property damage because the water may
be extremely hot. If after manually operating the valve, it
fails to completely reset and continues to release water,
immediately close the cold-water inlet to the water heater,
follow the draining instructions in this manual, and replace
the temperature-pressure relief valve with a properly rated/
sized new one.
Note: The purpose of a temperature-pressure relief valve
is to prevent excessive temperatures and pressures in the
storage tank. The T&P valve is not intended for the constant
relief of thermal expansion. A properly sized thermal
expansion tank must be installed on all closed systems to
control thermal expansion, see “Closed Water Systems”
and “Thermal Expansion” 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 16
Locate the temperature and pressure relief valve on the
water heater (also known as a T&P relief valve). See
Figure 16.
1. Locate the slit running the length of the T&P relief
valve insulation.
2. Spread the slit open and fi t the insulation over the T&P
relief valve. See Figure 16. Apply gentle pressure to
the insulation to ensure 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 16). Ensure a discharge pipe is installed into
the T&P valve discharge opening per the instructions
in this manual.
3. Locate the hot water (outlet) & cold water (inlet) pipes
to the water heater.
4. Locate the slit running the length of a section of pipe
insulation.
22
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 it is fully seated
around the pipe. Also, ensure the base of the insulation
is fl ush with the water heater. Once seated, secure the
insulation with duct tape, electrical tape, or equivalent.
6. Repeat steps 4 and 5 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 orifi ce with a high altitude
orifi ce 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 specifi c changes which may be
required in your area.
GAS PIPING
• Do not use water heater with
any gas other than the gas
shown on the rating plate.
• Excessive pressure to gas
control valve can cause serious
injury or death.
• Turn off gas lines during
installation.
• Contact qualified installer or
service agency.
Fire and Explosion Hazard
WARNING
Explosion Hazard
Have a qualified technician make sure that the L.P.
gas operating pressure does not exceed 14" water
column.
Failure to do so can result in death, explosion, or
fire.
WARNING
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
14” w.c. for natural gas and propane gas. The minimum
inlet gas pressure shown on the rating plate is that which
will permit fi ring at rated input.
All gas piping must comply with local codes and ordinances
or with the “National Fuel Gas Code”, ANSI Z223.1/
NFPA 54. Copper or brass tubing and fi ttings (except tin
lined copper tubing) should not be used.
If the gas control valve/thermostat is subjected to
pressures exceeding 1/2 psi, the damage to the gas
control valve/thermostat could result in a fi re 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 suffi cient size must be run to the water heater.
Consult the current edition of “National Fuel Gas Code”,
ANSI Z223.1/NFPA 54 and your gas supplier concerning
pipe size.
There must be:
• A readily accessible manual shut-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 fl exible 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 fl ame. Repair and retest as required. When
fi nished, rinse off soapy solution and wipe dry.
23
• Use joint compound or tape
compatible with natural gas
and 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 Tefl on
®
tape marked as being
resistant to the action of gases.
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
The appliance and its individual shut-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 17 & Figure 18.
FLEX PIPE
(PROPERLY SIZED
FOR THE HEATER
INPUT RATE)
SEDIMENT
TRAP
GAS
CONTROL
VALVE
GROUND
JOINT
UNION
(OPTIONAL)
CAP
3”
MIN.
Figure 17
BLACK PIPE
SEDIMENT
TRAP
GAS
CONTROL
VALVE
GROUND
JOINT
UNION
(OPTIONAL)
CAP
3 in. MIN.
Figure 18
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
Contaminants in the gas lines may cause improper
operation of the gas control valve/thermostat that may
result in fi re or explosion. Before attaching the gas line be
sure that all gas pipe is clean on the inside. To trap any
dirt or foreign material in the gas supply line, a sediment
trap (sometimes called a dirt leg) must be incorporated in
the piping. The sediment trap should be either a tee fi tting
with a capped nipple in the bottom outlet or other device
recognized as an effective sediment trap. If a tee fi tting is
used, it should be installed in conformance with one of the
methods of installation shown in Figure 17 & Figure 18.
Refer to the current edition of the “National Fuel Gas
Code”, ANSI Z223.1/NFPA 54.
HOT-WATER
OUTLET
COLD-
WATER
INLET
UNION
TEMPERATURE-
PRESSURE
RELIEF VALVE
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
6 in. 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 19
24
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 fi lled with water. Water must fl ow from the hot-water
faucet before turning “ON” gas to the water heater.
To fi ll the water heater with water:
1. Close the water heater drain valve by turning handle
to the right (clockwise). The drain valve is on the lower
front of water heater (see Figure 19).
2. If the heater is equipped with plumbing side taps and
they are not connected to piping, ensure 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 fi lling 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 fi lling of the tank, allow air to exit
by opening nearest hot-water faucet. Allow water to
run until a constant fl ow is obtained. This will let air
out of the water heater and the piping.
6. Check all water piping and connections for leaks.
Repair as needed.
VENTING
All venting must comply with the current edition of the
“National Fuel Gas Code”, ANSI Z223.1/NFPA 54. This
heater is certifi ed to be installed using Schedule 40 PVC,
ABS or CPVC 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 or mechanical seals.
Use only Schedule 40 CPVC piping and fi ttings for the fi rst
linear 5 ft. of the outlet vent system. A 5 ft. section of 3”
Schedule 40 CPVC vent pipe is supplied with the water
heater for this purpose. If 4” venting is to be used it must
be fi eld supplied. For the rest of the outlet vent system
use piping and fi ttings as defi ned above.
This unit includes an air intake terminal
and an exhaust vent terminal.
Improper Installation, use and service may result
in property damage.
CAUTION
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Install vent system In accordance with codes.
• Do not operate water heater if flood damaged.
• Install water heater in accordance with the
instruction manual.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake(s) with
insulating blanket.
• Do not place chemical vapor emitting products near
water heater.
• Gas and carbon monoxide detectors are available.
• Never operate the heater unless it is vented to the
outdoors and has adequate air supply to avoid risks
of improper operation, fire, explosion or asphyxia-
tion.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing Hazard - Carbon Monoxide Gas
WARNING
3” RUBBER
COUPLING
(SUPPLIED)
BLOWER
3” CPVC
VENT
PIPE
AIR DUCT
ADAPTER
3” INLET PIPE
3” CPVC ELBOW
3” CPVC VENT
PIPE, 3 in. MAX
LENGTH
Figure 20
Important: DO NOT common vent this water heater with
any power vented appliance. DO NOT vent into a common
chimney.
25
This water heater has a direct vent system in which all air
for combustion is taken from the outside atmosphere and
all combustion products are discharged to the outdoors.
This water heater must be properly vented for removal
of exhaust gases to the outside atmosphere. Correct
installation of the vent pipe system is mandatory for the
safe and effi cient operation of this water heater and is an
important factor in the life of the unit.
A Vent Kit included with this water heater consists of:
1. Blower outlet adapter (rubber coupling and gear
clamps),
2. Sound Suppressor
3. One (1) 45° Vent Termination Elbow,
4. More-restrictive Vent Termination Screens,
5. Less-restrictive Vent Termination Screens,
6. Wall Plates,
Vent pipe must be installed in accordance with all local
and provincial or state codes or, in the absence of such,
the latest edition of “National Fuel Gas Code”, ANSI
Z223.1/NFPA 54.
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
Important: Check to make sure the vent pipe is not
blocked in any way.
Note: Do not common vent this water heater with any other
appliance. Do not install in the same chase or chimney
with a metal or high-temperature plastic from another gas
or fuel burning appliance.
26
TERMINATION CLEARANCES (SIDEWALL)
Figure 21
Vent terminal clearances for “Power Direct Vent” installations.
A
Clearance above grade, veranda,
porch, deck or balcony
12” H
Clearance to each side of center
line extended above meter/regulator
assembly
N/A
B
Clearance to window or door that may
be opened
4’ below or to side
of opening; 1’ above
opening
I
Clearance to service regulator vent
outlet
3’*
C
Clearance to permanently closed
window
12” J
Clearance to a non mechanical
air supply inlet into building or
combustion air inlet to any other
appliance
4’ below or to side of
opening; 1 foot above
opening.
D
Vertical clearance to ventilated soffi t
located above the terminal within
a horizontal distance of 2’ from the
center line of the terminal
12” K
Clearance to a mechanical air supply
inlet
3’ above if within 10’
horizontally
E Clearance to unventilated soffi t 12” L
Clearance above paved sidewalk or
paved driveway located on public
property
7’
F Clearance to outside corner 2’ M
Clearance under veranda, porch,
deck, or balcony
12”‡
G Clearance to inside corner 18”
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the fl oor.
INSIDE CORNER
DETAIL
FIXED
CLOSED
OPERABLE
FIXED
CLOSED
OPERABLE
Vent terminal
Air supply inlet
Area where is not permitted
Gas meter / regulator
C
B
B
B
B
B
J
A
K
M
F
B
L
E
D
I
V
V
V
V
V
V
V
V
V
V
X
X
X
G
A
27
Side Wall Vent Terminal Installation
Important: When terminating the vent on a side wall, the
following specifi cations pertaining to terminal location must
be followed (see Figure 22).
1. The air intake terminal and the exhaust vent terminal
must terminate on the same exterior wall.
2. The vertical centerline of the air intake terminal must
be located at a minimum of 8 in. and not more than
24 in. from the vertical centerline of the exhaust vent
terminal.
3. The horizontal centerline of the air intake terminal may
not be located more than 4 in. below the horizontal
centerline of the exhaust vent terminal.
4. To avoid exhaust recirculation, the air intake terminal
may be rotated away from the exhaust vent terminal
(see Figure 22).
EXHAUST VENT
TERMINAL
INTAKE VENT
TERMINAL
4 in. MAX
8 in. MIN, 24
in. MAX.
L
C
L
C
L
C
L
C
SIDE WALL
Figure 22
Roof Vent Terminal Installation
Important: When terminating the vents through a roof,
the following specifi cations pertaining to terminal location
must be followed (see Figure 23).
1. The air intake termination and the exhaust vent
termination shall extend above anticipated snow level
or at least 18 in. above the roof.
2. Must provide proper support for all pipes protruding
through roof.
3. The vertical roof terminations should be sealed with a
plumbing roof boot or equivalent fl ashing.
A
B
1 in.
EXHAUST
VENT
TERMINAL
INTAKE
VENT
TERMINAL
8
MIN.,
24
MAX.
1 in.
“A” & “B”: ABOVE SNOW
ACCUMULATION LEVEL
OR 18 in. MIN. ABOVE
ROOF.
Figure 23
4. The air intake termination and the exhaust vent
termination must penetrate the same side of roof.
5. The centerline of the air intake termination and the
centerline of the exhaust vent termination must not
be closer than 8 in. and not farther away than 24 in. .
6. The air intake terminal and the exhaust vent terminal
must be oriented facing downward and the same
direction.
Concentric Vent Termination Kit Installation
A concentric vent termination kit (see Table 2) may be
used for vertical or horizontal terminations.
STRAP (FIELD
SUPPLIED)
COMBUSTION
AIR
COMBUSTION
AIR
ABOVE SNOW
ACCUMULATION
LEVEL OR 18
in. MIN. ABOVE
ROOF.
ELBOW (FIELD
SUPPLIED)
SCREEN INSIDE
EXHAUST
ROOF
45° ELBOW
(SEE LOCAL
CODES)
FLASHING (FIELD
SUPPLIED)
PIPE NIPPLE
Figure 24
Figure 24 illustrates the concentric vent termination kit in a
vertical (roof) installation. Ensure the combustion air intake
location is above the anticipated snow level.
28
STRAP (FIELD
SUPPLIED)
COMBUSTION
AIR
COMBUSTION
AIR
ORIENTATION OF EXHAUST PIPING AND COMBUSTION AIR PIPING RELATIVE
TO EACH OTHER MAY BE VERTICAL (AS SHOWN) OR AT ANY OTHER ANGLE
TO SUIT THE INSTALLATION.
ELBOW (FIELD
SUPPLIED)
SLOPE 1/4 in. OVER
5 ft.
SCREEN INSIDE
EXHAUST
1 in. MAXIMUM
WALL
90° ELBOW
(SEE LOCAL
CODES)
PIPE NIPPLE (USE
WITH ELBOW)
Figure 25
VENT DIA. P/N
3” 9006328005
Table 2
Figure 25 illustrates the concentric vent kit for a horizontal
(side wall) installation. To prevent rain water from entering
the exhaust outlet, slope the vent kit at a downward pitch
of 1/4 in. per 5 ft. away from the inside wall. Ensure the
combustion air intake location is above the anticipated
snow level.
Multiple Concentric Vent Installations
When two concentric vent kits are being installed, the
vent hood centers shall be either less than 9.5 in. apart
or more than 43.5 in. apart. Spacings between 9.5 in. and
43.5 in. are not allowed due to the possibility of exhaust
cross circulation (see Figure 26).
When more than 2 kits are installed only 2 of them shall
be less than 9.5 in. apart. Never install 3 termination kits
together less than 9.5 in. apart (see Figure 27).
9.5 in. MAX OR
43.5 in. MIN
WALL
SCREEN
NOTE: IF AN
ELBOW IS
REQUIRED
BY LOCAL
CODES
INSTALL
SCREEN
IN ELBOW
INSTEAD OF
CONCENTRIC
VENT
EXHAUST.
Figure 26
4
3.5 in.
MIN.
9.5 in
MAX..
WALL
NOTE: IF AN ELBOW IS REQUIRED BY
LOCAL CODES INSTALL SCREEN IN ELBOW
INSTEAD OF CONCENTRIC VENT EXHAUST.
SCREEN
Figure 27
Vent Pipe Length
The maximum allowable pipe lengths for air intake and
exhaust are listed in Table 3. The specifi ed maximum
lengths are for each of the intake and exhaust systems and
not for the combined lengths of both systems. In addition,
each system requires a 45° long sweep elbow termination
with a restrictive screen. Minimum pipe length is 3 ft. with a
minimum of one 90° elbow per side (intake and exhaust).
1. Determine termination type and pipe size.
2. Determine number of elbows in vent system. Do not
include termination elbow. Calculate the maximum
equivalent length of the exhaust and air intake system.
90° LONG SWEEP ELBOW
(LESS RESTRICTIVE)
90° SHORT SWEEP ELBOW
(MORE RESTRICTIVE)
Figure 28
29
WATER
HEATER
MODEL
HEATER
INPUT
(Btu/hr)
VENT
SIZE
(Inside
Diam.)
2 PIPE MAX.
EQUIV. VENT
LENGTH
2 PIPE
MIN. EQUIV.
VENT LENGTH
CONC. VENT
MAX. EQUIV.
VENT LENGTH
CONC. VENT
MIN. EQUIV.
VENT LENGTH
75 gal. 76,000
3”
50’ + term. elbow
and screen*
7’ + term. elbow
and screen*
30’ + term. elbow
and screen*
7’ + term. elbow
and screen*
4”
125’ + term. elbow
and screen*
50’ + term. elbow
and screen*
N/A N/A
* see Figure 29, “Venting Terminations And Sizing” and “Vent Screen Installation”.
Equivalent lengths of straight pipe for various elbows using
Schedule 40 PVC, CPVC, ABS, and polypropylene.
Notes:
1. Vent lengths shown do not include vent termination
elbow.
2. A horizontal vent must have a 45° vent termination
elbow to direct the vent pipe downward.
3. A vertical vent must have a 90° elbow to direct the
vent pipe horizontally followed by a vent termination
45° elbow to direct the vent pipe downward.
4. If additional elbows are used in the vent system
the allowable vent lengths are reduced (see chart
below).
5. Two 45° elbows are considered the equivalent of
one 90° elbow.
6. The equivalent length of the sound suppressor is
similar to that of a short sweep 90° elbow.
Vent Pipe
Size
Elbow
Type
Short Sweep/
Radius
Long Sweep/
Radius
3"
4"
90° 8’ 5’
3"
4"
45° 4’ 2.5’
Table 3
Vent Pipe Termination
This water heater includes one (1) pair of more restrictive
Vent Termination Screens and one (1) pair of less
restrictive Vent Termination Screens. For safety and
optimum effi ciency performance, ensure the correct Vent
Termination Screen is installed for the vent length in your
installation.
Note: Before installing the Power Direct Vent Water
Heater, it is recommended that the location of the pipe
terminations (air intake and exhaust vent) be determined.
Use the Vent Termination Screen as shown in Figure 29.
Install the same Vent Termination Screen in the Termination
Elbow on both the air intake pipe and the exhaust pipe.
Venting Terminations And Sizing
• Refer to Table 3 for vent pipe materials and sizing. If
the installation requires a vent riser, suitable drainage
must be provided to ensure condensation does not
accumulate (see Figure 36). Termination through a roof
is shown Figure 23.
Vent Screen Installation
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 effi ciency of the
vent system based on the “equivalent length” of the vent
piping. CHOOSE ONLY the ONE PAIR OF SCREENS
THAT MATCH YOUR VENTING CONFIGURATION (see
Figure 29). How to determine the “equivalent length” is
shown in Table 3.
• Supplied with this heater are several vent termination
screens (see Figure 29).
• 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) screws:
• Install plastic screen into elbow (see Figure 30).
• Orient screen as shown in see Figure 30 with an
opening at the bottom of the assembly and the
smooth side facing in.
• Ensure screen is fully seated against shoulder in
elbow.
• Secure screen in place with screws (fi eld supplied)
(see Figure 30).
Important: Failure to install the appropriate screen in the
vent termination elbows could result in improper heater
operation with attendant risk of property damage, personal
injury or death by fi re or carbon monoxide poisoning.
30
with 4” venting
VENT LENGTH GREATER THAN
50 EQUIVALENT FT. USE THIS
SCREEN (SUPPLIED).
with 3” venting (short) with 3” venting (long)
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 29
#6 SHEET
METAL
SCREW
ELBOW
#6 SHEET
METAL
SCREW
(FIELD
SUPPLIED)
PLASTIC
SCREEN
SHOULDER
OPEN
POCKET
CLOSED
POCKET
POCKETS
FACING OUT
Figure 30
Vent Pipe Material
This heater is certifi ed to be installed using Schedule
40 PVC or CPVC or polypropylene or ABS plastic vent
material for the exhaust. The combustion air intake material
may be PVC, ABS, CPVC or polypropylene. Check local
codes to determine which materials are allowed in your
area and only use approved material. All venting material
and components must be joined with the approved primer/
cleaner and solvent cement or mechanical seals. Do not
cement the venting system to the heater.
Note: Use only solid (not foam core) piping. Plastic pipe
and fi ttings are available through most plumbing suppliers.
Always check the marking on the pipe to make sure you
are using the correct material.
VENT PIPE PREPARATION
1. INITIAL PREPARATION
• Make sure the solvent cement you are planning to
use is designed for the specifi c application you are
attempting.
• Know the physical and chemical characteristics and
limitations of the PVC and CPVC piping materials
that you are about to use.
• Know the reputation of your manufacturer and their
products.
• Know your own qualifications or those of your
contractor. The solvent welding technique of joining
PVC and CPVC pipe is a specialized skill just as any
other pipe fi tting technique.
• Closely supervise the installation and inspect the
fi nished job before start-up.
• Contact the manufacturer, supplier, or competent
consulting agency if you have any questions about
the application or installation of PVC and CPVC
pipe.
• Take the time and 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 (PVC 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
fi ttings 6” and above.
31
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 fi ttings for
solvent welding. Do not use water, rags, gasoline
or any other substitutes for cleaning PVC or CPVC
surfaces. A chemical cleaner such as MEK may be
used.
Cement:
PVC Materials should use ASTM D-2564 Grade
Cement; CPVC Materials should use ASTM F-493
Grade Cement and ABS Materials should use ASTM
D-2235 Grade Cement. 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 fi ttings.
.
• Primers and cements are
extremely flammable, and must
not be stored or used near heat
or open flame.
• Also, use only in a well venti-
lated area.
Fire Hazard
WARNING
Applicators:
Select a suitable pure bristle type paint brush. Use
a proper width brush or roller to apply the primer
and cement (see chart below). Speedy application
of cement is important due to its fast drying
characteristics. IMPORTANT NOTE: A dauber type
applicator should only be used on pipe sizes 2” and
below. For larger diameter pipe, a brush or roller
must be used.
RECOMMENDED BRUSH* SIZE FOR
PRIMER AND CEMENT APPLICATIONS
Nominal
Pipe (IPS)
Brush Size
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 fi tting socket
bottom. This can be accomplished with a miter box
saw or wheel type cutter. Wheel type cutters are not
generally recommended for larger diameters since
they tend to fl are the corner of the pipe end. If this
type of cutter is used, the fl are on the end must be
completely removed.
Note: Power saws, if used, should be specifi cally
designed to cut plastic pipe.
Figure 31
B. Deburring
Use a knife, plastic pipe deburring tool, or fi le to
remove burrs from the end of small diameter pipe.
Be sure to remove all burrs from around the inside
as well as the outside of the pipe. A slight chamfer
(bevel) of about 10°-15° should be added to the end
to permit easier insertion of the pipe into the end of
the fi tting. Failure to chamfer the edge of the pipe
may remove cement from the fi tting socket, causing
the joint to leak.
Figure 32
32
C. Test dry fi t of the joint
Tapered fitting sockets are designed so that
an interfaced fi t should occur when the pipe is
inserted about 1/3 to 2/3 of the way into the socket.
Occasionally, when pipe fi tting dimensions are at
the tolerance extremes, it will be possible to fully
insert dry pipe to the bottom of the fi tting socket.
When this happens, a suffi cient quantity of cement
must be applied to the joint to fi ll the gap between
the pipe and fi tting. The gap must be fi lled to obtain
a strong, leak-free joint.
D. Inspection, cleaning, priming
Visually inspect the inside of the pipe and fi tting
sockets and remove all dirt, grease or moisture
with a clean dry rag. If wiping fails to clean the
surfaces, a chemical cleaner must be used. Check
for possible damage such as splits or cracks and
replace if necessary.
Depth-of-entry
Marking the depth of entry is a way to check if the
pipe has reached the bottom of the fi tting socket
in Step F. Measure the fi tting depth and mark this
distance on the pipe O.D. You may want to add
several inches to the distance and make a second
mark as the primer and cement will most likely
destroy your fi rst one.
Apply primer to the surface of the pipe and fi tting
socket with a natural bristle brush. This process
softens and prepares the PVC or CPVC for the
solvent cementing step. Move quickly and without
hesitation to the cementing procedure while the
surfaces are still wet with primer.
E. Application of solvent cement
• Apply solvent cement evenly and quickly around
outside of pipe at a width a little greater than the
depth of the fi tting socket.
• Apply a light coat of cement evenly around the inside
of the fi tting socket. Avoid puddling.
• Apply a second coat of cement to the pipe end.
• Cans of cement and primer should
be closed at all times when not in
use to prevent evaporation of
chemicals and hardening of cement.
• They are also very flammable and
should be kept away from heat or
flame.
Fire Hazard
WARNING
Figure 33
F. Joint assembly
Working quickly, insert the pipe into the fi tting socket
bottom and give the pipe or fi tting a 1/4 turn to evenly
distribute the cement. Do not continue to rotate the
pipe after it has hit the bottom of the fi tting socket.
A good joint will have suffi cient cement to make a
bead all the way around the outside of the fi tting hub.
The fi tting will have a tendency to slide back while
the cement is still wet so hold the joint together for
about 15 seconds.
Figure 34
G. Cleanup and joint movement
Remove all excess cement from around the pipe
and fi tting with a dry cotton rag. This must be done
while the cement is still soft.
The joint should not be disturbed immediately after
the cementing procedure, and suffi cient time should
be allowed for proper curing of the joint. Exact drying
time is diffi cult to predict because it depends on
variables such as temperature, humidity and cement
integrity. For more specifi c information, you should
contact your solvent cement manufacturer.
Figure 35
33
Vent Pipe Installation
The following guidelines should be followed when installing
the air intake and exhaust vent system:
• Venting should be as direct as possible with a minimum
number of pipe fi ttings.
• Vent diameter must not be reduced unless specifi cally
noted in the installation instructions.
• Support all horizontal pipe runs every 4 ft. and all
vertical pipe runs every 5 ft. or according to local codes
or venting manufacturer’s instructions.
• Vents run through unconditioned spaces where
below freezing temperatures are expected, are not
recommended.
• Vents run through unconditioned spaces inside a
building may result in the condensation of fl ue gases
during the winter season. The rubber coupling joined to
the blower includes a nipple with a cap. In installations
such as this connect a condensation trap to this nipple.
The combustion air intake and exhaust vent system and
termination may be installed in one of the following type
terminations:
1. Concentric Vent Termination (horizontal/side wall
installation).
2. Concentric Vent Termination (vertical/roof installation).
All pipe, fi ttings, pipe cement, primers and procedures
must conform to American National Standard Institute and
American Society for Testing and Materials (ANSI/ASTM)
standards. This water heater has been design certifi ed by
CSA International for use with the specifi ed (CSA) listed
plastic vent pipe.
• 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
• 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
Do not use solvent cement to connect the exhaust vent
system to the blower. Use the rubber coupling and gear
clamps instead. This connection must be removable to
service the heater. All other joints in the air intake and
exhaust vent systems must be properly joined and sealed.
Vent Pipe Runs
1. The exhaust vent system must not, under any
circumstances, be run downhill then run uphill thus
forming a valley. It may leave a space to accumulate
condensation and block vent pipe.
2. Horizontal runs require a minimum 1/8 in. rise per 5
ft. and a support every 4 ft. or according to venting
manufacturer’s instructions. Ensure there is enough
height between heater and termination to raise vent
pipe runs the required distance.
3. Vertical runs require a support every 5 ft. that must
provide proper support to prevent stress on the pipes
or according to venting manufacturer’s instructions.
Vent Terminal Installations
Important: The vent system must terminate so that proper
clearances are maintained as cited in local codes or the
latest edition of “National Fuel Gas Code”, ANSI Z223.1/
NFPA 54.
In addition, the manufacturer recommends the vent
terminal not to be installed closer than 6 in. from an inside
or outside corner.
Plan the vent system layout so that proper clearances are
maintained from plumbing and wiring. Vent pipes serving
power vented appliances are classifi ed by building codes as
“vent connectors”. Required clearances from combustible
materials must be provided in accordance with information
in this manual under “Locating The New Water Heater”
and with the latest edition of “National Fuel Gas Code”,
ANSI Z223.1/NFPA 54 and local codes.
BLOWER ASSEMBLY INSTALLATION
1. This power vented water heater comes with blower
assembly installed.
2. After unit is set in place, make sure blower assembly is
still mounted securely. Make sure there is no damage
to blower.
3. 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 motor
housing. Make sure the plastic tubing is not folded
anywhere between the pressure switch and the blower
motor housing (see Figure 37 & Figure 38).
5. This water heater is a polarity sensitive appliance and
will not operate if the power supply polarity is reversed.
Power to this water heater must be wired properly
(correct polarity).
6. Do not plug in power cord until vent system is
completely installed. The Power Direct Vent operates
on 110 -120 VAC. therefore a grounded outlet must be
within reach of the 6 foot fl exible power cord supplied
with the heater. The power cord supplied may be used
on a unit only where local codes permit. If local codes
do not permit use of fl exible power supply cord:
a. Make sure the unit is unplugged from the wall
outlet. Remove the screw and open panel on the
front of the junction box on the blower.
34
b. Cut the fl exible power cord, leaving enough to be
able to make connections. Remove the strain relief
fi tting from the box.
c. Install a suitable conduit fi tting inside the enclosure.
d. Splice fi eld wiring into existing wiring using code
authorized method (wire nuts, etc).
e. Be certain that the neutral and line connections
are not reversed when making these connections.
f. Ground heater properly. This water heater must be
grounded in accordance with the current edition
of “National Electrical Code”, NFPA 70 and/or
local codes. These must be followed in all cases.
The water heater must be connected to a grounded
metal, permanent wiring system or an equipment
grounding conductor must be run with the circuit
conductors and connected to the equipment
grounding terminal or lead on the water heater (see
Figure 11; the wiring diagram).
g. Close the panel on the junction box. Make sure that
the access panel is properly secured.
7. The blower discharge has a rubber coupling made to
accept only straight sections of 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
in the rubber coupling.
8. A rubber coupling is an integral part of the vent system
and must be used in every installation. Failure to do so
may result in overheating, poor performance, nuisance
lock-outs, personal injury or death.
Vent/Intake Pipe Connections To Blower/Air Duct
1. The CPVC vent piping ( 5 ft. supplied) 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.
Important: These connections must be properly seated
and tightened to prevent the leakage of fl ue gases into the
area. See Figure 37 & Figure 38.
2. The heaters are supplied with a 3” rubber coupling
to accept the vent pipe. Note: Polypropylene vent
systems require separate adaptor (fi eld supplied).
3. Before installing clean and lightly sand the end of
the CPVC plastic vent piping that will connect into
the rubber coupling. For polypropylene vent systems
follow manufacturer’s instructions.
4. Loosen the upper clamp on the rubber coupling and
insert the sanded end of the vent piping a full 1-1/4
in. . 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.
5. Tighten the upper clamp so that the vent piping is
fi rmly secured in the coupling and is gas tight. Do not
over tighten or cause distortion of any of the parts.
Ensure the bottom of the rubber coupling is fi rmly
seated on the blower outlet and that the lower gear
clamp is also secure. Check to ensure there is no
distortion or movement of the clamped assembly once
it is completed.
• Do not overtighten the top and bottom gear clamps of the
rubber coupling.
• Do not apply solvent cement or silicone to the rubber
coupling connection.
Property Damage Hazard
CAUTION
HOSE CONNECTION
PORT FOR
CONDENSATE DRAIN
8 in.
LOOP
TO
DRAIN
BLOWER
ASSEMBLY
Figure 36
35
Coupling Installations According To Vent Sizes
3” RUBBER
COUPLING
(SUPPLIED)
BLOWER
3” CPVC
VENT
PIPE
AIR DUCT
ADAPTER
3” INLET PIPE
CONFIGURATION FOR HI-INPUT HEATERS CONNECTED TO 3”
VENTING.
(OPTIONAL CONFIGURATION FOR LO-INPUT HEATERS CONNECTED TO
3” VENTING.)
Figure 37
4” CPVC
VENT PIPE
3” RUBBER
COUPLING
(SUPPLIED.)
3” CPVC VENT
PIPE, 3 in. MAX
LENGTH
3”-4” CPVC
ADAPTER (FIELD
SUPPLIED)
BLOWER
CONFIGURATION FOR HI-INPUT HEATERS CONNECTED TO 4”
VENTING.
4” INLET PIPE
AIR DUCT
ADAPTER
3” PIPE
(FIELD
SUPPLIED)
Figure 38
SOUND SUPPRESSOR
Included with this water heater is a Tee fi tting confi gured as
a sound suppressor which should be used as the exhaust
termination (see Figure 39 and Figure 40). The Vent
Termination Screen (see “Vent Pipe Termination” section)
must be installed in the straight through end of the Sound
Suppressor (see Figure 39 and Figure 40).
EXHAUST VENT
TERMINAL
INTAKE VENT
TERMINAL
SIDE WALL
RODENT SCREEN
(INSTALL INTO
TERMINATION)
Figure 39
EXHAUST
VENT
TERMINAL
INTAKE
VENT
TERMINAL
SOUND
SUPPRESSOR
WITH SCREEN
Figure 40
36
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.
Protected from moving vehicles.
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 latest
edition of “National Fuel Gas Code”, ANSI Z223.1/
NFPA 54.
Horizontal piping slopes at an upward pitch of 1/8 in.
rise per 5 ft. away from the water heater.
Not obstructed in any way.
Vent Termination
Horizontal
12 in. min. above grade/snow level.
Away from corners, other vents, windows etc.
Vertical
Air Intake and Exhaust terminations 18 in. min.
above roof/snow level.
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.
Side taps plugged if not used for combo heating.
Heater completely filled with water.
Closed system pressure build-up precautions
installed.
Electrical Connections
Unit connected to a 120V electrical supply.
Proper polarity.
Water heater properly grounded.
Installed in accordance with prevailing provisions
of local codes, or in the absence of such, the latest
edition of “National Electrical Code” (NFPA 70).
After all actions on checklist are checked/
completed, read the Lighting Instructions and
proceed with lighting the heater.
37
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 fi lled 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
fl ammable vapor safety features of this heater.
This heater is equipped with a hot-surface ignition
system that automatically ignites the burner. Do not
attempt to light this heater manually with a match or
fl ame-producing device.
323546-000
1. Turn the thermostat counter-clockwise to the lowest setting.
2. Set the gas control switch to the “OFF” position.
3. Turn off electrical power to the appliance if service is to be performed.
TO TURN OFF GAS TO APPLIANCE
1. STOP! Read the safety
information above on this
label.
2. Turn off all electric power to the
appliance.
3. Turn the thermostat
counter-clockwise to the
lowest setting.
4. Set the switch on the control to
the “OFF” position.
5. Do not attempt to light manually.
6. Wait five (5) minutes to clear out
any gas. If you then smell gas, STOP!
Follow “B” in the safety information above on
this label. If you don't smell gas, go the next
step.
7. Turn on all electric power to
the appliance.
8. Set the switch on the control
to the “ON” position.
9. Turn thermostat to desired
setting.
DANGER Hotter water
increases the risk of
scald injury. Consult the
instruction manual before
changing temperature.
10. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas
supplier.
OPERATING INSTRUCTIONS
DANGER
A. This appliance does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do NOT try
to light the burner by hand.
B. BEFORE OPERATING smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier
than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; Do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to turn the gas control
buttons. Never use tools. If the control
buttons will not turn, don't try to repair them,
call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.
D. Do not use this appliance if any part has
been under water. Immediately contact a
qualified installer or service agency to
replace a flooded water heater. Do not
attempt to repair the unit. It must be
replaced!
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
FLAMMABLE
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
38
OPERATING THE TEMPERATURE CONTROL SYSTEM
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 satisfi es your hot-water needs. This
will also provide the most energy effi cient operation of
the water heater.
Short repeated heating cycles caused by small hot-water
uses can cause a temperature increase of the hot water
by 20F° 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.
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 and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Temperature limiting devices
such as mixing must be
installed when required by
codes and to ensure safe
temperatures at fixtures.
BURN
HOT
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, 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 infi rm, or physically/
mentally handicapped. If anyone using hot water fi ts into
one of these groups or if there is a local code or state law
requiring certain temperature water at the hot-water tap,
then you must take special precautions. In addition to
using lowest possible temperature setting that satisfi es
your hot water needs, a means such as a mixing valve,
should be used at hot-water taps used by these people
or at the water heater (see Figure 6 & Figure 7). Follow
manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat, see
Table 5 in this manual.
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 41).
Hot water temperatures required for automatic dishwasher
and laundry use can cause scald burns resulting in serious
personal injury and/or death. The temperature at which
injury occurs varies with the person’s age and time of the
exposure. The slower response time of children, aged or
disabled persons increases the hazards to them. Never
allow small children to use a hot-water tap, or to draw their
own bath water. Never leave a child or disabled person
unattended in a bathtub or shower.
The hot setting shown on the dial is approximately 120°F .
This is a good starting point to set the temperature.
Setting the water heater temperature at 120°F will reduce
the risk of scalds. Some states require settings at specifi c
lower temperatures.
The thermostat settings on the gas control valve are shown
in Figure 41.
The water temperature setting was factory set at the lowest
(VAC) temperature setting.
39
GAS CONTROL VALVE/THERMOSTAT
ON/OFF
SWITCH
TEMPERATURE
SETTING DIAL
181°F
70°F
140°F 155°F 165°F
130°F 110°F
Figure 41
Temperature
Dial Setting
Approximate
Temperature
°F
Time to induce a 2nd
and 3rd Degree burn
to adult skin
VERY HOT 181 Less than 1 second
C 165 Less than 1 second
B 155 About 1.5 seconds
A 140 Less than 5 seconds
HOT 130 More than 30 seconds
LOW 110 Normal shower temp
VAC 70 N/A
Table 5
Note: The temperatures indicated are approximate. The
actual temperature of the heated water may vary.
The Vacation Setting (VAC) sets the controller at
approximately 70°F . This setting is recommended when
the water heater is not in use for a long period of time. This
effectively turns the controller temperature setting down to
a temperature that prevents the water in the water heater
from freezing while still conserving energy.
40
FOR YOUR INFORMATION
START UP CONDITIONS
Condensate
Whenever the water heater is fi lled with cold water, some
condensate will form while the burner is ON. A water
heater may appear to be leaking when in fact the water is
condensate. This usually happens when:
a. A new water heater is fi lled with cold water for the
fi rst time.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue
temperatures are lower.
c. Large amounts of hot water are used in a short time
and the refi ll water in the tank is very cold.
Moisture from the products of combustion condense on
the cooler tank surfaces and form drops of water which
may fall onto the burner or other hot surfaces to produce
a “sizzling” or “frying” noise.
Because of the suddenness and amount of water,
condensate water maybe diagnosed as a “tank leak”.
After the water in the tank warms up (about 1-2 hours),
the condition should disappear.
Do not assume the water heater is leaking until there has
been enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the
family’s demands for hot water including dishwashers,
washing machines and shower heads.
Excessive condensate maybe noticed during the
winter and early spring months when incoming water
temperatures are at their lowest.
Good venting is essential for a gas fi red 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.
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 fl ammable and explosive. To prevent
the possibility of injury under these conditions, it is
recommended that the hot-water faucet, located farthest
away, be opened for several minutes before any electrical
appliances which are connected to the hot-water system
are used (such as a dishwasher or washing machine). If
hydrogen gas is present, there will probably be an unusual
sound similar to air escaping through the pipe as the hot-
water faucet is opened. There must be no smoking or open
fl ame near the faucet at the time it is open.
41
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 defi ciencies or abnormalities are encountered during
these inspections call a qualifi ed service technician.
Flood damage to a water heater may not be readily visible
or immediately detectable. However, over a period of time
a fl ooded water heater will create dangerous conditions
which can cause death, serious bodily injury, or property
damage. Contact a qualifi ed installer or service agency to
replace a fl ooded water heater. Do not attempt to repair
the unit! It must be replaced!
VENTING SYSTEM INSPECTION
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
• Flue gases may escape if vent pipe is not properly
connected.
• Be alert for obstructed, sooted or deteriorated vent
system to avoid serious injury or death.
• Do not store corrosive chemicals in vicinity of water
heater.
• Chemical corrosion of flue and vent system can
cause serious injury or death.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
Breathing Hazard - Carbon Monoxide Gas
WARNING
At least once a year a visual inspection should be made
of the venting system. You should look for:
• Obstructions which could cause improper venting. The
combustion, dilution and ventilation air fl ow must not
be obstructed.
• Damage or deterioration which could cause improper
venting or leakage of combustion products.
Be sure the vent piping is properly connected to prevent
escape of dangerous fl ue gases which could cause deadly
asphyxiation.
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Chemical vapor corrosion of the fl ue and vent system
may occur if air for combustion contains certain chemical
vapors. Spray can propellants, cleaning solvents,
refrigerator and air conditioner refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes, bleach
and process chemicals are typical compounds which are
potentially corrosive.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility
to correct the problem and clean or replace the fl ue and
venting before resuming operation of the water heater.
BURNER OPERATION AND INSPECTION
At least once a year a visual inspection should be made of
the main burner and the hot surface igniter assembly for
proper fl ame characteristics and ignition sequences. This
can be done by removing the outer door and viewing the
main burner operation through the viewport on the inner
door (see Figure 42). The main burner should provide
complete combustion of gas, ignite rapidly, give reasonably
quiet operation, and cause no excessive fl ame lifting from
the burner ports. If the proper fl ame characteristics are
not evident (see Figure 43), make sure that the fl ow of
combustion and ventilation air is not blocked. Inspection
of exhaust/air intake termination is needed to ensure there
is no blockage there.
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 42).
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 fi re causing death, serious injury, or property damage.
VIEWPORT
MAIN
BURNER
IGNITER
AND
FLAME
ROD
Figure 42
42
CORRECT FLAME
SOFT BLUE
INCORRECT
FLAME LAZY
YELLOW
BLUE TIPS
LIGHT BLUE INNER
CONES ARE
SATISFACTORY
Figure 43
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 place chemical vapor
emitting products near air intake
and exhaust terminations.
• 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 fl ammable liquids, etc. must not be placed
against or adjacent to the water heater which can cause
a fi re.
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 44). 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 44
If the Temperature-Pressure Relief Valve on the water
heater weeps or discharges periodically, it may be due to
thermal expansion.
Note: Excessive water pressure is the most common
cause of temperature-pressure relief valve leakage.
Excessive water system pressure is most often caused
by “thermal expansion” in a “closed system.” See
“Closed Water Systems” and “Thermal Expansion”
sections of this manual. The T&P valve is not intended
for the constant relief of thermal expansion.
Temperature-pressure relief valve leakage due to pressure
build up in a closed system that does not have a thermal
expansion tank installed is not covered under the Limited
Warranty. Thermal expansion tanks must be installed on
all closed water systems.
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperature-
pressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
Explosion Hazard
WARNING
43
DRAINING AND FLUSHING
Periodic draining and cleaning of sediment from the tank
maybe necessary. It is recommended that the tank be
drained and fl ushed every 6 months to remove sediment
which may build up during operation. The water heater
should be drained if being shut down during freezing
temperatures. See “Typical Installation” section in this
manual for location of the water heater components
described below.
• Burn hazard.
• Hot water discharge.
• Keep hands clear of drain
valve discharge.
BURN
HOT
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 if the water heater is going to be shut down for
an extended period.
3. CLOSE the cold-water inlet valve to the water heater.
4. OPEN a nearby hot-water faucet and leave open to
allow for draining.
5. Connect a hose to the drain valve and terminate to
an adequate drain.
Note: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
6. Close the water heater drain valve when all water in
the storage tank has drained.
7. Follow instructions in the “Filling The Water Heater”
section.
8. Turn “ON” the gas supply at the main gas shut-off
valve.
9. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
To Flush The Water Heater Storage Tank:
1. Turn “OFF” the electrical supply to the water heater.
2. Ensure the cold-water inlet valve is open.
3. Connect a hose to the drain valve and terminate it to
an adequate drain.
4. Ensure the drain hose is secured before and during the
entire fl ushing procedure. Flushing is performed with
system water pressure applied to the water heater.
5. Open the water heater drain valve to fl ush the storage
tank. Caution: Water will be hot.
6. Flush the water heater storage tank to remove
sediment and allow the water to fl ow until it runs clean.
7. Close the water heater drain valve when fl ushing is
completed.
8. Remove the drain hose.
9. Ensure the heater is full of water.
10. Turn “ON” electrical supply to place water heater back
in operation and follow the lighting instructions.
11. Allow the water heater to complete several heating
cycles to ensure it is operating properly.
Caution: Do not turn on power to the water heater unless
the tank is full. Open a hot-water faucet and allow the
water to run until the air is purged and the water fl ows
uninterrupted from the faucet.
Important: When operating a cold tank, condensation can
occur and drip on the burner. This should not be confused
with a tank leak.
44
ANODE ROD MAINTENANCE
Each water heater contains at least one anode rod,
which will slowly deplete (due to electrolysis) prolonging
the life of the water heater by protecting the glass-lined
tank from corrosion. Adverse water quality, hotter water
temperatures, high hot water usage, hydronic heating
devices, and water softening methods can increase
the rate of anode rod depletion. Once the anode rod
is depleted, the tank will start to corrode, eventually
developing a leak.
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfi de gas
dissolved in the water.
Important: Do not remove this rod permanently as it 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
fi ltration equipment from a water conditioning company to
successfully eliminate all water odor problems.
Artifi cially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease
the life of the water heater tank.
The anode rod should be inspected after a maximum of
three years and annually thereafter until the condition of
the anode rod dictates its replacement (see Figure 45).
Note: Artifi cially softened water requires the anode rod to
be inspected annually. The following are typical (but not
all) signs of a depleted anode rod:
• The majority of the rods diameter
is less than 3/8 in. .
• Signifi cant sections of the support
wire (approx. 1/3 or more of the
anode rod’s length) are visible.
If the anode rod show signs of either
or both it should be replaced.
Note: Whether re-installing or
replacing the anode rod, check for
any leaks and immediately correct
if found.
Figure 45
To replace the anode:
1. Turn off gas supply to the water heater.
2. Shut off the water supply and open a nearby hot water
faucet to depressurize the water tank.
3. Drain approximately 5 gallons of water from tank. (Refer
to “Draining And Flushing” for proper procedures).
Close drain valve.
4. Remove old anode rod.
5. Use Tefl on
®
tape or approved pipe sealant on threads
and install new anode rod.
6. Turn on water supply and open a nearby hot water
faucet to purge air from water system. Check for any
leaks and immediately correct any if found.
7. Restart the water heater as directed in this manual.
See the “Reference Parts Listing” for anode rod
location.
Figure 46
EXPOSED
SUPPORT
WIRE
PITTED
ANODE
ROD
EXPOSED
SUPPORT
WIRE
45
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 qualifi ed installer to check the water heater.
Ensure the venting is properly attached and secured.
Never use this water heater unless it is completely fi lled
with water. To prevent damage to the tank, the tank must
be fi lled with water. Water must fl ow from the hot-water
faucet before turning “ON” gas to the water heater.
C. Water at the blower assembly is water vapo r 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.
D. *Condensation may be seen on pipes in humid weather
or pipe connections may be leaking.
E. *The anode rod fi tting may be leaking.
F. Small amounts of water from temperature-pressure
relief valve may be due to thermal expansion or high
water pressure in your area.
G. *The temperature-pressure relief valve may be leaking
at the tank fi tting.
H. Water from a drain valve may be due to the valve being
slightly opened.
I. *The drain valve may be leaking at the tank fi tting.
J. Combustion products contain water vapo r 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.
K. 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
fi tting. If cotton is wet, follow the instructions in the
“Draining And Flushing” section and then remove
fi tting. Put pipe dope or Tefl on
®
tape on the threads
and replace. Then follow the instructions in the
“Filling The Water Heater” section.
A
C
B
H
E
F
G
I
D
Figure 47
46
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 Termination Elbow with Rodent Screen
2 *Vent Pipe
3 *Coupling (if required)
4 CPVC Vent Pipe (5 ft. supplied)
5 *Vent Pipe Elbow (long radius)
6 *CPVC Vent Pipe Elbow
8 Cold-Water Inlet Nipple/Diptube
9 **Combo Heating System Supply Outlet
(Optional)
10 T&P Valve
11 * Discharge Pipe
12 **Combo Heating System Return Inlet
(Optional)
13 Gas Control Valve/Thermostat
(Honeywell)
14 Gas Valve Electronic Control Module
And Cover (Honeywell)
15 Drain Valve
16 Outer Gas Door
17 Manifold Door Assembly (behind
outer door) (see Figure 3) (see also
Figure 50)
18 *Metal Drain Pan
19 *Floor Drain
26 Anode (under cap)
27 Baffl e Assembly
28 Hot-Water Outlet Nipple/Anode
29 Sound Suppressor (Tee fi tting)
31 ****Rubber Coupling (see Figure 4)
(see also Figure 51)
32 Gear Clamp (see Figure 4) (see also
Figure 51)
33 ***Blower with Power Cord (see Figure
4) (see also Figure 51)
34 Air Duct Adapter
35 Air Inlet Snorkel
36 Air Duct
38 Flame Sensor Rod (see Figure 3) (see
also Figure 50)
39 Sheet Metal Burner (see Figure 3) (see
also Figure 50)
40 Gas Orifi ce (see Figure 3) (see also
Figure 50)
41 Gas Manifold (see Figure 3) (see also
Figure 50)
42 Hot-Surface Igniter (see Figure 3) (see
also Figure 50)
43 Manifold Door Gasket (see
Figure 3) (see also Figure 50)
44 Manifold Door (see Figure 3) (see also
Figure 50)
45 Two Piece Grommet With Clip (see
Figure 3) (see also Figure 50)
46 Viewport (see Figure 3) (see also
Figure 50)
47 Air Tubing (Intake) (see Figure 4) (see
also Figure 51)
48 Blower High Limit Switch (see Figure
4) (see Figure 51)
49 Intake Air Pressure Switch (NC)
(inside box) (see Figure 4) (see also
Figure 51)
50 Capacitor (see Figure 4) (see also
Figure 51)
51 Air Tubing (Exhaust) (see Figure 4)
(see also Figure 51)
52 Exhaust Air Pressure Switch (NO)
(inside box) (see Figure 4) (see also
Figure 51)
*, **, ***, **** see notes on following
page
Front View
1
2
5
10
8
11
15
18
19
27
28
29
2
13 14
16 17
26
8
9
12
6
3 4
Rear View
32
33
36
31
AIR INLET
PIPING
EXHAUST OUTLET
PIPING
35
34
Figure 48 Figure 49
47
Natural gas and Propane
(LP) main burner with
igniter assembly. NG burner
shown. LP burner similar
but with drain hole (item 17
in Figure 1).
Flare
Nut
††
44
46
42
39
41
43
40
38
45
Figure 50
31
32
47
49
33
52
Shown with
Junction Box Cover
removed for clarity.
48
51
50
Figure 51
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 120 VAC In operation.
**** See “Vent Pipe Installation” for more information.
† The orifi ce on Natural gas models has Right-hand
thread, the orifi ce on Propane (LP) models has Left-
hand thread.
†† For Natural gas models the Flare Nut has Right-hand
thread. For Propane (LP) models the Flare Nut has
Left-hand thread.
48
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualifi ed service
agent.
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 try to start 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.
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 fl ame current)
Post-purge 30 seconds
Pressure Switch (PS)
Prove Period
2 minutes
Pressure Switch (PS)
Fault Delay (failed
open/closed)
2 minutes
Soft Lockout 20 minutes
Energy Cut Off
(ECO) Limit Lockout
Indefi nite
49
SYSTEM STATUS AND ERROR CODES
The micro-controller inside the gas control monitors 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 fl ash an error code. The table below lists the System Status Codes for the Honeywell control. Refer to it
and to the “Ignition State And Timing” to diagnose the problem before attempting corrective action.
LED Flash Sequence Control Status
Corrective
Action
Number
Short fl ash once every four seconds IDLE (no call for heat, no fault conditions) 1
“Heartbeat”, alternates bright/dim Call For Heat (no fault conditions) 2
One Flash, three second pause Low Flame Signal (control continues to operate) 3
Two Flash, three second pause Pressure Switch Failed Closed 4
Three Flash, three second pause Pressure Switch Failed Open 5
Four Flash, three second pause
ECO (Energy Cut Off) Limit Lockout
thermostat temperature limit was exceeded.
6
Five Flash, three second pause Flame Out Of Sequence 7
Six-One Flash, three second pause
Soft Lockout
- Retry Limit
- Failed Trial For Ignition
8
Six-Two Flash, three second pause
Soft Lockout
- Recycle Limit
- Pressure Switch/ High Limit opened
9
Six-Three Flash, three second pause
Soft Lockout
- Recycle Limit
- Flame Lost
10
Six-Four Flash, three second pause
Soft Lockout
- Flame out of Sequence Sensed
11
Seven Flash, three second pause N/A (Flammable Vapor Sensor Lockout) 12
Eight-One Flash, three second pause N/A (Flammable Vapor Sensor Fault Detected) 13
Eight-Two Flash, three second pause Temperature Sensor Fault Detected 14
Eight-Three Flash, three second pause Electronics Fault Detected 15
Eight-Four Flash, three second pause Valve Fault Detected 16
LED continuously “ON” Hard Lockout 17
READING THE LED FLASH SEQUENCE.
The LED indicator light is active when the gas valve/thermostat is in operation. The light will normally show a fl ash
sequence of a short fl ash once every four seconds or a “Heartbeat” of alternating bright/dim. Multiple fl ash codes indicate
an error and can be read as follows:
Example: Corrective Action Number 9, Six-Two Flash, three second pause. For this code, the LED indicator light will
make six bright fl ashes, pause for one second and then make two more bright fl ashes. The LED will pause for three
seconds and repeat the six-two cycle of fl ashes.
50
CORRECTIVE ACTIONS
See the table below for corrective actions corresponding to the Corrective Action Number in the “System Status And Error Codes”
section above. If following those corrective actions does not resolve the error, refer to “Other Symptoms“ table later in
this manual.
Corrective
Action
Number
Corrective Action
1 Normal operation, no action necessary.
2
Normal operation, no action necessary.
3
1. Flame rod not properly seated in flame, reposition rod.
2. Clean flame sensor rod with fine steel wood to avoid lock-out.
4
1. Check that blower operates and does not have any blockages.
2. Check that all wiring is correct.
3. Ensure the air pressure sensing tubes are properly connected and not kinked or damaged.
4. Ensure the air pressure switch is correct and the air pressure switch (N.O.) is not bypassed
(jumpered).
5. Turn power to the unit “OFF” – check for continuity of the air pressure switch (N.O.) with wires
disconnected;
a. If the pressure switch contacts show continuity (closed circuit), replace the pressure switch,
b. If the pressure switch contacts are open and all wiring is correct, replace the Gas Control.
5
1. Ensure the blower is running - check for 120 VAC to the blower when the heating cycle begins.
a. If the Gas Control does not energize the blower - replace the Gas Control.
b. If the blower fails to start when energized:
i. Turn power to the heater “OFF” – check if the capacitor is connected;
ii. Turn power to the heater “OFF” – check the capacitor rating ( 3uF +/-5%);
iii. Turn power to the heater “OFF” - replace the blower assembly.
2. Ensure the air pressure sensing tubes are properly connected and not kinked or damaged;
3. Check continuity of the vent temperature limit switch – replace switch if contact remain open.
4. Check continuity of the air pressure switch (N.C.) – replace switch if contact remain open.
5. Ensure the correct size of exhaust and air intake pipes were used per the instruction manual
for vent length. Ensure maximum number of elbows or equivalent feet of both pipes was not
exceeded.
6. Ensure there are no obstructions in the exhaust and air intake pipes.
7. If there are excessive restrictions in the air intake pipe the air pressure switch (N.C.) will open.
8. Check air pressure switch performance - Check blower vacuum with a manometer - Compare
with air pressure switch (N.O.) setting. If the air pressure switch proves defective – replace the air
pressure switch (N.O.).
9. If the air pressure switch (N.O.) performance test results prove the air pressure switch is working
properly, and all other steps are followed, and fault code persist – replace the control.
6
Resetting the ECO (Energy Cut-Out) requires manual intervention. It cannot be reset by cycling power
to the control.
Reset Procedure
1. Manual reset is performed by turning the set point knob to lowest set point position for a minimum
of 10 seconds and then return it to the desired set point.
2. The manual reset of the ECO can only be performed 2 times, after the ECO trips a third time, the
gas valve will enter a hard lock out where the gas control will need to be replaced.
7
1. Turn the power “OFF” for 10-20 seconds then “ON” again to clear the fault code.
2. Flame rod not properly seated in flame, reposition rod.
3. Clean flame sensor rod with fine steel wood to avoid lock-out.
4. Replace the control if the fault code persists.
51
Corrective
Action
Number
Corrective Action
8
1. Gas supply is turned off or gas pressure is too low. Ensure supply pressure and manifold gas
pressures are within requirements. Manifold pressure is nonadjustable, if gas supply pressure
proves correct and manifold pressure is off by more than 0.3” WC replace the control.
2. Low supply voltage - should be 115 - 125 VAC
3. Ensure flame sensor is making good contact with the burner flame and flame is steady.
4. Ensure flame sensor is clean, use ultra- fine steel wool to clean flame sensor.
5. Ensure the Hot Surface Igniter is positioned properly to provide consistent ignition.
6. Check for any cracks in igniter assembly ceramic insulators - replace igniter assembly if damaged.
7. Check resistance of igniter at room temperature (at the plug). Replace the igniter if resistance is
not within 42-76 ohms at room temperature.
8. Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent
length. Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded.
9
1. Ensure the blower is running - check for 120 VAC to the blower when the heating cycle begins.
a. If the Gas Control does not energize the blower - replace the Gas Control.
b. If the blower fails to start when energized:
i. Turn power to the unit “OFF” – check if the capacitor is connected;
ii. Turn power to the unit “OFF” – check the capacitor rating ( 3uF +/-5%);
iii. Turn power to the unit “OFF” - replace the blower assembly.
2. Ensure the air pressure sensing tubes are properly connected and not kinked or damaged;
3. Check continuity of the vent temperature limit switch – replace switch if contacts remain open.
4. Check continuity of the air pressure switch (N.C.) – replace switch if contacts remain open.
5. Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent
length. Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded.
6. Ensure there are no obstructions in the exhaust and air intake pipes.
7. If there are excessive restrictions in the air intake pipe the air pressure switch (N.C.) will open.
8. Check air pressure switch performance - Check blower vacuum with a manometer - Compare
with air pressure switch (N.O.) setting. If the air pressure switch proves defective – replace the air
pressure switch (N.O.).
9. If the air pressure switch (N.O.) performance test results prove the air pressure switch is working
properly, and all other steps are followed, and fault code persist – replace the control.
10
1. Gas supply is turned “OFF” or gas pressure is too low. Ensure supply pressure and manifold gas
pressures are within requirements. Manifold pressure is nonadjustable. If supply pressure proves
correct and manifold, pressure is off by more than 0.3” WC replace the control.
2. Low supply voltage - should be 115 - 125 VAC
3. Ensure flame sensor is making good contact with the burner flame and flame is steady.
4. Ensure the flame sensor is clean, use ultra-fine steel wool to clean flame sensor.
5. Ensure the Hot Surface Igniter is positioned properly to provide consistent ignition.
6. Check for any cracks in igniter assembly ceramic insulators - replace igniter assembly if damaged.
7. Check resistance of igniter at room temperature (at the plug). Replace the igniter if resistance is
not within 42-76 ohms at room temperature.
8. Ensure correct size of exhaust and air intake pipes were used per the instruction manual for vent
length. Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded.
11
1. Turn the power “OFF” for 10-20 seconds then “ON” again to clear the fault code.
2. Replace the control if fault code persists.
12 N/A – If this happens replace the gas control.
13 N/A – If this happens replace the gas control.
14
1. Turn the power “OFF” for 10-20 seconds then “ON” again to clear the fault code.
2. Replace the control if the fault code persist.
15
1. Turn the power “OFF” for 10-20 seconds then “ON” again to clear the fault code.
2. Replace the control if the fault code persist.
16
1. Turn the power “OFF” for 10-20 seconds then “ON” again to clear the fault code.
2. Replace the control if the fault code persist.
17 1. Control has failed. If resetting the control does not clear the fault code, replace the control.
52
OTHER SYMPTOMS
Problem Possible Cause(S) Corrective Action
Insuffi cient
Hot Water
1. Thermostat set too low
2. Leaking faucets/Wasted hot water
3. Wrong piping connections
4. Water heater too small
5. Sediment or lime in tank
6. Long runs of exposed piping
7. Hot-water piping in outside wall
1. Turn temperature knob to higher setting
2. Repair faucets
3. Correct piping: dip tube must be in cold inlet
4. Install adequate heater
5. Drain/flush-provide water treatment if needed
6. Insulate piping
7. Insulate piping
Water Is
Too Hot
1. Thermostat is set too high
2. Heater stacking (Failure to install
the proper restrictive screens)
1. Turn temperature knob to lower setting
2. Ensure correct size of exhaust and air intake pipes
were used per the instruction manual for vent
length. Ensure proper restrictive screens were
used.
Slow Hot
Water Recovery
1. Thermostat set too low
2. Wrong piping connection
3. Wasted hot water
4. Heater too small
1. Turn temperature knob to higher setting
1. Correct piping-dip tube must be in cold inlet
2. Advise customer
3. Install adequate heater
Drip From
Relief Valve
1. Heater stacking (Failure to install
the proper restrictive screens)
2. Closed water system
3. Pressure build-up
4. Improperly seated valve
1. Ensure the correct size of exhaust and air intake
pipes were used per the instruction manual for vent
length. Ensure the proper restrictive screens were
used.
2. See “Thermal Expansion” section
3. Use a pressure-reducing valve and relief valve
4. Check Relief valve for proper operation
5. (Do Not plug T&P valve)
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. Water dripping from blower
assembly
1. Normal operation: the condensation should
disappear after heater warms up
2. Install condensate hose to drain port on the rubber
coupling
Water Leakage 1. Check “Leakage Checkpoints”
Exhaust Pipe
Too Hot
1. Failure to use correct size of
exhaust and air intake pipes;
2. Failure to install the restrictive
screens;
3. Blower high limit switch fails to
open - switch defective
1. Ensure the correct size of exhaust and air intake
pipes were used per the instruction manual for
vent length. Ensure maximum number of elbows or
equivalent feet of both pipes was not exceeded.
2. Ensure that the proper restrictive screens were
used.
3. Replace blower high limit switch
53
LIMITED WARRANTY
SERVICE INQUIRIES:
For service inquiries call the telephone number listed below. Be prepared to provide the following information:
name, address, and telephone number; the model and serial number of the water heater; proof of installation; and a clear description
of the problem.
For your records, ¿ ll in the product:
Serial: ___________________
Model: ___________________
U.S. Customers: Canadian Customers:
A. O. Smith Corporation A. O. Smith Enterprises
500 Tennessee Waltz Parkway 599 Hill St. West
Ashland City, Tennessee 37015 Fergus, ON N1M 2X1
800-527-1953 888-479-8324
EFFECTIVE
For 3 Years, in the event of a tank leak, we will repair or, at our
discretion, replace the defective water heater.
For 1 Year, in the event of part failure, we will repair or, at our
discretion, replace the defective part.
We warrant this product against defects in materials or
workmanship as described in this document if installed within the
United States or Canada and provided the product remains at its
original place of installation.
Warranty coverage begins the date of installation OR the date of
manufacture if installation cannot be veri¿ ed.
WHAT’S COVERED
Subject to these terms, in the event of defect in materials and/or
workmanship resulting in a tank leak during the ¿ rst three years,
we will:
• Replace the water heater should the tank leak.
Subject to these terms, in the event of a defect in materials and/or
workmanship appearing during the ¿ rst year, we will:
• Repair or, at our discretion, replace any part of the water heater
covered under this limited warranty excluding parts subject to
normal maintenance (Example: non-electronic anode rod, ¿ lter,
etc)
Service/labor, shipping, delivery, installation, handling or any
other costs are not covered at any time under this warranty.
Any replacement part or product will be warranted only for the
unexpired portion of the original water heater’s limited warranty
period.
If an identical model is no longer available due to a change in
law, regulation, or standard, we will replace the product with
one having comparable capacity and input. In these instances,
the owner will have the option of paying the difference between
what was paid for the original model and the new model with the
additional features, or receiving a refund of the portion of the
purchase price, on a pro-rata basis allocable to the unexpired
portion of the warranty.
WHAT’S NOT COVERED
• Problems caused by improper: gas supply line sizing, gas type,
venting, connections, combustion air, voltage, wiring, or fusing
• Failure to follow applicable codes
• Failure to follow printed instructions
• Abuse, misuse, accident, ¿ re, À ood, Acts of God
• Improper installation, sizing, delivery, or maintenance
• Claims related to rust, noise, smell, or taste of water
• Failure to conduct authorized factory start up if required
• Alterations to the water heater
• Non-outdoor heaters installed outdoors
• Damages due to a failure to allow for thermal expansion
• Heat exchanger failure due to lack of adequate / proper supply
of water
• Heaters moved from their original location
• Service trips to explain proper installation, use, or maintenance
of the product/unit or to describe compliance requirements
under applicable codes and regulations
• Charges related to accessing your heater including but not
limited to door/wall removal, equipment rental, etc.
• Replacement parts after expiration of this warranty
LIMITATIONS
NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY,
THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY. ALL
OTHER WARRANTIES INCLUDING A WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE ARE EXPRESSLY DISCLAIMED. SELLER SHALL
NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL,
SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES. TOTAL
LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE
PURCHASE PRICE PAID WHETHER BASED ON CONTRACT,
TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY.
COMMERCIAL
WATER HEATER
LIMITED WARRANTY
54
NOTES
55
NOTES
500 Tennessee Waltz Parkway,
Ashland City, TN 37015
• Technical Support: 800-527-1953
• Parts: 800-433-2545
• Fax: 800-644-9306
www.hotwater.com
Copyright © 2013 A. O. Smith Corporation. All rights reserved.
