Instruction Manual

PRINTED 1007 185884-001

Keep thIs Manual In the pocKet on heater for future reference whenever MaIntenance adjustMent or servIce Is requIred.

power dIrect vented Gas Models NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

all technIcal and warrantY questIons: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

resIdentIal Gas water heaters

• for Your safety •AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

GAMA certification applies to all residential gas water heaters with capacities of 20 to 100 gallons with input rating of 75,000 BTU/Hr. or less.

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safe InstallatIon, use, and servIceYour 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 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.

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, including formaldehyde, carbon monoxide and soot.

IMportant defInItIons

• Qualified Installer: Aqualifiedinstallermusthaveabilityequivalenttoalicensedtradesmaninthefieldsofplumbing,airsupply,venting,andgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGasCodeasitrelatestotheinstallationofgasfiredwaterheaters.Thequalifiedinstallermustalsobefamiliarwiththedesignfeaturesanduseofflammablevaporignitionresistantwaterheaters,andhaveathoroughunderstandingofthisinstructionmanual.

• service agency: Aserviceagencyalsomusthaveabilityequivalenttoalicensedtradesmaninthefieldsofplumbing, air supply, venting,andgassupply, includinga thoroughunderstandingof the requirementsof theNationalFuelGasCodeasitrelatestotheinstallationofgasfiredwaterheaters.Theserviceagencymustalsohaveathorough understandingofthisinstructionmanual,andbeabletoperformrepairsstrictlyinaccordancewiththeserviceguidelinesprovidedbythemanufacturer.

• Gas Supplier: TheNaturalGasorPropaneUtilityorservicewhosuppliesgas forutilizationby thegasburning applianceswithinthisapplication.Thegassuppliertypicallyhasresponsibilityfortheinspectionandcodeapprovalof gaspipinguptoandincludingtheNaturalGasmeterorPropanestoragetankofabuilding.Manygassuppliersalso offerserviceandinspectionofapplianceswithinthebuilding.

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General safetY

4

thank Youforpurchasingthiswaterheater.Properlyinstalledandmaintained,itshouldgiveyouyearsoftroublefreeservice.

AbbreviationsFoundInThisInstructionManual:

• CSA-CanadianStandardsAssociation

• ANSI-AmericanNationalStandardsInstitute

• NFPA-NationalFireProtectionAssociation

• ASME-AmericanSocietyofMechanicalEngineers

•GAMA-GasApplianceManufacturer’sAssociation

Thisgas-firedwaterheaterisdesigncertifiedbyCSAInternationalunderAmericanNationalStandard/CSAStandard forGasWaterHeatersANSIZ21.10.1•CSA4.1(currentedition).

preparInG for the InstallatIon

1. Readthe“GeneralSafety”section,page3ofthismanualfirstandthentheentiremanualcarefully.Ifyoudon’tfollowthesafetyrules,thewaterheaterwillnotoperateproperly.ItcouldcauseDEATH,SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

Thismanualcontainsinstructionsfortheinstallation,operation,andmaintenanceofthegas-firedwaterheater.Italsocontainswarningsthroughoutthemanualthatyoumustreadandbeawareof. All warnings and all instructions are essential to the proper operationofthewaterheaterandyoursafety.read the entIre Manual Before atteMptInG to Install or operate the water heater.

2.Theinstallationmustconformwiththeseinstructionsandthelocalcodeauthorityhavingjurisdiction.Intheabsenceoflocalcodes,installationsshallcomplywiththeNationalFuelGasCodeANSIZ223.1/NFPA 54 and the National Electrical Code, NFPA 70. ThesepublicationsareavailablefromTheNationalFireProtectionAssociation,1BatterymarchPark,Quincy,MA02269.

3. Thewaterheaterwheninstalledmustbegroundedinaccordancewiththelocalcodes,orintheabsenceoflocalcodes:TheNationalElectrical Code. ANSI/NFPA 70.

4.Ifafter reading thismanualyouhaveanyquestionsordonotunderstandanyportionoftheinstructions,callthelocalgasutilityorthemanufacturerwhosenameappearsontheratingplate.

5.Carefully plan your placement of thewater heater. Correctcombustion, vent action, and vent pipe installation are veryimportant in preventingdeath frompossible carbonmonoxidepoisoningandfires,seeFigures1and2.

Examinethelocationtoensurethewaterheatercomplieswiththe“LocatingtheNewWaterHeater”sectioninthismanual.

6.ForCalifornia installation thiswater heatermust be braced,anchored, or strapped to avoid falling ormoving during anearthquake.Seeinstructionsforcorrectinstallationprocedures.InstructionsmaybeobtainedfromCaliforniaOfficeoftheStateArchitect,400PStreet,Sacramento,CA95814.

7.MassachusettsCoderequiresthiswaterheatertobeinstalledinaccordancewithMassachusetts248-CMR2.00:StatePlumbingCodeand248-CMR5.00.Formoreinformationseenextpage.

8.ComplieswithSCAQMDrule#1121anddistrictshavingequivalentNOxrequirements.

IntroductIon

taBle of contentsSAFE INSTALLATION, USE AND SERVICE.................................. 2GENERAL SAFETY........................................................................ 3TABLE OF CONTENTS .................................................................. 4INTRODUCTION ............................................................................ 4 Preparing for the New Installation............................................... 4INSTALLATIONREQUIREMENTSFORTHECOMMONWEALTH OF MASSACHUSETTS ................................. 5TYPICAL INSTALLATION ............................................................... 6MIXING VALVE USAGE ................................................................. 7LOCATING THE NEW WATER HEATER .................................. 8-11 FactstoConsiderAboutLocation ............................................8-9 CombustionAirandExhaustTerminationClearances ...........9-10 Wire Fence ............................................................................... 10 AirforVentilationforAppliancesLocatedinConfinedSpaces .... 10 InsulationBlankets............................................................... 10-11INSTALLING THE NEW WATER HEATER ............................. 12-22 Water Piping ........................................................................ 12-13 Temperature-PressureReliefValve .......................................... 13 Gas Piping ................................................................................ 14 SedimentTraps......................................................................... 15 Filling the Water Heater ............................................................ 15 BlowerAssemblyInstallation .................................................... 15 VentConnectionstoBlowerAssembly ..................................... 16 Venting and Installation........................................................16-17 Venting Through an Outside Wall ........................................ 17-18 VentingSystemExampleInstallationforAllModels ................. 18 Vent Pipe Separation ................................................................ 18

Cutting Openings Through an Outside Wall and Collar Installation ..................................................18-19 Installation Showing Use of PVC, ABS or CPVC Pipe for Inlet and Outlet Vent Piping ................................................. 19 Connecting Vent to Blower ....................................................... 19 InstallationShowingUseof(optional) DeluxeHorizontalVentKit ...................................................19-20 Venting Through a Roof ............................................................ 20 Vent Pipe Preparation .......................................................... 20-22LIGHTING & OPERATING LABEL ............................................... 23TEMPERATURE REGULATION .................................................. 24FOR YOUR INFORMATION ......................................................... 25 Start Up Conditions................................................................... 25 Operational Conditions ............................................................. 25PERIODIC MAINTENANCE ....................................................26-28 VentingSystemInspection ....................................................... 26 Burner Operation and Inspection .............................................. 26 Burner Cleaning ........................................................................ 26 Housekeeping ........................................................................... 26 Anode Rod ................................................................................ 27 Temperature-PressureReliefValveOperation ......................... 27 Draining ............................................................................... 27-28 DrainValveWasherReplacement ............................................ 28 Service ...................................................................................... 28LEAKAGECHECKPOINTS .......................................................... 29REPAIR PARTS LIST ................................................................... 30TROUBLESHOOTING GUIDELINES ...................................... 31-33NOTES .................................................................................... 34-35

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Forallsidewallterminated,horizontallyventedpowervent,directvent,andpowerdirectventgasfueledwaterheatersinstalledineverydwelling,buildingorstructureusedinwholeorinpartforresidentialpurposes,includingthoseownedoroperatedbytheCommonwealthandwherethesidewallexhaustventterminationislessthanseven(7)feetabovefinishedgradeintheareaoftheventing,includingbutnotlimitedtodecksandporches,thefollowingrequirementsshallbesatisfied:

InstallatIon of carBon MonoXIde detectors Atthetimeof installationofthesidewallhorizontalventedgasfueledequipment,theinstallingplumberorgasfittershallobservethatahardwiredcarbonmonoxidedetectorwithanalarmandbatteryback-upisinstalledonthefloorlevelwherethegasequipmentistobeinstalled.Inaddition,theinstallingplumberorgasfittershallobservethatabatteryoperatedorhardwiredcarbonmonoxidedetectorwithanalarmisinstalledoneachadditionallevelofthedwelling,buildingorstructureservedbythesidewallhorizontalventedgasfueledequipment.Itshallbetheresponsibilityofthepropertyownertosecuretheservicesofqualifiedlicensedprofessionalsfortheinstallationofhardwiredcarbonmonoxidedetectors.

Intheeventthatthesidewallhorizontallyventedgasfueledequipmentisinstalledinacrawlspaceoranattic,thehardwiredcarbonmonoxidedetectorwithalarmandbatteryback-upmaybeinstalledonthenextadjacentfloorlevel.

Intheeventthattherequirementsofthissubdivisioncannotbemetatthetimeofcompletionofinstallation,theownershallhaveaperiodofthirty(30)daystocomplywiththeaboverequirementsprovidedthatduringsaidthirty(30)dayperiod,abat-teryoperatedcarbonmonoxidedetectorwithanalarmshallbeinstalled.

approved carBon MonoXIde detectorsEachcarbonmonoxidedetectorasrequiredinaccordancewiththeaboveprovisionsshallcomplywithNFPA720andbeANSI/UL2034listedandCSAcertified.

sIGnaGe Ametalorplasticidentificationplateshallbepermanentlymountedtotheexteriorofthebuildingataminimumheightofeight(8)feetabovegradedirectlyinlinewiththeexhaustventterminalforthehorizontallyventedgasfueledheatingappli-anceorequipment.Thesignshallread,inprintsizenolessthanone-half(1/2)inchinsize,“Gas vent dIrectlY Below. Keep clear of all oBstructIons.”

InspectIon Thestateorlocalgasinspectorofthesidewallhorizontallyventedgasfueledequipmentshallnotapprovetheinstallationunless,uponinspection,theinspectorobservescarbonmonoxidedetectorsandsignageinstalledinaccordancewiththeprovisionsof248CMR5.08(2)(a)1through4.

eXeMptIons:Thefollowingequipmentisexemptfrom248CMR5.08(2)(a)1through4:

1.TheequipmentlistedinChapter10entitled“EquipmentNotRequiredToBeVented”inthemostcurrenteditionofNFPA54asadoptedbytheBoard;and

2.ProductApprovedsidewallhorizontallyventedgasfueledequipment installed inaroomorstructureseparatefromthedwelling,building,orstructureusedinwholeorinpartforresidentialpurposes.

Manufacturer requIreMents - Gas equIpMent ventInG sYsteM provIdedWhenthemanufacturerofProduct Approvedsidewallhorizontallyventedgasequipmentprovidesaventingsystemdesignorventingsystemcomponentswiththeequipment,theinstructionsprovidedbythemanufacturerforinstallationoftheequipmentandtheventingsystemshallinclude:

1.Detailedinstructionsfortheinstallationoftheventingsystemdesignortheventingsystemcomponents;and

2.Acompletepartslistfortheventingsystemdesignorventingsystem.

Manufacturer requIreMents - Gas equIpMent ventInG sYsteM not provIdedWhenthemanufacturerofaProductApprovedsidewallhorizontallyventedgasfueledequipmentdoesnotprovidethepartsforventingthefluegases,butidentifies“specialventingsystems,”thefollowingrequirementsshallbesatisfiedbythemanufacturer:

1.The referenced “special venting system” instructions shall be includedwith the appliance or equipment installation instructions;and

2.The“specialventingsystems”shallbeProductApprovedbytheBoard,andtheinstructionsforthatsystemshallincludeaparts list and detailed installation instructions.

AcopyofallinstallationinstructionsforallProductApprovedsidewallhorizontallyventedgasfueledequipment,allventinginstructions,allparts lists forventing instructions,and/orallventingdesign instructionsshall remainwith theapplianceor equipmentatthecompletionoftheinstallation.

InstallatIon requIreMents for the coMMonwealth of Massachusetts

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tYpIcal InstallatIonGet to Know Your water heater - Gas Models

a vent pipe–exhaust B vent terminal–exhaust c Intake or combustion air pipe d Intake or combustion air terminal e vent adapter f Blower assembly G cold water Inlet h Inlet water shut-off valve I union

fIGure 1.

j Inlet dip tube K anode** l hot water outlet M outlet receptacle (115 vac) n temperature-pressure relief valve o flue P Flue Baffle Assembly** q Insulation r rating plate s Gas supply

t Manual Gas shut-off valve u Ground joint union v drip leg (sediment trap) w drain valve X Gas control valve Y drain pan Z Inner door aa outer door BB hsI Burner assembly*** cc fv sensor assembly

*cautIon: 115 vaccontrol harness InsIde outer jacKet

* all pIpInG MaterIals to Be supplIed BY custoMers.** located under the Blower asseMBlY.*** not pIctured

tYpIcal hot surface IGnIter & MaIn Burner

hot surface IGnIter

flaMesensor

teMperature IndIcators

teMperature adjustMent Buttons

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MIXInG valve usaGe

fIGure 2.

ThisappliancehasbeendesigncertifiedascomplyingwithAmericanNational Standard/CSA Standard for water heaters and is considered suitablefor:

water (potable) heating and space heating:Allmodels areconsideredsuitableforwater(potable)heatingandspaceheating.

HOTTERWATERCANSCALD:

Water heaters are intended to produce hot water. Water heated to a temperaturewhichwillsatisfyspaceheating,clotheswashing,dishwashing,andothersanitizingneedscanscaldandpermanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,theinfirm,orphysically/mentallydisabled.Ifanyoneusinghotwaterinyourhomefitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthelowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasa*MixingValve,shouldbeusedat thehotwatertapsusedbythesepeopleoratthewaterheater.Mixingvalvesareavailableatplumbingsupplyorhardwarestores.ConsultaQualifiedInstaller orServiceAgency. Followmixing valvemanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,readthe“TemperatureRegulation”sectioninthismanual,seeFigure31.

suGGested pIpInG arranGeMent for top connectIons

8

facts to consIder aBout the locatIon

Carefullychooseanindoorlocationforthenewwaterheater,becausetheplacementisaveryimportantconsiderationforthesafetyoftheoccupantsinthebuildingandforthemosteconomicaluseoftheappliance. 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 anewlocation,thefollowingcriticalpointsmustbeobserved:

1.Selectalocationindoorsascloseaspracticaltotheventterminalorlocationtowhichthewaterheaterventpipingisgoingtobeconnected,andascentralizedwiththewaterpipingsystemaspossible.

2.Selectedlocationmustprovideadequateclearancesforservicingand proper operation of the water heater.

Installationof thewater heatermust beaccomplished in suchamannerthatifthetankoranyconnectionsshouldleak,theflowwillnotcausedamagetothestructure.Forthisreason,itisnotadvisabletoinstallthewaterheaterinanatticorupperfloor.Whensuchlocationscannotbeavoided,asuitabledrainpanshouldbeinstalledunderthewaterheater.Drainpansareavailableatyourlocalhardwarestore.Suchadrainpanmusthaveaminimumlengthandwidthofatleast2”(5.1cm)greaterthatthewaterheaterdimensionsandmustbepipedtoanadequatedrain.Drainpandepthmustallowforaccesstotheouterdoorsforservicingtheignitorandburner.

Waterheaterlifedependsuponwaterquality,waterpressureandtheenvironmentinwhichthewaterheaterisinstalled.Waterheatersaresometimesinstalledinlocationswhereleakagemayresultinpropertydamage,evenwiththeuseofadrainpanpipedtoadrain.However,unanticipateddamagecanbereducedorpreventedbyaleakdetectororwatershut-offdeviceusedinconjunctionwithapipeddrainpan.Thesedevicesareavailablefromsomeplumbingsupplywholesalersandretailers,anddetectandreacttoleakageinvariousways:

• Sensorsmountedinthedrainpanthattriggeranalarmorturnofftheincomingwatertothewaterheaterwhenleakageisdetected.

• Sensorsmountedinthedrainpanthatturnoffthewatersupplytotheentirehomewhenwaterisdetectedinthedrainpan.

•Watersupplyshut-offdevices thatactivatebasedon thewaterpressuredifferentialbetweenthecoldwaterandhotwaterpipesconnected to the water heater.

• Devicesthatwillturnoffthegassupplytoagaswaterheaterwhileatthesametimeshuttingoffitswatersupply.

INSTALLATIONS INAREASWHERE FLAMMABLE LIQUIDS(VAPORS)ARELIKELYTOBEPRESENTORSTORED(GARAGES,STORAGEANDUTILITYAREAS,ETC.):Flammableliquids(suchasgasoline,solvents,propane(LPorbutane,etc.)andothersubstances(suchasadhesives,etc.)emitflammablevaporswhichcanbeignited

locatInG the new water heaterbyagaswaterheater’shotsurfaceigniterormainburner.Theresultingflashbackandfirecancausedeathorseriousburnstoanyoneintheareaandpropertydamage.ThiswaterheaterisequippedwithaFVsensorfordetectingthepresenceofflammablevapors,seeFigure3.Whenthe sensordetects thosevapors, theunitwillshutdownandnotoperate.Shouldthishappen,pleaserefertotroubleshootingguideinthismanual.Eventhoughthiswaterheater isaflammablevapors ignitionresistantwaterheaterandisdesignedtoreducethechancesofflammablevaporsbeingignited,gasolineandotherflammablesubstancesshouldneverbestoredorusedinthesamevicinityorareacontainingagaswaterheaterorotheropenflameorsparkproducingappliance.

fIGure 3.

Also,thewaterheatermustbelocatedand/orprotectedsoitisnotsubjecttophysicaldamagebyamovingvehicle.

This water heatermust not be installed directly on carpeting.Carpetingmustbeprotectedbymetalorwoodpanelbeneaththeapplianceextendingbeyondthefullwidthanddepthoftheappliancebyatleast3”(7.6cm)inanydirection,oriftheapplianceisinstalledinanalcoveorcloset,theentirefloormustbecoveredbythepanel.Failuretoheedthiswarningmayresultinafirehazard.

9

Minimumclearancesbetween thewater heater and combustibleconstructionare0inchatthesidesandrear,6”(15.2cm)fromthefrontofthejacket,and12”(30.5cm)fromthetop(standardclearance).Ifclearancesstatedontheheaterdifferfromstandardclearances,install water heater according to clearances stated on the heater.

Adequateclearanceforservicingthisapplianceshouldbeconsideredbeforeinstallation,suchaschangingtheanodes,etc.

Aminimumclearanceof5”(12.7cm)fromthefrontofthejacketmustbeallowedforaccesstoreplaceablepartssuchasthethermostats,drainvalveandreliefvalve.Provide24”(61cm)frontclearanceforservicingandadequateclearancebetweenthejackettopandceilingforservicingthefluearea.

Wheninstallingtheheater,considerationmustbegiventoproperlocation. Location selected should be as close to thewall aspracticable and as centralizedwith thewater piping systemaspossible.

fIGure 4.

Donotinstallinaconfinedareasuchasacloset,unlessyouprovideventilationairasshown in the"LocatingTheNewWaterHeater"sectionandFigure5.Neverobstructtheflowofventilationair.Ifyouhaveanydoubtsorquestionsatall,callyourgascompany.FailuretoprovideventilationaircanresultinafireorexplosionandcancauseDEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

fIGure 5.

If thiswater heaterwill be used in beauty shops, barber shops,cleaningestablishments,orself-servicelaundrieswithdrycleaningequipment,it isimperativethatthewaterheaterorwaterheatersbe installedso thatcombustionandventilationairbe taken fromoutside these areas.

Propellantsofaerosolspraysandvolatilecompounds,(cleaners,chlorine based chemicals, refrigerants, etc.) in addition to beinghighlyflammableinmanycases,willalsoreacttoformcorrosivehydrochloric acidwhen exposed to the combustion products ofthewaterheater.The resultscanbehazardous,andalsocauseproduct failure.

coMBustIon aIr and eXhaust terMInatIon clearances

venting through an outside wall - clearances, see figure 7.

• 0"clearancefor3"PVC,ABS,orCPVCSchedule40pipingfromcombustiblesurfaces.

• Thelocationselectionmustprovideclearancesforservicingandproper operation of the water heater, see Figure 8.

fIGure 6.

• TheventingsystemmustbeinstalledinamannerwhichallowsinspectionoftheinstallationoftheventingpipesandjointsaswellasperiodicinspectionafterinstallationasrequiredbytheNational Fuel Gas Code ANSI Z223.1.

10

fIGure 7.

vent terMInatIon clearances

wIre fence

Whenthewaterheateroutletterminalislowenoughtobetouchedaccidentally,orisaccessibletosmallchildren,awiremeshchainlinkfence(asshowninFigure8)maybeused.Careshouldbetakentomaintainadequateventilationaroundtheoutletterminal.Ifachainlinkfenceisinstalled,itmustnotbeusedasastorageareaforitemsthatmayblockproperventilation.

fIGure 8.

venting through roof - clearances

• 0"clearancefor3"PVC,ABS,orCPVCSchedule40pipingfromcombustibleandnoncombustiblesurfaces.

• Theventexhaustoutletandairinletterminalsshallterminateatleast18"(45.7cm)abovetheroofsurface,seeFigure9.

fIGure 9.

aIr for ventIlatIon for applIances located In confIned spaces

Airforventilationshouldbeprovidedifinstalledinaconfinedspace.Refer to the National Fuel Gas Code, ANSI Z223.1.

InsulatIon BlanKets

Insulationblanketsareavailabletothegeneralpublicforexternaluseongaswaterheatersbutarenotnecessarywiththeseproducts.Thepurposeofaninsulationblanketistoreducethestandbyheatloss encounteredwith storage tank heaters.Your water heatermeetsorexceedstheNationalApplianceEnergyConversationActstandardswithrespecttoinsulationandstandbylossrequirements,makinganinsulationblanketunnecessary.

11

Shouldyouchoosetoapplyaninsulationblankettothisheater,youshould follow these instructions (For identification of componentsmentionedbelow,seeFigure1).Failuretofollowtheseinstructionscanrestrict theairflowrequired forpropercombustion,potentiallyresultinginfire,asphyxiation,seriouspersonalinjury,ordeath.

• Do notapplyinsulationtothetopofthewaterheater,asthiswill interfere with safe operation of the water heater.

• Do notcovertheouterdoor,thermostat,temperature&pressure reliefvalveorFVSensor.

• Do not let insulation around the gas water heater get within 8 inches ofthefloor(accessforservicingtheburner).

• Do not cover the instructionmanual. Keep iton thesideof the waterheaterornearbyforfuturereference.

• Doobtainnewwarningandinstructionlabelsfromthemanufacturer forplacementontheblanketdirectlyovertheexistinglabels.

• Do inspect the insulation blanket frequently tomake certain it doesnotsag,therebyobstructingaccesstoburner.

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therMal eXpansIon

Aswater isheated, itexpands(thermalexpansion).Inaclosedsystem thevolumeofwaterwillgrowwhen it isheated.As thevolumeofwatergrowstherewillbeacorrespondingincreaseinwaterpressureduetothermalexpansion.Thermalexpansioncancauseprematuretankfailure(leakage).Thistypeoffailureisnotcoveredunderthelimitedwarranty.Thermalexpansioncanalsocause intermittent temperature-pressure relief valve operation:waterdischargedfromthevalveduetoexcessivepressurebuildup.Thisconditionisnotcoveredunderthelimitedwarranty.Thetemperature-pressurereliefvalveisnotintendedfortheconstantreliefofthermalexpansion.

A properly sized thermal expansion tank should be installedon all closed systems to control the harmful effects of thermalexpansion.Contact a local plumbing service agency to have athermalexpansiontankinstalled.

note: to protect against untimely corrosion of hot and cold water fittings, it is strongly recommended that dielectric unions or couplings be installed on this water heater when connected to copper pipe.

AllgaspipingmustcomplywithlocalcodesandordinancesorwiththeNationalFuelGasCode(ANSIZ223.1/NFPA-54)whicheverapplies.Copperandbrasstubingandfittings(excepttinlinedcoppertubing)shallnotbeused.

fIGure 10.

Figure10shows the typicalattachmentof thewaterpiping to thewater heater. The water heater is equipped with 3/4 inch NPT water connections.

water pIpInG

HOTTERWATERCANSCALD:Water heaters are intended to produce hot water. Water heated to a temperaturewhichwill satisfy space heating, clotheswashing,dishwashing, cleaning andother sanitizing needs can scald andpermanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,theinfirm,orphysically/mentallydisabled.Ifanyoneusinghotwaterinyourhomefitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthelowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasamixingvalveshouldbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater,seeFigure2.Valvesforreducingpointofusetemperaturebymixingcoldandhotwaterarealsoavailable. ConsultaQualifiedInstallerorServiceAgency.Followmanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,readthe“TemperatureRegulation”sectioninthismanual.

Thiswaterheatershallnotbeconnectedtoanyheatingsystemsorcomponent(s)usedwithanon-potablewaterheatingappliance.

All piping components connected to this unit for space heatingapplicationsshallbesuitableforusewithpotablewater.

Toxicchemicals,suchasthoseusedforboilertreatmentshallnotbeintroducedintothissystem.

Whenthesystemrequireswaterforspaceheatingattemperatureshigherthanrequiredfordomesticwaterpurposes,atemperingvalvemust be installed. Please refer to Figure 2 for suggested pipingarrangement.

Watersupplysystemsmay,becauseofcoderequirementsorsuchconditions as high line pressure, among others, have installeddevicessuchaspressurereducingvalves,checkvalves,andbackflowpreventers.Devicessuchasthesecausethewatersystemtobeaclosedsystem.

InstallInG the new water heater

13

note: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. do not solder the cold water supply line directly to the cold water inlet. It will harm the dip tube and damage the tank.

t & p valve and pipe Insulation (if supplied)

RemoveinsulationforT&Pvalveandpipeconnectionsfromcarton.

fIGure 11.

Fitpipeinsulationovertheincomingcoldwaterlineandthehotwaterline.Makesurethattheinsulationisagainstthetopcoveroftheheater.FitT&Pvalveinsulationovervalve.MakesurethattheinsulationdoesnotinterferewiththeleveroftheT&Pvalve.

Secure all insulation using tape.

teMperature-pressure relIef valve

This heater is provided with a properly certified combination temperature-pressurereliefvalvebythemanufacturer.

Thevalve iscertifiedbyanationally recognized testing laboratorythatmaintainsperiodicinspectionofproductionoflistedequipmentofmaterialsasmeetingtherequirementsforReliefValvesforHotWaterSupplySystems,ANSIZ21.22•CSA4.4,andthecoderequirementsof ASME.

Ifreplaced,thevalvemustmeettherequirementsoflocalcodes,butnot less thanacombination temperatureandpressure reliefvalvecertifiedasindicatedintheaboveparagraph.

The valvemust bemarkedwith amaximum set pressure not toexceedthemarkedhydrostaticworkingpressureofthewaterheater

(150psi=1,035kPa)andadischargecapacitynotlessthanthewaterheaterinputrateasshownonthemodelratingplate.

Forsafeoperationofthewaterheater,thereliefvalvemustnotberemovedfromitsdesignatedopeningnorplugged.

Thetemperature-pressurereliefvalvemustbeinstalleddirectlyintothefittingofthewaterheaterdesignedforthereliefvalve.Positionthevalvedownwardandprovidetubingsothatanydischargewillexitonlywithin6inches(15.2cm)aboveanadequatedrainoroutsideofthebuildingorstructure.Becertainthatnocontactismadewithanyliveelectricalpart.Thedischargeopeningmustnotbeblockedorreducedinsizeunderanycircumstances.Excessivelength,over30feet(9.14m),oruseofmorethanfourelbowscancauserestrictionandreducethedischargecapacityofthevalve,seeFigures10or14.

Novalveorotherobstructionistobeplacedbetweenthereliefvalveandthetank.Donotconnecttubingdirectlytodischargedrainunlessa6”(15.2cm)airgapisprovided.Topreventbodilyinjury,hazardtolife,orpropertydamage,thereliefvalvemustbeallowedtodischargewater inquantitiesshouldcircumstancesdemand. If thedischargepipeisnotconnectedtoadrainorothersuitablemeans,thewaterflowmaycausepropertydamage.

TheDischargePipe:•Shallnotbesmallerinsizethantheoutletpipesizeofthevalve,or haveanyreducingcouplingsorotherrestrictions.•Shallnotbepluggedorblocked.•Shallbeofmateriallistedforhotwaterdistribution.•Shallbe installedsoas toallowcompletedrainageofboth the temperature-pressurereliefvalve,andthedischargepipe.•Shallterminateatanadequatedrain.•Shallnothaveanyvalvebetweenthereliefvalveandtank.

Thetemperature-pressurereliefvalvemustbemanuallyoperatedatleastonceayear.Cautionshouldbetakentoensurethat(1)nooneisinfrontoforaroundtheoutletofthetemperature-pressurereliefvalvedischargeline,and(2)thewatermanuallydischargedwillnotcauseanybodilyinjuryorpropertydamagebecausethewatermaybeextremelyhot.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetandcontinues to releasewater, immediately close the coldwater inletto the water heater, follow the draining instructions, and replace the temperature-pressurereliefvalvewithanewone.

14

Gas pIpInG

Makesurethegassuppliedisthesametypelistedonthemodelratingplate.Theinletgaspressuremustnotexceed10.5inchwatercolumn(2.6kPa)fornaturaland13inchwatercolumn(3.2kPa)forpropanegas(L.P.).Theminimuminletgaspressureshownontheratingplateisthatwhichwillpermitfiringatratedinput.

AllgaspipingmustcomplywithlocalcodesandordinancesorwiththeNationalFuelGasCode (ANSIZ223.1/NFPA-54)whicheverapplies.Copperandbrasstubingandfittings(excepttinlinedcoppertubing)shallnotbeused.

Ifthegascontrolvalveissubjectedtopressuresexceeding1/2psi(14inchesofwatercolumnor3.5kPa),thedamagetothegascontrolvalvecouldresultinafireorexplosionfromleakinggas.

IfthemaingaslineShut-offservingallgasappliancesisused,alsoturn“off”thegasateachappliance.Leaveallgasappliancesshut“off”untilthewaterheaterinstallationiscomplete.

Agaslineofsufficientsizemustberuntothewaterheater.Consultthe current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54andyourgassupplierconcerningpipesize.

Theremustbe:• Areadilyaccessiblemanualshutoffvalveinthegassupplylineservingthewaterheater,and

• Adripleg(sedimenttrap)aheadofthegascontrolvalvetohelppreventdirtandforeignmaterials fromentering thegascontrolvalve.

• Aflexiblegasconnectororagroundjointunionbetweentheshutoffvalveandthegascontrolvalvetopermitservicingoftheunit.

Besuretocheckallthegaspipingforleaksbeforelightingthewaterheater. Useasoapywatersolution,notamatchoropenflame.Rinseoffsoapysolutionandwipedry.

Wheninstalledatelevationsabove7,700feet(2,347meters),inputratingshouldbereducedattherateof4percentforeach1,000feet (305meters)abovesea levelwhichrequiresreplacementof the burner orifice in accordancewithTheNational FuelGasCodeANSIZ223.1/NFPA54.Contactyourlocalgassupplierforfurtherinformation.

Failuretoreplacethestandardorificewithahighaltitudeorificewheninstalled could result in improper and inefficient operationof theappliance,producingcarbonmonoxidegasinexcessofsafelimits,whichcouldresultinseriousinjuryordeath.Contactyourgassupplierforanyspecificchangeswhichmayberequiredinyourarea.

UsepipejointcompoundorTeflontapemarkedasbeingresistanttotheactionofpetroleum[Propane(L.P.)]gases.

Theapplianceanditsgasconnectionmustbeleaktestedbeforeplacing the appliance in operation.

TheapplianceanditsindividualShut-offvalveshallbedisconnectedfromthegassupplypipingsystemduringanypressuretestingofthatsystemattestpressuresinexcessof1/2psi(14inchesofwatercolumnor3.5kPa).Itshallbeisolatedfromthegassupplypipingsystembyclosing its individualmanualShut-off valve during any pressuretestingofthegassupplypipingsystemattestpressuresequaltoorlessthan1/2psi(14inchesofwatercolumnor3.5kPa).

Connecting the gaspiping to the gas control valve of thewaterheatercanbeaccomplishedbyeitherofthetwomethodsshowninFigures 12 and 13.

fIGure 12. Gas pIpInG wIth fleXIBle connector.

fIGure 13. Gas pIpInG wIth allBlacK Iron pIpe to Gas control.

15

sedIMent traps

Asedimenttrapshallbeinstalledasclosetotheinletofthewaterheater as practical at the time ofwater heater installation.Thesedimenttrapshallbeeitherateefittingwithacappednippleinthebottomoutletorotherdevicerecognizedasaneffectivesedimenttrap.Ifateefittingisused,itshallbeinstalledinconformancewithoneofthemethodsofinstallationshowninFigures12and13.

Contaminantsinthegaslinesmaycauseimproperoperationofthegascontrolvalvethatmayresultinfireorexplosion.Beforeattachingthegaslinebesurethatallgaspipeiscleanontheinside.Totrapanydirtorforeignmaterialinthegassupplyline,adripleg(sometimescalledasedimenttrap)mustbeincorporatedinthepiping.Thedriplegmustbereadilyaccessible. Install inaccordancewiththe“GasPiping”section. Refer to the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

fIGure 14.

fIllInG the water heater

Neverusethiswaterheaterunlessitiscompletelyfullofwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gastothewaterheater.

Tofillthewaterheaterwithwater:1. Close thewaterheaterdrainvalveby turning thehandle to theright

(clockwise).Thedrainvalveisonthelowerfrontofthewaterheater.2. Open the cold water supply valve to the water heater.

note: the cold water supply valve must be left open when the water heater is in use.

3. Toinsurecompletefillingofthetank,allowairtoexitbyopeningthenearesthotwaterfaucet.Allowwatertorununtilaconstantflowisobtained.Thiswillletairoutofthewaterheaterandthepiping.

4. Check allwater piping and connections for leaks.Repair asneeded.

Blower asseMBlY InstallatIon

sequence of InstallatIon

1. This power direct ventwater heater comeswith the blowerassemblyinstalled.

2 Aftertheunitissetinplace,makesuretheblowerassemblyisstillmountedsecurely,andmakesurethereisnodamagetotheblower.

3. Makesurethereisnopackingmaterialinthedischargeoftheblowerortheintake,seeFigure15.

4. Makesure that the rubber tubing isstillattached from theairpressureswitchtotheportontheblowerhousing.Makesuretherubbertubingisnotfoldedanywherebetweenthepressureswitchandtheblowerhousing.

5. MakesuretheON/OFFswitchisintheOFFpositionandthatthewiringharnessisconnectedfromtheblowercontrolboxtotheconnectoronthebottomsideofthegascontrolvalve.

6. Ifthewiringharnessisnotfactoryinstalled,makesuretheON/OFF switch is in the OFF position and then connect the wiring harness from theblower control box to the connector on thebottomsideofthegascontrolvalve.

7. Thiswaterheater isapolaritysensitiveapplianceandwillnotoperateifthepowersupplypolarityisreversed.Thepowersupplyor outlet providing power to thiswater heatermust bewiredproperly(correctpolarity).

8. Donotpluginpowercorduntilventsystemiscompletelyinstalled.Thispowerdirectventheateroperateson110-120Vac,thereforeagroundedoutletmustbewithinreachofthesix(6)foot(1.8m)flexiblepowercordsuppliedwiththeunit,seeFigure2.Ensurethepolarityattheoutletiscorrect.Thepowercordsuppliedmaybeusedonlywherelocalcodespermit.Iflocalcodesdonotpermittheuseofaflexiblepowersupplycord:

a.)Makesuretheunitisunpluggedfromwalloutlet.Removescrewsandremovecontrolbox.

b.)Cuttheflexiblepowercord,leavingenoughtobeabletomakeconnections,theremovethestrainrelieffittingfrombox.

c.)Installsuitableconduitfittinginsideofenclosureandthenfollow(d.)and(e.)below.

d.)Splice fieldwiring into existingwiring using code authorizedmethod(wirenuts,etc.).

e.)Be certain that neutral and live connectionsarenot reversedwhenmakingtheseconnections.

f.) Replacecontrolbox,makesurethatcontrolboxissecuredshut.

16

vent connectIons to Blower asseMBlY

Figure15showsthetypicalventconnections.

fIGure 15.

ventInG and InstallatIon

Planthelayoutoftheventsystemfromtheventterminationtothewaterheaterconsideringallofthe90°and45°elbowsplusthenumberoffeetofpipethatwouldbeneededtoinstallthetotalventsystem.Thewaterheatermustbeventedtotheoutdoorsasdescribedintheseinstructions.DONOTconnectthiswaterheatertoanexistingventorchimney.Itmustbeventedseparatelyfromallotherappliances.Thefittings,otherthanthesuppliedVentTerminationshouldbeequivalenttothefollowing:PVC(Schedule40,DWV,ASTMD-2665),CPVC(Schedule40,DWV,ASTMF-438),ABS(Schedule40DWV,ASTMD-2661).

The cement used should be as recommended by the ventpipemanufacturer. See the instructions in the “VENT PIPEPREPARATION”sectionof thismanual for thepropermethodofcuttingandcementingthePVCpipeandfittings.

Allventgasesmustbecompletelyvented to theoutdoorsof thestructure(dwelling).Whendeterminingtheinstallationlocationforapowerdirectventwaterheater,snowaccumulationanddriftingshouldbeconsideredinareaswhereapplicable.

17

fIGure 16.

Horizontal runsmust be securely supported at 3 1/2 foot (1m)intervalsandverticalrunssupportedat5foot(1.5m)intervals.

fIGure 17.

ventInG throuGh an outsIde wall

a. all 75 Gallon ModelsInthecartonissupplied:

1.Two3”inletandoutletPVCSchedule40-45°ventcaps.

2. One3”CPVCSchedule80-90°elbow;usedtoconnecttheoutlet ventpipetothewaterheaterwhentheoutletventpipeistobeturnedhorizontallydirectlyofftheblower.

3. One5’(1.5m)sectionof3”CPVCSchedule40outletventpipe.(Moremayberequiredandmustbepurchasedlocally.)

fIGure 18.

1. Thewaterheaterrequiresitsown(separate)ventingsystem.

2. only3”CPVCSchedule40pipingandfittingsareacceptablematerialsonthefirstfivefeetoftheoutletventsystem.

3. 3” PVC,ABS, orCPVCSchedule 40 piping and fittings areacceptablematerialsfortheinletventsystemandfortheoutlet ventsystemafterthefirstfivefeet.

4. Theunitcannotbeconnectedtoexistingventpipingorchimney.

5. Whenventingthroughanoutsidewall,theventsmustterminatehorizontallytotheoutdoors.

B. all 50 Gallon 65,000 Btu/hr ModelsInthecartonissupplied:

1. Two3”inlet and outletPVCSchedule40-45°ventcaps.

2. One3”ABSSchedule40-90°streetelbow;usedtoconnecttheoutletventpipetothewaterheaterwhentheoutletventpipeistobeturnedhorizontallydirectlyofftheblower.

3. One5’(1.5m)sectionof3”ABSSchedule40outletventpipe.(Moremayberequiredandmustbepurchasedlocally.)

fIGure 19.

1. Thewaterheaterrequiresitsown(separate)ventingsystem.

2. only3”CPVCorABSSchedule40pipingandfittingsareacceptablematerialsonthefirstfivefeetoftheoutletventsystem.

3. 3” PVC,ABS, orCPVCSchedule 40 piping and fittings areacceptablematerialsfortheinletventsystemandfortheoutlet ventsystemafterthefirstfivefeet.

4. Theunitcannotbeconnectedtoexistingventpipingorchimney.

5. Whenventingthroughanoutsidewall,theventsmustterminatehorizontallytotheoutdoors.

18

c. all 40 and 50 Gallon 40,000 Btu/hr ModelsInthecartonissupplied:

1. Two3”inletandoutletPVCSchedule40-45°ventcaps.Allotherpipingmustbesuppliedbythesupplier.

fIGure 20.

* Ifmakinganimmediatehorizontalrunofventofftheblower,two3”PVCorABSschedule40streetelbowsarerequired.

ventInG sYsteM eXaMple InstallatIons for all Models

Theventpipingcannotunderanycircumstancesberundownhill.

fIGure 21.

correct installation of the vent piping:

1. Horizontalrunsrequireaminimum1/8”(3.2mm)riseperfivefeetof length.

fIGure 22.

2. The total vertical andhorizontal vent runs cannot exceed themaximumlengthwiththenumberof90°elbowsasspecifiedinthetablebelow.Ifmoreelbowsarerequired,theventingdistancemustbereduced5feet(1.5m)forevery90°elbow:

Thenumberof90°elbowsshowninthetableisforboththeintakeairandventpipes.IE:Theventpipecancontainthree90°elbows,

theintakeairpipecanalsocontainthree90°elbows.

3" dIa. vents MaX. lenGth (ft.)

nuMBer of 90° elBows*

45 1

40 2

35 3

*NOTE:Two45°elbowsareequivalenttoone90°elbow.One90°elbowequals5feet(1.5m)ofequivalentventlength.

fIGure 23.

3. Minimumventlengthforallmodelsis18inches(46cm).

vent pIpe separatIon

Theinletandoutletventpipesmustbeseparatedbyaminimumdistance of 6 1/2 inches (16.5 cm) up to 24 inches (61 cm)maximum.

fIGure 24.

cuttInG openInGs throuGh an outsIde wall and collar InstallatIon

After reading themanual and determining the location for theopening in thewall, cut one31/2” (9 cm)diameter hole for theinletventpipingandone31/2”(9cm)diameterholefortheoutletventpipingthroughanexteriorwall,seeFigure25.

note: when determining the location of the openings in the outside wall, allow for the 1/8” (3.2 mm) rise per five feet (1.5 m) of length required in the horizontal run.

19

fIGure 25.

The3”PVC,ABS, orCPVCSchedule 40 vent pipe canbe runfromthewaterheaterthroughthewallorfromthewalltothewaterheater,whicheverismostconvenient.Theventpipemustextendaminimumof11/2”(4cm)throughtheexteriorwall.Extendingthevent capas faraspossible from thesurfaceof theexteriorwallwillhelpminimizediscolorationofthewall.Notethattheinsidefluemounting adaptorsmust be slipped over the vent piping beforelocating the pipe through the wall. Before securing the inside and outsidecollarstothewall,useasiliconesealerbetweenpipeandopening to insure a water and air tight seal.

InstallatIon showInG use of pvc, aBs or cpvc pIpe for Inlet and outlet vent pIpInG

Inletpipingthroughanytypewall.

fIGure 26.

connectInG vent to Blower

1. Ifmakinganimmediatehorizontalrunofventofftheblower,one3”PVC inletandone3”PVC(CPVCfor75gallonmodelsandABSfor50gallon65,000Btu/Hrmodels)outletSchedule40streetelbowsarerequired.Placetheelbowintherequireddirectionontheblowerandattachtheelbowwith3sheetmetalscrews.

fIGure 27.

2. Ifthereistobeaverticalrunofventfromtheblower,the3”PVCinletandthe3”PVC(CPVCfor75gallonmodelsandABSfor50gallon65,000Btu/Hrmodels)outletpipesmustbeattachedtotheblowerandventinghoodusing6sheetmetalscrews.

fIGure 28.

InstallatIon showInG use of (optIonal) deluXe horIZontal vent KIt

Typicalinstallation.

fIGure 29a.

optional 3” pvc horizontal vent Kit:

fIGure 29B.

20

Ifthisconcentrictermination,throughthewalltypeofventingsystemispreferred,theconcentricventkitcanbeorderedfromtheServicePartsDepartmentunderkit#9002749.Installationinstructionsareprovidedwiththekit.

ventInG throuGh a roof

Two3”inletandoutletPVCSchedule40-45°ventcapsaresupplied.

A5’ (1.5m)sectionof3”CPVCSchedule40outlet ventpipe issuppliedwith75gallonmodelsanda5’(1.5m)sectionof3”ABSSchedule40outletventpipeissuppliedwith50gallon65,000Btu/Hrmodels.Moremayberequiredandmustbepurchasedlocally.

1. Thewaterheaterrequiresitsown(separate)ventingsystem.2. Only 3"ABSSchedule 40 piping and fittings are acceptable

materialsonthefirstfivefeetoftheoutletventsystemonthe50gallon65,000BTU/HRmodelsand3"CPVCSchedule40pipingandSchedule80fittingsareacceptablematerialsonthefirstfivefeetoftheoutletventsystemon75gallonmodels.

3. 3” PVC,ABS, orCPVCSchedule 40 piping and fittings areacceptablematerialsfortheinletventsystemandfortheoutletventsystemafterthefirstfivefeet(1.5m).

4. Theunitcannotbeconnectedtoexistingventpipingorchimney.5. Ventingmustterminateverticallytotheoutdoors.6. The total vertical andhorizontal vent runs cannot exceed the

maximum lengthwith amaximumnumber of 90° elbows asspecified in the tablebelow. Ifmoreelbowsare required, theventingdistancemustbereduced5feetforevery90°elbow.

Thenumberof90°elbowsshowninthetableisforboththeintakeairandventpipes.IE:Theventpipecancontainthree90°elbows,theintakeairpipecanalsocontainthree90°elbows.

3" dIa. vents MaX. lenGth (ft.)

nuMBer of 90° elBows*

45 1

40 2

35 3

*NOTE:Two45°elbowsareequivalenttoone90°elbow.One90°elbowequals5feet(1.5m)ofequivalentventlength.

fIGure 30.

vent pIpe preparatIon

1. InItIal preparatIon

A. Makesurethesolventcementyouareplanningtouseisdesignedforthespecificapplicationyouareattempting.

B. Know the physical and chemical characteristics andlimitationsofthePVC,ABSandCPVCpipingmaterialsthatyouareabouttouse.

C. Knowthereputationofyourmanufacturerandtheirproducts.

D. Knowyourownqualificationsorthoseofyourcontractor.ThesolventweldingtechniqueofjoiningPVC,ABSandCPVCpipeisaspecializedskilljustasanyotherpipefittingtechnique.

E. Closelysupervisetheinstallationandinspectthefinishedjobbeforestart-up.

F. Contactthemanufacturer,supplier,orcompetentconsultingagencyifyouhaveanyquestionsabouttheapplicationorinstallation of PVC, ABS and CPVC pipe.

G. Takethetimeandefforttodoaprofessionaljob.Shortcutswillonlycauseyouproblemsanddelaysinstart-up.Byfar,themajorityoffailuresinPVC,ABSandCPVCsystemsaretheresultofshortcutsand/orimproperjoiningtechniques.

2. selectIon of MaterIals

• CuttingDevice-SaworPipeCutter

• DeburringTool,Knife,File,orBevelingMachine(2”[5cm]andabove)

• Brush-PureBristle

• Rag-Cotton(NotSynthetic)

• PrimerandCleaner

• SolventCement - PVC forPVCComponents andCPVC forCPVCComponentsandABSforABScomponents.

• Containers-MetalorGlasstoholdPrimerandCement.SelectthetypeofPVC,ABSorCPVCmaterialstobeusedonthebasisoftheirapplicationwithrespecttochemicalresistance,pressurerating,temperaturecharacteristics,etc.

• InsertionTool -Helpful for larger diameter pipeand fittings6inches(15.2cm)andabove.

21

prIMer

ItisrecommendedthatTetrahydrofuran(THF)beusedtopreparethesurfacesofpipeandfittingsforsolventwelding.Donotusewater,rags,gasolineoranyothersubstitutesforcleaningPVC,ABSorCPVCsurfaces.AchemicalcleanersuchasMEKmaybeused.

ceMent

Thecementshouldbeabodiedcementofapproximately500 to1600centipoiseviscositycontaining10-20%(byweight)virginPVCmaterial solvatedwith tetrahydrofuran (THF).Small quantities ofdimethylformamide(DMF)maybeincludedtoactasaretardingagenttoextendcuringtime.Selectthepropercement;Schedule40cementshouldbeusedforSchedule40pipe.Neveruseall-purposecements,commercialgluesandadhesivesorABScementtojoinPVCorCPVCpipeandfittings.

applIcators

Selectasuitablepurebristletypepaintbrush.Useaproperwidthbrushorrollertoapplytheprimerandcement(seechartbelow).Speedyapplicationof cement is important due to its fast dryingcharacteristics.

recoMMended Brush* sIZe for prIMer

and ceMent applIcatIons

nominal pipe (Ips) size Brush width (Ins.)

3 1-1/2 – 2-1/2

*use onlY natural BrIstle

3. MaKInG the joInt

a. cutting Pipemustbesquarelycuttoallowfortheproperinterfacingofthe

pipeendandthefittingsocketbottom.Thiscanbeaccomplishedwithamiterboxsaworwheeltypecutter.Wheeltypecuttersarenotgenerallyrecommendedforlargerdiameterssincetheytendtoflarethecornerofthepipeend.Ifthistypeofcutterisused,theflareontheendmustbecompletelyremoved.

NOTE:Powersawsshouldbespecificallydesignedtocutplasticpipe.

step aB. deburring Useaknife,plasticpipedeburringtool,orfiletoremoveburrs

fromtheendofsmalldiameterpipe.Besuretoremoveallburrsfromaroundtheinsideaswellastheoutsideofthepipe.Aslightchamfer (bevel)ofabout10°-15°shouldbeadded to theendtopermiteasierinsertionofthepipeintotheendofthefitting.Failuretochamfertheedgeofthepipemayremovecementfromthefittingsocket,causingthejointtoleak.

step B

C. Test dry fit of the joint Tapered fitting sockets are designed so that an interfaced fit

shouldoccurwhenthepipeisinsertedabout1/3to2/3ofthewayintothesocket.Occasionally,whenpipefittingdimensionsareatthetoleranceextremes, itwillbepossibletofully insertdrypipetothebottomofthefittingsocket.Whenthishappens,asufficientquantityofcementmustbeappliedtothejointtofillthegapbetweenthepipeandfitting.Thegapmustbefilledtoobtainastrong,leak-freejoint.

d. Inspection, cleaning, priming Visually inspect the insideof thepipeandfittingsocketsand

removealldirt,greaseormoisturewithacleandryrag.Ifwipingfails toclean thesurfaces,achemicalcleanermustbeused.Checkforpossibledamagesuchassplitsorcracksandreplaceifnecessary.

depth-of-entry Markingthedepthofentryisawaytocheckifthepipehas

reachedthebottomofthefittingsocket inStepF.MeasurethefittingdepthandmarkthisdistanceonthepipeO.D.Youmaywanttoaddseveralinchestothedistanceandmakeasecondmarkastheprimerandcementwillmostlikelydestroyyourfirstone.

22

Applyprimertothesurfaceofthepipeandfittingsocketwithanaturalbristlebrush.ThisprocesssoftensandpreparesthePVC,ABSorCPVCforthesolventcementingstep.Movequicklyandwithouthesitationtothecementingprocedurewhilethesurfacesarestillwetwithprimer.

e. application of solvent cement • Applythesolventcementevenlyandquicklyaroundtheoutsideofthe

pipeatawidthalittlegreaterthanthedepthofthefittingsocket. • Applyalightcoatofcementevenlyaroundtheinsideofthe

fittingsocket.Avoidpuddling. • Applyasecondcoatofcementtothepipeend.

step e

f. joint assembly Workingquickly,insertthepipeintothefittingsocketbottomand

givethepipeorfittinga1/4turntoevenlydistributethecement.

Donotcontinuetorotatethepipeafterithashitthebottomofthefittingsocket.Agoodjointwillhavesufficientcementtomakeabeadallthewayaroundtheoutsideofthefittinghub.Thefittingwillhaveatendencytoslidebackwhilethecementisstillwetsoholdthejointtogetherforabout15seconds.

step f

G. cleanup and joint movement Removeallexcesscementfromaroundthepipeandfittingwitha

drycottonrag.Thismustbedonewhilethecementisstillsoft.

Thejointshouldnotbedisturbedimmediatelyafterthecementingprocedure,andsufficienttimeshouldbeallowedforpropercuringof the joint.Exactdrying time isdifficult topredict because itdependsonvariablessuchastemperature,humidityandcementintegrity.Formorespecificinformation,youshouldcontactyoursolventcementmanufacturer.

step G

23

24

Due to the nature of the typical gas water heater, the watertemperatureincertainsituationsmayvaryupto30°F(16.7°C)higherorloweratthepointofusesuchas,bathtubs,showers,sink,etc.

Itisrecommendedthatlowerwatertemperaturesbeusedtoavoidtheriskofscalding.Itisfurtherrecommended,inallcases,thatthewatertemperaturebesetforthelowesttemperaturewhichsatisfiesyourhotwaterneeds.Thiswillalsoprovide themostenergyefficientoperationofthewaterheater.

HOTWATERCANSCALD:Waterheatersareintendedtoproducehotwater.Waterheatedtoatemperaturewhichwillsatisfyspaceheating, clothes washing, dish washing, and other sanitizingneedscanscaldandpermanentlyinjureyouuponcontact.Somepeoplearemore likely tobepermanently injuredbyhotwaterthan others. These include the elderly, children, the infirm, orphysically/mentallydisabled. Ifanyoneusinghotwater inyourhomefitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthe lowest possible temperature setting that satisfies your hotwaterneeds,ameanssuchasamixingvalveshouldbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater.Mixingvalvesareavailableatplumbingsupplyorhardwarestores,seeFigure2.Followmanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,see Figure 31.

Never allow small children to use a hotwater tap, or to drawtheirownbathwater.Neverleaveachildorhandicappedpersonunattendedinabathtuborshower.

Thewaterheatershouldbelocatedinanareawherethegeneralpublicdoesnothaveaccess.Ifasuitableareaisnotavailable,a cover should be installed over the thermostat to preventtampering.

The water temperature setting was factory set at the lowesttemperature; Pressing the “COOLER” button decreasestemperatureandpressing the “HOTTER” button increasesthetemperature.

Settingthewaterheatertemperatureat120°F(49°C)(Approx.“”markontemperaturesettingofgascontrolvalve)willreduce

theriskofscalds.Somestatesrequiresettingsatspecificlowertemperatures.

teMperature reGulatIonToavoidanyunintentionalchangesinwatertemperaturesettings,thegascontrolvalvehasatamperresistantfeatureforchangingthetemperaturesetting.Tochangethetemperaturesettingfollowtheseinstructions:

1.“WakeUp”thetemperatureindicatorsbyholdingdownboth“COOLER”and“HOTTER”temperatureadjustmentbuttonsatthesametimeforonesecond,seeFigure31.Oneortwoofthetemperatureindicatorswilllightup.Theseindicatorswillonlyremainonfor30secondsifnofurtherbuttonsarepressed.After30secondsthecontrolwillgobackto“Sleep”mode.

2.Releasebothofthetemperatureadjustmentbuttons.

a.Todecreasethetemperaturepressandreleasethe“COOLER” buttonuntilthedesiredsettingisreached.

b.Toincreasethetemperaturepressandreleasethe“HOTTER” buttonuntilthedesiredsettingisreached.

NOTE:Holdingdownthebuttonwillnotcontinuetolowerorraisethetemperaturesetting.Thebuttonmustbepressedandreleasedforeachtemperaturechangedesired.

Shouldoverheatingoccurorthegassupplyfailtoshutoff,turnoffthemanualgascontrolvalvetotheappliance.

Gas control valve - front vIew

temperature settingdisplay

A B C

time to produce 2nd and 3rd degree Burns on

adult skin

C-Flashing=approx.160°F(71°C) About1/2second

C=approx.150°F(66°C) About1-1/2seconds

B=approx.140°F(60°C) Less than 5 seconds

A=approx.130°F(54°C) About30seconds

=approx.120°F(49°C) Morethan5minutes

WARM=approx.80°F(27°C) - - - - - - - - - - - - -

fIGure 31.

25

for Your InforMatIonstart up condItIons

condensateWhenever the water heater is filled with cold water, somecondensatewillformwhiletheburnerison.Awaterheatermayappeartobeleakingwheninfactthewateriscondensate.Thisusuallyhappenswhen:

a. Anewwaterheaterisfilledwithcoldwaterforthefirsttime.b. Burninggasproduceswatervaporinwaterheaters,particularly

highefficiencymodelswherefluetemperaturesarelower.c. Largeamountsofhotwaterareusedinashorttimeandtherefill

waterinthetankisverycold.

Moisturefromtheproductsofcombustioncondenseonthecoolertanksurfacesandformdropsofwaterwhichmayfallontotheburnerorotherhotsurfacestoproducea“sizzling”or“frying”noise.

Becauseofthesuddennessandamountofwater,condensatewatermaybediagnosedasa“tankleak”.Afterthewaterinthetankwarmsup(about1-2hours),theconditionshoulddisappear.

Donot assume thewater heater is leakinguntil therehasbeenenoughtimeforthewaterinthetanktowarmup.

Anundersizedwaterheaterwillcausemorecondensation.Thewaterheatermustbesizedproperlytomeetthefamily’sdemandsforhotwaterincludingdishwashers,washingmachinesandshowerheads.

Excessive condensatemay be noticed during the winter andearly springmonthswhen incomingwater temperatures are attheir lowest.

Goodventing isessential foragasfiredwaterheater tooperateproperlyaswellastocarryawayproductsofcombustionandwatervapor.

sMoKe/odor

Itisnotuncommontoexperienceasmallamountofsmokeandodorduringtheinitialstart-up.Thisisduetoburningoffofoilfrommetalparts, and will disappear in a short while.

closed water sYsteMs

Watersupplysystemsmay,becauseofcoderequirementsorsuchconditions as high line pressure, among others, have installeddevicessuchaspressurereducingvalves,checkvalves,andbackflowpreventers.Devicessuchasthesecausethewatersystemtobeaclosedsystem.

therMal eXpansIon

Aswaterisheated,itexpands(thermalexpansion).Inaclosedsystemthevolumeofwaterwillgrowwhenitisheated.Asthe

volumeofwatergrowstherewillbeacorrespondingincreaseinwaterpressureduetothermalexpansion.Thermalexpansioncancauseprematuretankfailure(leakage).Thistypeoffailureisnotcoveredunderthelimitedwarranty.Thermalexpansioncanalsocauseintermittenttemperature-pressurereliefvalveoperation:waterdischargedfromthevalveduetoexcessivepressurebuildup.Thisconditionisnotcoveredunderthelimitedwarranty.Thetemperature-pressurereliefvalveisnotintendedfortheconstantreliefofthermalexpansion.

A properly sized thermal expansion tank should be installedonallclosedsystemstocontrol theharmfuleffectsof thermalexpansion.Contactalocalplumbingserviceagencytohaveathermalexpansiontankinstalled.

stranGe sounds

Possiblenoisesduetoexpansionandcontractionofsomemetalpartsduringperiodsofheat-upandcool-downdonotnecessarilyrepresentharmfulordangerousconditions.

Condensationcausessizzlingandpoppingwithintheburnerareaduringheatingandcoolingperiodsandshouldbeconsiderednormal.See“Condensate”inthissection.

operatIonal condItIons

“aIr” In hot water faucets

HYDROGENGAS: Hydrogen gas can be produced in a hotwatersystemthathasnotbeenusedforalongperiodoftime(generally two weeks or more). Hydrogen gas is extremelyflammable and explosive. To prevent the possibility of injuryunder these conditions, we recommend the hot water faucet,located farthest away, be opened for severalminutes beforeanyelectricalapplianceswhichareconnectedtothehotwatersystemareused(suchasadishwasherorwashingmachine).Ifhydrogengasispresent,therewillprobablybeanunusualsoundsimilartoairescapingthroughthepipeasthehotwaterfaucetisopened.Theremustbenosmokingoropenflamenear thefaucetatthetimeitisopen.

hIGh water teMperature shut off sYsteMThiswater heater is equippedwith an automatic gas shut-offsystem.Thissystemworkswhenhighwater temperaturesarepresent.Turn “OFF” theentiregassupply to thewaterheater.Thehightemperatureshut-offisbuiltintothegascontrolvalve.Itisnon-resettable.Ifthehightemperatureshut-offactivates,thegascontrolvalvemustbereplaced.Contactyourgassupplierorserviceagency.

26

ventInG sYsteM InspectIon

Atleastonceayearavisualinspectionshouldbemadeoftheventingsystem.Youshouldlookfor:

1.Obstructions which could cause improper venting. Thecombustionandventilationairflowmustnotbeobstructed.

2.Damageordeteriorationwhichcouldcauseimproperventingorleakageofcombustionproducts.

Besuretheventpipingisproperlyconnectedtopreventescapeofdangerousfluegasseswhichcouldcausedeadlyasphyxiation.

Obstructionsanddeterioratedventsystemsmaypresentserioushealthriskorasphyxiation.

Chemicalvaporcorrosionoftheflueandventsystemmayoccurifairforcombustioncontainscertainchemicalvapors.Spraycanpropellants, cleaning solvents, refrigerator and air conditionerrefrigerants,swimmingpoolchemicals,calciumandsodiumchloride,waxes,bleachandprocesschemicalsaretypicalcompoundswhicharepotentiallycorrosive.

If after inspection of the vent system you found sooting ordeterioration, something iswrong. Call the local gas utility tocorrecttheproblemandcleanorreplacetheflueandventingbeforeresumingoperationofthewaterheater.

Burner operatIon and InspectIon

Flood damage to awater heatermay not be readily visible orimmediatelydetectable.However,overaperiodoftimeafloodedwater heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualified installer or service agency to replace afloodedwaterheater.Donotattempttorepairtheunit!Itmustbereplaced!

At least oncea year a visual inspection should bemadeof themainburnerandthehotsurfaceigniterassemblyforproperflame

perIodIc MaIntenancecharacteristicsandignitionsequences.ThiscanbedonebyviewingthemainburneroperationthroughtheViewportontheOuterDoor,seeFigure1.Themainburnershouldprovidecompletecombustionofgas, igniterapidly,givereasonablyquietoperation,andcausenoexcessiveflameliftingfromtheburnerports.IftheproperflamecharacteristicsarenotevidentasinFigure32,makesurethattheflowofcombustionandventilationairisnotblockedintheventingsystem. Youshouldalsocheckforsooting.Sootisnotnormalandwillimpairpropercombustion.AvisualinspectionofthemainburnerandHSIigniter assembly should also bedoneat least oncea year, seeFigure 32.

Sootbuild-up indicatesaproblemthat requirescorrectionbeforefurtheruse.Turn“OFF”gastowaterheaterandleaveoffuntilrepairsaremade,becausefailuretocorrectthecauseofthesootingcanresultinafirecausingdeath,seriousinjury,orpropertydamage.

fIGure 32.

Burner cleanInG

Intheeventyourburnerorburnerairopeningsrequirecleaning,turntheblowerswitchtothe“OFF”positionandallowtheburnertocool.Callaserviceagencytoremoveandcleantheburnerandcorrecttheproblemthatrequiredtheburnertobecleaned.

houseKeepInG

Vacuumaroundbaseofwaterheater fordust,dirt,and lintonaregularbasis.

27

anode rod

Eachwaterheatercontainsatleastoneanoderod,whichwillslowlydepletewhile protecting the glass-lined tank fromcorrosionandprolonging the life of the water heater. Once the anode is depleted, thetankwillstarttocorrode,eventuallydevelopingaleak.Certainwaterconditionswillcauseareactionbetweenthisrodandthewater.Themostcommoncomplaintassociatedwith theanoderod isa"rotteneggsmell"producedfromthepresenceofhydrogensulfidegasdissolved in thewater. IMPORTANT:Donotremovethisrodpermanentlyas itwillvoidanywarranties.Theparts list includesaspecialanodethatcanbeorderedifwaterodorordiscolorationoccurs.NOTE:Thisrodmayreducebutnoteliminatewaterodorproblems.Thewatersupplysystemmayrequirespecialaerationor chlorinationequipment fromawater conditioning company tosuccessfullyeliminateallwaterodorproblems.

Theuseofawatersoftenermaydecreasethelifeofthewaterheatertank.Theanoderodshouldberemovedfromthewaterheatertankevery3yearsforinspection.Thefollowingaretypical(butnotall)signsofadepletedanoderod:

• Themajorityoftherod'sdiameterislessthan3/8".

• Significantsectionsofthesupportwire(approx.1/3ormoreoftheanoderod'slength)arevisible.

Iftheanoderodshowssignsofeitherorbothitshouldbereplaced.NOTE:Whetherre-installingorreplacingtheanoderod,checkforany leaks and immediately correct if found. In situationswhereclearanceabovethewaterheaterislimiteditmaybenecessarytobendtheanoderodforremoval.Flexibleanoderodsareavailableforreplacement.

Inreplacingtheanode:

1. Turnoffgassupplytothewaterheater.

2. Shutoffthewatersupplyandopenanearbyhotwaterfaucettodepressurizethewatertank.

3. Drainapproximately5gallonsofwaterfromthetank(Refertothe"DrainingandFlushing"sectionforproperprocedures).Closedrainvalve.

4. Removeoldanoderod.

5. UseTeflon®tapeorapprovedpipesealantonthreadsandinstallnew anode rod.

6. Turnonwatersupplyandopennearbyhotwaterfaucettopurgeair fromwater system.Check for any leaks and immediatelycorrectanyiffound.

7. Restartthewaterheaterasdirectedunderthe"OperatingYourWaterHeater"section.Seethe"RepairPartsIllustration"sectionfor anode rod location.

teMperature-pressure relIef valve operatIon

Thetemperature-pressurereliefvalvemustbemanuallyoperatedatleastonceayear.

fIGure 33.

When checking the temperature-pressure relief valve operation,makesurethat(1)nooneisinfrontoforaroundtheoutletofthetemperature-pressure reliefvalvedischarge line,and(2) that thewaterdischargewillnotcauseanypropertydamage,asthewatermaybeextremelyhot,seeFigure33.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetandcontinuestoreleasewater,immediatelyclosethecoldwaterinletto the water heater, follow the draining instructions, and replace the temperature-pressurereliefvalvewithanewone.

Ifthetemperature-pressurereliefvalveontheapplianceweepsordischargesperiodically,thismaybeduetothermalexpansion.Youmayhaveacheckvalveinstalledinthewaterlineorawatermeterwithacheckvalve. Consultyour localwatersupplierorserviceagencyforfurtherinformation.Donotplugthetemperature-pressurereliefvalve.

draInInG

28

Thewaterheatershouldbedrainedifbeingshutdownduringfreezingtemperatures.Alsoperiodicdrainingandcleaningofsedimentfromthetankmaybenecessary.

1.Settheblowerswitchtothe“OFF”position.

2.CLOSEthecoldwaterinletvalvetothewaterheater.

3.OPENa nearby hotwater faucet and leave open to allow fordraining.

4.Connectahosetothedrainvalveandterminatetoanadequatedrain.

5.OPENthewaterheaterdrainvalvetoallowfortankdraining.

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.CLOSEthedrainvalve.

7.Followinstructionsinthe“FillingTheWaterHeater”section.

8.Followthelightinginstructionsonthelabelorseepage23under“LightingInstructions”torestartthewaterheater.

draIn valve washer replaceMent

(SeeFigure34)

1.Turn“OFF”gassupplytowaterheater.

2.Follow“Draining”instructions.

3.Turningcounterclockwise( ),removethehexcapbelowthescrew handle.

4.Removethewasherandputthenewoneinplace.

5.Screwthehandleandcapassemblybackintothedrainvalveandretighten using a wrench. DO NOT OVER TIGHTEN.

6.Followinstructionsinthe“FillingTheWaterHeater”section.

7.Checkforleaks.

8.Followthelightinginstructionsinthe“Lighting”sectiontorestartthe water heater.

fIGure 34.

servIce

Ifaconditionpersistsoryouareuncertainabouttheoperationofthewaterheatercontactaserviceagency.

Usethisguidetochecka“Leaking”waterheater.Manysuspected“Leakers”arenotleakingtanks.Oftenthesourceofthewatercanbefoundandcorrected.

Ifyouarenotthoroughlyfamiliarwithgascodes,yourwaterheater,andsafetypractices,contactyourgassupplierorqualifiedinstallertocheckthewaterheater.

29

leaKaGe checKpoIntsReadthismanualfirst.Thenbeforecheckingthewaterheatermakesurethegassupplyhasbeenturned“OFF”,andneverturnthegas“ON”beforethetankiscompletelyfullofwater.

Never use thiswater heater unless it is completely filledwithwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gastothewaterheater.

A.Waterattheblowerassemblyiswatervaporwhichhascondensedoutofthecombustionproducts.Thisiscausedbyaprobleminthevent.Contactthegasutility.

B.*Condensationmaybeseenonpipesinhumidweatherorpipeconnectionsmaybeleaking.

C.*Theanoderodfittingmaybeleaking(anodeislocatedundertheBlowerAssembly).

D.Smallamountsofwaterfromtemperature-pressurereliefvalvemaybedue to thermalexpansionorhighwaterpressure inyourarea.

E.*The temperature-pressure relief valvemaybe leakingat thetankfitting.

F.Waterfromadrainvalvemaybeduetothevalvebeingslightlyopened.

G.*Thedrainvalvemaybeleakingatthetankfitting.

H.Combustion products contain water vapor which cancondenseonthecoolersurfacesofthetank.Dropletsformanddripontotheburnerorrunonthefloor.Thisiscommonatthetimeofstart-upafterinstallationandwhenincomingwater is cold.

I. Water in the water heater bottom or on the floormay befrom condensation, loose connections, or the relief valve.DO NOT replace the water heater until a full inspection of allpossiblewatersourcesismadeandnecessarycorrectivestepstaken.

Leakage fromother appliances,water lines, or ground seepageshouldalsobechecked.

* To checkwhere threaded portion enters tank, insert cottonswabbetweenjacketopeningandfitting.Ifcottoniswet,follow“Draining” instructionsinthe“PeriodicMaintenance”sectionandthenremovefitting.PutpipedopeorTeflontapeonthethreads and replace.Then follow “Filling theWaterHeater”instructionsinthe“InstallingtheNewWaterHeater”section.

30

repaIr parts lIstKey no. part description

1 vent cap w/screen

2 adaptor, flue Mounting

3 5' aBs schedule 40 vent pipe (50 gal. 65,000)

3 5' cpvc schedule 40 vent pipe (75 gal.)

4 90° aBs schedule 40 elbow (50 gal. 65,000)

4 90° cpvc schedule 80 elbow (75 gal.)

5 vent/Blower adapter

6 Blower

7 flue adaptor Gasket (6' x 10.102")

8 Blower Gasket

9 venting; Manual reset switch

10 vent hood assembly

11 junction Box

12 t & p valve

13 dip tube

14 anode rod

15 fv sensor Bracket

16 drain pan

17 hot surface Ignition assembly

18 Orifice

19 Burner assembly

20 Inner door

21 drain valve

22 Manifold

23 right access door w/Gasket

24 left access door w/Gasket

25a access door clips (2)

25B jacket/access door clips (6)

26 fv sensor

27 Gas control valve

28 pressure switch (air)

29 Flue Baffle Assembly

30 Baffle Adaptor Collar Assembly

31 optional (deluxe) horizontal vent Kit

32 optional (3") pvc horizontal vent Kit (75 Gallon only)

Nowthatyouhavepurchasedthiswaterheater,shouldaneedeverexistforrepairpartsorservice,simplycontactthecompanyitwaspurchasedfromordirectfromthemanufacturerlistedontheratingplate on the water heater.

Besuretoprovideallpertinentfactswhenyoucallorvisit.

selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly.

ThemodelnumberofyourGasWaterHeaterwillbefoundontheratingplatelocatedabovethegascontrolvalve.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWINGINFORMATION:

• MODELNUMBER

• TYPEGAS(NATURALORPROPANE(L.P.)

• SERIALNUMBER

• PARTDESCRIPTION

thIs Is a repaIr parts lIst, not a pacKInG lIst.

31

trouBleshootInG GuIdelInestrouBleshootInG GuIdelInesTheseguidelinesshouldbeutilizedbyaqualifiedserviceagent.Whencallingforservicenotifytheserviceagent

thatthisisa“FlammableVaporIgnitionResistant”Product.

# led status proBleM solutIon

1 Thegascontrolvalvehassensedinadequate or no earth ground.

1 Ensurethewalloutlet(powersupply)isproperlygrounded.

2 Ensure all ground connections/wires on the water heateraresecurelyconnected.

2Thegascontrolvalvehassensedreversedpolarityinthe120VACpowersupply.

1 Ensurethewalloutlet/powersupplyisproperlywired.

2 Ensure all internal 120 VAC wiring connections and wiringharnesshavenoreversedwires.120VAC"hot"wiremustconnecttotheon/offswitch.

3

Pressureswitchcircuitremainingclosedformorethan5secondsafterheatingcyclebegins.

Blower may not start in this condition.

1 Ensure air pressure switch circuit wiring is correct and theairpressureswitchisnotjumpered.

2 Replace the air pressure switch.

4

Pressureswitchcircuitremainsopen longer than 5 seconds after theblowerisenergized.

Blower may run continuously in this condition.

1 Ensuretheairpressureswitchsensingtubeisproperlyconnectedatbothendsandisnotkinkedordamaged.

2 Ensurethecorrectsizeofventandintakeairpipe(directventproducts)wasusedpertheinstallationinstructionsinthemanualthatcamewiththewaterheater.

3 Ensuremaximumnumberofelbowsormaximumequivalentfeetofventorintakeairpipehasnotbeenexceededpertheinstallationinstructionsinthemanualthatcamewiththewaterheater.

4 Ensuretherearenoobstructionsintheventorintakeair pipe.

5 Thegascontrolvalvehasdetectedan open igniter circuit.

1 Checkwiringtothehotsurfaceigniterassembly-replaceigniterassemblyifwiringisdamagedorworn.

2 Checkresistanceoftheigniteratigniterassemblyplug-shouldbebetween11and18ohms-replaceigniterifopen or shorted.

3 Checkigniterassemblyplugandthesocketonthebottomofthegascontrolvalveforgoodconnection.

4 Replaceigniterassemblyiftheplugiswornordamaged.

5 Replacethegascontrolvalveiftheigniterassemblysocketonthebottomofthecontroliswornordamaged.

6

Ignition/flamefailure.

Thegascontrolvalvehasreachedthemaximumnumberorretries(3)forignitionandiscurrentlylockedout for one hour.

Cyclethepowertothewaterheateroff and on to reset.

1 Gassupplyisturnedoff-pressureistoolow.

2 Ensuretheflamesensorisclean-usefinesteelwooltocleantheflamesensor.

3 Manifoldgaspressuretotheburneristoolow.

4 Checkigniterassemblyplugandthesocketonthebottomofthegascontrolvalveforgoodconnection.Replaceigniterassemblyiftheplugiswornordamagedreplacethegascontrolvalveifsocketiswornordamaged.

5 Replaceigniterassembly.

32

trouBleshootInG GuIdelInestrouBleshootInG GuIdelInesTheseguidelinesshouldbeutilizedbyaqualifiedserviceagent.Whencallingforservicenotifytheserviceagent

thatthisisa“FlammableVaporIgnitionResistant”Product.

# led status proBleM solutIon

7

8

9

Thegascontrolvalvehasdetectedaproblemwiththegasvalvedrivercircuit,internalmicroprocessor,orother internal circuits.

1 Turn the power off for 10-20 seconds then on again to clear these error codes.

2 Ifanyoftheseerrorcodespersistorcannotbecleared-replacethegascontrolvalve.

10Thegascontrolvalvehassensedmainburnerflameoutofpropersequence.

1 Turn the power off for 10-20 seconds then on again to clear these error codes.

2 Replacethegascontrolvalveifthiserrorcodepersists.

11

ThegascontrolvalvehasdetectedexcessivewatertemperatureinthetankandhasactivatedtheECO(energycutoff)hightemperaturelimit.

1 Turn the power off for 10-20 seconds then on again to clear these error codes.

2 Replacethegascontrolvalveiftheerrorcodepersists.

12Thegascontrolvalvehasdetectedthatoneorbothofthetemperatureadjustbuttonsarestuck.

1 Pressandreleasebothtemperatureadjustbuttonsseveraltimes-cyclewaterheaterpoweroffandon.

2 Replacethegascontrolvalveiftheerrorcodepersists.

13

Thegascontrolvalvehasdetectedthewatertemperaturesensor(locatedinthecontrolvalve'simmersionprobe)iseitheropenorshorted.

1 Turn the power off for 10-20 seconds then on again to clear these error codes.

2 Replacethegascontrolvalveiftheerrorcodepersists.

14ThegascontrolvalvehasdetectedtheFV(flammablevapor)sensoriseither open or shorted.

1 Ensure all FV sensor wiring is correct and the igniter assemblyplugandsocketconnectionsonthebottomofthegascontrolvalvearemakinggoodcontact.

2 Replace the FV sensor.

15

ThegascontrolvalvehasdetectedthepresenceofflammablevaporsfromtheFV(flammablevapor)sensor.

1 Donottouchanyelectricalswitch,donotuseanyphoneinyourbuilding,anddonottrytolightanyappliance.

2 Smellaroundthewaterheatertoensuretherearenogasleaksatthegascontrolvalve,inthesupplygasline(s),oranyothertypeofflammablevapor(s)inthearea.

3 Carefullyinspecttheareasurroundingthewaterheaterforanysubstancessuchasgasoline,paint,paintthinners,varnish,orcleanersthatcouldemitflammablevapors.Removeanythingthatcanpotentiallyemitflammablevaporsfromtheareaandstoreitproperlyina different location.

4 Callthetechnicalinformationsupportphonenumbershownonthewaterheaterlabelingforfurtherassistance.

16

Thegascontrolvalvehasdetectedthe air pressure switch circuit is openingrepeatedlyduringoneheatingcycle.

LDO(Lint,Dust,andOil)lockoutcondition.

1 Onmodelsequippedwithadilutionairintakescreenontheblowerassembly-check/cleanthisscreen.

2 Onmodelsequippedwithacombustionairintakescreenonthebasering(bottom)ofthewaterheater-check/cleanthescreen.

3 Ensureintakeairscreen(s)onmodelssoequippedarenotobstructed.

33

Theseguidelinesshouldbeutilizedbyaqualifiedserviceagent.Whencallingforservicenotifytheserviceagentthatthisisa“FlammableVaporIgnitionResistant”Product.

proBleM cause solutIon

not enouGh orno hot water

1. Blower will not run.

A) "ON/OFF"controlswitchturnedoff. Turnswitchtothe"ON"position.

B) Blowerunplugged. Plugblowerbackinto115vac.outlet.

C) Nopoweratoutlet. Repairservicetooutlet.

D) Thermostatdefective. Replacethermostat.

E) Controlharnessdefective. Replace control harness.

F) Highlimitcontrolcircuitopen. Replace ECO.

G) Blowermotordefective. Replaceblowerassembly.

3. Thermostatproblems

A) Thermostatsettoolow. Turntemperaturecontrolhigher.

B) ThermostatorECOdefective. ReplacethermostatorECOasrequired.

4. Others

A) Heaterundersized. Reduce hot water use.

B) Lowgaspressure. Contact dealer.

C) Incomingwaterisunusuallycold. Allowmoretimeforheatertoreheat.

D) Leakinghotwaterpipesorfixtures. Haveplumbercheckandrepairleaks.

vent pIpe too hot(aBove 170° f)

Defectiveairflowrestrictor. Take unit out of service immediately; call a servicerepresentative.

Notenoughdilutionairtomixwithfluegasesininletelbow.Properdilutionairmustbeprovidedforcombustionanddilutionoffluetemperature.Refertothe"INSTALLINGTHENEWWATERHEATER"sectioninthemanual.

Dilutionairtoohotformixingwithfluegases. Supply air is too hot.Check for heat sources around intaketerminalandblockageofdilutionairleg.

Wrongburnerorifice. Installcorrectorifice.

Yellow flaMe

Dirtinburnerports. Turnoffheaterandgas,cleanburnerhead.

Combustionairpathrestricted. Checkintakeventingarrangementforobstructions.

Notenoughdilutionairforpropercombustion. Checkintakeventingarrangementforobstructions.

condensatIonWateronthefloorunderheater. See"CONDENSATION"section.

Waterdrippingfromblowerassembly. Providedrip"TEE"tocatchcondensationfromhorizontalsectionofexhaustventclosetoblowerassembly.

water leaKs

Improperly sealed hot or cold supply connections, reliefvalve,drainvalveorthermostatthreads. Tighten threaded connections.

Leakagefromotherappliancesorwaterlines. Inspect other appliances near water heater.

Condensationofflueproducts. See"CONDENSATION"section.

leaKInG t & p valveThermalexpansioninclosedwatersystem. Installthermalexpansiontank(DONOTplugT&Pvalve).

Improperlyseatedvalve. Checkreliefvalve forproperoperation(DONOTplugT&Pvalve).

hot water odors (refer to cathodIc protectIon)

Highsulfateormineralcontentinwatersupply. Drainandflushheaterthoroughlythenrefill.

Bacteriainwatersupply. Chlorinatewatersupply.

water too hot Thermostatsettoohigh. Referto"TEMPERATUREREGULATION"section.

water heater soundssIZZlInG - ruMBlInG

Condensationdrippingonburner. See"CONDENSATION"section.

Sedimentatbottomofheatertank. Cleansedimentfromtank.Referto"DRAINING"instructionsinthe"MAINTENANCE"section.

sootInG Impropercombustion. Refer to the "COMBUSTION AIR AND VENTILATION"section.

heater lIGht Goes outIn 4–5 seconds Outletpolarityisreversed. Testpolarityandcorrect.

vent Gas odors

Lackofairsupply.

Immediatelyshutdownthewaterheaterandcontactaserviceagencytodeterminecause.

Improperlyinstalledventpiping.

Downdraft.

PoorCombustion.

trouBleshootInG GuIdelInestrouBleshootInG GuIdelInes

34

resIdentIal Gas warrantY

Thiswarrantyshallapplyonlywhentheheateris:

• ownedbytheoriginalpurchaser;• installedforindooroperationonly;• used at temperatures not exceeding the maximum calibratedsettingofitsthermostat;• used at water pressure not exceeding the working pressureshownontheheater;• filledwithpotablewater,freetocirculateatalltimesand with the tank freeofdamagingwatersedimentorscale deposits;• used in a non-corrosive and non-contaminated atmosphere;• usedwithfactoryapprovedanode(s)installed;• initsoriginalinstallationlocation;• in theUnitedStates, its territories or possessions, and Canada;• sized in accordancewith proper sizing techniques for residentialwaterheaters;• bearingaratingplatewhichhasnotbeenaltered,defaced orremovedexceptasrequiredbythewarrantor;• used in an open systemor in a closed systemwith a properlysizedandinstalledthermalexpansiontank;• operatedwithproperlyinstalleddripleginthegassupply line;• firedwiththefuelforwhichitwasfactorybuilt;• firedatthefactoryratedinput;• operatedwith the innerandouter combustion chamber doors in place and all factory seals to combustion chamberintact.• installedwith no attempted, nor actualmodification or alteration of the water heater’s design in any way, including but not limited to, the attachment of non- companyapprovedappliancesorequipment.

Anyaccidenttothewaterheateroranypartthereof(includingfreezing, fire, floods, or lightning), anymisuse, abuse oralteration of it, any operation of it in amodified form, anyoperation of thewater heater on desalinated (deionized)water, or any damage caused by attempts to repair tankleaks or parts,will void thiswarranty. Thiswarranty doesnotcoverwaterheatersreplacedforcosmeticreasonsorforreasonsofnoise,taste,odor,discoloredand/orrustywater.Thiswarrantydoesnotapplytowaterheatersusedtoheatpools,whirlpoolsorhottubsorusedforspaceheatingwhereitssizingdoesnotconformwithspecificationsoftheheatingcomponentmanufacturer.

Thiswarranty gives you specific legal rights, and youmayhaveotherrightswhichvaryunderthelawsofeachprovince.Ifanyprovisionofthiswarrantyisprohibitedorinvalidunderapplicableprovincelaw,thatprovisionshallbeineffectivetotheextentoftheprohibitionor invaliditywithout invalidatingtheremainderoftheaffectedprovisionortheotherprovisionsofthiswarranty.

THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNERONLY, inaccordancewith thewarranty termsandconditionsspecifiedbelow.

A.O.SmithWaterHeaters (thewarrantor)will furnish theORIGINALOWNER, 1) a replacementA.O.Smithwaterheaterofequivalentsizeandcurrentmodeliftheglass-linedtankinthiswaterheaterleaksand,2)areplacementpartforanycomponentpartwhichfails.

THE A. O. SMITH WATER HEATERS REPLACEMENT MODEL OR PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY. Thewarrantyperiodwillbedeterminedbytheoriginaldateofpurchaseofthewaterheater,orintheabsenceofaBillofSaleverifyingsaiddate, from thedateofmanufactureindicatedonratingplateaffixedtothiswaterheater.Thiswarranty isnot transferrableandapplies tomodels listedbelow:

serIes tanK parts

promax 6-year Model 6-year 6-year

Gpd, GpdX

Whenthewaterheaterhasbeenusedforotherthansingle familyresidentialapplication;

1. Thetankwarrantyshallbereducedto1yearfor6year models.

2. The partswarranty shall be reduced to 1 year for all models.

condItIons and eXceptIons

Thiswarrantyshallapplyonlywhenthewaterheaterisinstalledandoperated in accordancewith 1) all local fire codesandplumbing codes, ordinances and regulations, 2) the printedinstructionsprovidedwithit,3)goodindustrypractices,and4)propersafetypracticessuchasbutnotlimitedtoaproperlysizeddrainpanifinstalledinanareawhereleakagefromthetankoritsconnectionswouldresultindamagetotheareaadjacenttotheheater.Inaddition,anewtemperatureandpressurereliefvalve,certifiedbytheCanadianGasAssociationmusthavebeenproperlyinstalledandpipedtothenearestdrain.

35

servIce and laBor responsIBIlItY

UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR ALLOTHERCOSTS. Suchcostsmay includebutarenotlimitedto:

a. Labor charges for service, removal, or reinstallation of the water heater or part thereof.

b. Shippinganddeliverychargesforforwardingthenewwater heater or replacement part from the nearest distributor andreturningtheclaimeddefectiveheaterorparttosuch distributor.

c. All cost necessary or incidental for handling and administrative charges, and for anymaterials and/or permitsrequiredforinstallationofthereplacementheater or part.

lIMItatIon on IMplIed warrantIes

Impliedwarranties,includinganywarrantyofmerchantabilityimposedon the sale of this heater under province lawarelimitedtooneyeardurationfortheheateroranyofitsparts.Someprovincesdonotallowlimitationsonhowlonganimpliedwarrantylasts,sotheabovelimitationsmaynotapplytoyou.

claIM procedure

Any claimunder thiswarranty should be initiatedwith thedealerwhosoldtheheater,orwithanyotherdealerhandlingthewarrantor’s products. If this is not practical, theownershouldcontact:A.O.SmithWaterHeaters,500TennesseeWaltz Parkway,AshlandCity, Tennessee 37015. Phone:1.800.365.0024orvisitourwebsite:www.hotwater.com.

Replacement Partsmay be ordered through authorizedservicersordistributors.RefertoyourlocalYellowPagesforwhere to call or contactA.O.SmithWaterHeaters,500TennesseeWaltzParkway,AshlandCity,TN37015,phone:1.800.821.2017.

Thewarrantorwill only honor replacementwith identical orsimilarwaterheaterorpartsthereofwhicharemanufacturedordistributedbythewarrantor.

Dealerreplacementsaremadesubjecttoin-warrantyvalidationbywarrantor.

PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION DATEAREREQUIREDTOSUPPORTWARRANTYCLAIMFROM ORIGINAL OWNER. THIS FORM DOES NOT CONSTITUTE PROOF-OF-PURCHASE OR PROOF-OF-INSTALLATION.

dIsclaIMers

NO EXPRESSED WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER OR PARTS. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TOPERSONALPROPERTY,OROTHERCONSEQUENTIALDAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.

Should governmental regulations or industry standardsprohibittheManufacturerfromfurnishingacomparablemodelreplacementunderthiswarranty,theOwnerwillbefurnishedwith theclosestcomparablewaterheatermeeting the thencurrentgovernmental regulationsand industrystandards.Asupplementaryfeemaybeassessedtocovertheadditionalcostassociatedwith thechangesmade tomeetapplicableregulations and standards.

IMportant InforMatIon ModelNumber ________________________________ SerialNumber ________________________________

InstallatIon InforMatIon

Date Installed _______________________________ Company’sName _____________________________

StreetorP.O.Box ____________________________ City,Province,andZipCode _____________________ PhoneNumber ________________________________

Plumber’sName ______________________________

500TennesseeWaltzParkway,AshlandCity,TN37015Phone:800-821-2017•Fax:800-644-9306

Website:www.hotwater.com