Instruction Manual for
Residential Power Vent
Gas Water Heaters
with Hot Surface Ignition
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
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.
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 COM-
PANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
AN ODORANT IS ADDED TO THE GAS
For Your Safety
USED BY THIS WATER HEATER
WARNING
WARNING: If the information in these
instructions are not followed exactly, a fire
or explosion may result, causing property
damage, personal injury or death.
Improper installation, adjustment, alteration,
service or maintenance can cause DEATH, SERI-
OUS BODILY INJURY, OR PROPERTY DAM-
AGE. Refer to this manual for assistance or con-
sult the local gas utility for further information.
–Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WARNING
Flammable vapors may be drawn by air cur-
rents from other areas of the structure to this
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 supplier’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
READ THE GENERAL SAFETY SECTION BEGIN-
NING ON INSIDE COVER AND THEN THIS
ENTIRE MANUAL BEFORE INSTALLING OR
OPERATING THIS WATER HEATER.
184326-001
11-03
Save this Manual for Future Reference.
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General Safety
WARNING
WARNING
Improper installation, adjustment, alteration, service or main-
tenance can cause death, serious bodily injury, or property
damage. Refer to this manual or consult your local gas utility for
further assistance.
WATER HEATERS EQUIPPED FOR ONE TYPE GAS ONLY: This
water heater is equipped for one type gas only. Check the model
rating plate near the gas control valve for the correct gas. DO NOT
USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE
ONE SHOWN ON THE MODEL RATING PLATE. Failure to use the
correct gas can cause problems which can result in DEATH, SERI-
OUS BODILY INJURY, OR PROPERTY DAMAGE. If you have any
questions or doubts consult your gas supplier or local utility.
WARNING
At the time of manufacture this water heater was provided with
a combination temperature-pressure relief valve certified by a
nationally recognized testing laboratory that maintains period-
ic inspection of production of listed equipment or materials, as
meeting the requirements for Relief Valves and Automatic Gas
Shutoff Devices for Hot Water Supply Systems, and the current
edition of ANSI Z21.22 • CSA 4.4 and the code requirements of
ASME. If replaced, the valve must meet the requirements of
local codes, but not less than a combination temperature and
pressure relief valve certified as meeting the requirements for
Relief Valves and Automatic Gas Shutoff Devices for Hot Water
Supply Systems, ANSI Z21.22 • CSA 4.4 by a nationally recog-
nized testing laboratory that maintains periodic inspection of
production of listed equipment or materials.
WARNING
A fire can start if combustible materials such as clothing, cleaning
materials, or flammable liquids are placed against or next to the
water heater.
WARNING
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES,
STORAGE, AND UTILITY AREAS, ETC): Flammable liquids (such as
gasoline, solvents, propane (LP) or butane, etc.), all of which emit
flammable vapors, may be improperly stored or used in such areas.
The gas water heater ignitor or main burner can ignite such vapors.
The resulting flashback and fire can cause death or serious burns
to anyone in the area, as well as property damage.
The valve must be marked with a maximum set pressure not to
exceed the marked hydrostatic working pressure of the water
heater (150 lbs. p.s.i.) and a discharge capacity not less than
the water heater input rate as shown on the model rating plate.
(Electric heaters - watts divided by 1000 x 3412 equal BTU/Hr.
rate.)
Your local jurisdictional authority, while mandating the use of
a temperature-pressure relief valve complying with ANSI
Z21.22 • CSA 4.4 and ASME, may require a valve model dif-
ferent from the one furnished with the water heater.
Compliance with such local requirements must be satisfied by
the installer or end user of the water heater with a locally pre-
scribed temperature-pressure relief valve installed in the des-
ignated opening in the water heater in place of the factory fur-
nished valve.
For safe operation of the water heater, the relief valve must not
be removed from it’s designated opening or plugged.
The temperature-pressure relief valve must be installed direct-
ly into the fitting of the water heater designated for the relief
valve. Position the valve downward and provide tubing so that
any discharge will exit only within 6 inches above, or at any
distance below the structural floor. 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 circum-
stances. Excessive length, over 30 feet, or use of more than four
elbows can cause restriction and reduce the discharge capaci-
ty of the valve.
If installation in such areas is your only option, then the installa-
tion must be accomplished in a way that the ignitor and main burn-
er flame are elevated from the floor at least 18 inches. While this
may reduce the chances of flammable vapors from a floor spill
being ignited, gasoline and other flammable substances should
never be stored or used in the same room or area containing a gas
water heater or other open flame or spark producing appliance.
NOTE: Flammable vapors may be drawn by air currents from other
areas of the structure to the appliance.
WARNING
HOTTER WATER CAN SCALD: Water heaters are intended to pro-
duce hot water. Water heated to a temperature which will satisfy
clothes washing, dish washing, and other sanitizing needs can scald
and permanently injure you upon contact. Some people are more
likely to be permanently injured by hot water than others. These
include the elderly, children, the infirm, or physically/mentally
handicapped. If anyone using hot water in your home fits into one
of these groups or if there is a local code or state law requiring a
certain temperature water at the hot water tap, then you must take
special precautions. In addition to using the lowest possible tem-
perature setting that satisfies your hot water needs, some type of
tempering device, such as a mixing valve, should be used at the hot
water taps used by these people or at the water heater. Mixing
valves are available at plumbing supply or hardware stores. Follow
manufacturers instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
No valve or other obstruction is to be placed between the relief
valve and the tank. Do not connect tubing directly to discharge
drain unless a 6″ air gap is provided. To prevent bodily injury,
hazard to life, or property damage, the relief valve must be
allowed to discharge water in quantities should circumstances
demand. If the discharge pipe is not connected to a drain or other
suitable means, the water flow may cause property damage.
The Discharge Pipe:
WARNING
BEFORE OPERATING [PROPANE (L.P.) GAS WATER HEATERS]:
Propane (L.P.) gas is heavier than air. Should there be a leak in the
system, the gas will settle near the ground. Basements, crawl
spaces, skirted areas under manufactured (mobile) homes (even
when ventilated), closets and areas below ground level will serve as
pockets for the accumulation of this gas. Before attempting to oper-
ate the water heater or turning on a nearby electrical light switch,
be absolutely sure there is no accumulated gas in the area. Search
for odor of gas by sniffing at ground level in the vicinity of the appli-
ance. If odor is detected, follow steps indicated at “For Your Safety”
on the cover page of this manual then leave the premises.
—Must not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
—Must not be plugged or blocked.
—Must be of material listed for hot water distribution.
—Must be installed so as to allow complete drainage of both
the temperature-pressure relief valve, and the discharge pipe.
—Must terminate at an adequate drain.
—Must not have any valve between the relief valve and tank.
2
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General Safety (cont’d)
WARNING
WARNING
Obstructed or deteriorated vent systems may present a serious
health risk or asphyxiation.
This water heater must not be installed directly on carpeting. Car-
peting must be protected by a metal or wood panel beneath the
appliance extending beyond the full width and depth of the ap-
pliance by at least 3 inches (76.2mm) in any direction, or if the ap-
pliance is installed in an alcove or closet, the entire floor must be
covered by the panel. Failure to heed this warning may result in a
fire hazard.
WARNING
Chemical vapor corrosion of the flue and vent system may occur if
air for combustion contains certain chemical vapors. Spray can pro-
pellants, cleaning solvents, refrigerator and air conditioner refrig-
erants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach, and process chemicals are typical compounds which
are potentially corrosive.
WARNING
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area such
as a closet, unless you provide air as shown in the “Locating The
New Water Heater” section. Never obstruct the flow of ventilation
air. If you have any doubts or questions at all, call your gas com-
pany. Failure to provide the proper amount of combustion air can
result in a fire or explosion and can cause DEATH, SERIOUS BOD-
ILY INJURY, OR PROPERTY DAMAGE.
WARNING
Minimum clearances between the water heater and combustible
and non-combustible construction are: 0 inches from sides, 0 inch-
es from back, 5 inches from front of jacket to closet door and 14
inches from top of jacket to combustible and non-combustible
material. Minimum vent clearance: 0 inches. Provide 24 inches
front clearance for servicing and adequate clearance between the
jacket top & ceiling for servicing the flue area.
WARNING
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater or water heaters be
installed so that combustion and ventilation air be taken from out-
side these areas. Refer to the “Locating The New Water Heater”
section of this manual and also the current edition of the National
Fuel Gas Code, ANSI Z223.1, also referred to as NFPA 54 for
specifics provided concerning air required.
WARNING
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of injury under these condi-
tions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before any electrical appliances which
are connected to the hot water system are used (such as a dish-
washer or washing machine). If hydrogen gas is present, there will
probably be an unusual sound similar to air escaping through the
pipe as the hot water faucet is opened. There must be no smoking or
open flame near the faucet at the time it is open.
WARNING
The power vent water heater requires its own (separate) venting
system. It cannot be connected to an existing vent pipe or chim-
ney. It must be terminated to the outdoors. Failure to properly in-
stall the venting system can result in asphyxiation, a fire or explo-
sion and can cause DEATH, SERIOUS BODILY INJURY, OR
PROPERTY DAMAGE.
WARNING
INSULATING JACKETS: When installing an external water heater
insulation jacket on a gas water heater:
WARNING
a. DO NOT cover the temperature-pressure relief valve.
b. DO NOT put insulation over any part of the top of the gas water
heater.
No vent damper installation is compatible with this power vented
water heater design. No vent damper, whether it is operated ther-
mally or otherwise is to be installed on this power vented water
heater. Alteration of any part of the factory-furnished vent assembly
could result in improper operation due to restriction of flue gases,
spillage of flue gases and may cause carbon monoxide poisoning.
c. DO NOT put insulation over the gas control valve or gas con-
trol valve/burner cover, or any access areas to the burner.
d. DO NOT let insulation around the gas water heater to get with-
in 8 inches of the floor (air must get to the burner).
e. DO NOT remove operating instructions, and safety related warn-
ing labels and materials affixed to the water heater. DO obtain
new warning and instruction labels from the manufacturer for
placement on the jacket directly over the existing labels.
Failure to heed this will result in the possibility of a fire or explosion.
WARNING
1. The appliance and its individual shutoff valve must be discon-
nected from the gas supply piping system during any pressure
1
testing of the gas system at test pressures in excess of ⁄2 pound
per square inch (3.5kPa).
2. The appliance must be isolated from the gas supply piping sys-
tem by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test pres-
WARNING
Flood damage to a water heater may not be readily visible or imme-
diately detectible. However, over a period of time a flooded water
heater will create dangerous conditions which can cause DEATH,
SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Call a qual-
ified service technician or contractor to replace a flooded water
heater. Do not attempt to repair the unit! It must be replaced!
1
sures equal or less than ⁄2 pound per square inch (3.5kPa).
WARNING
Soot build-up indicates a problem that requires correction before
further use. Turn “off” gas to water heater and leave “off” until re-
pairs are made, because failure to correct the cause of the sooting
can result in a fire or explosion causing DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE.
CAUTION
WATER HEATERS EVENTUALLY LEAK: Installation of the water
heater must be accomplished in such a manner that if the tank or
any connections should leak, the flow of water will not cause dam-
age to the structure. For this reason, it is not advisable to install the
water heater in an attic or upper floor. When such locations cannot
be avoided, a suitable drain pan should be installed under the water
heater. Drain pans are available at your local hardware store. Such
WARNING
The water heater with vent pipe installed must be properly vented
outdoors. Never operate the water heater unless it is vented to the
outdoors and has adequate air supply to avoid risks of improper
operation, explosion or asphyxiation.
1
a drain pan must be not greater than 1 ⁄2 inches deep, have a mini-
WARNING
Vent termination must not be within 4 feet of any items such as gas
meters, gas valves or other gas regulating equipment.
3
mum length and width of at least 2 inches greater than the water
heater dimensions and must be piped to an adequate drain. The pan
must not restrict combustion air flow.
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Table of Contents
General Safety................................................................................................................................2,3
Table of Contents
.........................................................................................................................4
Introduction
.........................................................................................................................................5
..................................................................5
Preparing for the New Installation
Typical Installation.....................................................................................................................6
Locating the New Water Heater
....................................................................7-10
Facts to Consider About Location..........................................................................................................................7
Combustion Air and Ventilation .........................................................................................................................8,9
Venting Clearances...........................................................................................................................................8,9
Combustion Air and Ventilation for Appliances Located in Unconfined Spaces.....................................................9
Combustion Air and Ventilation for Appliances Located in Confined Spaces.......................................................10
Installing the New Water Heater
................................................................11-24
Water Piping .......................................................................................................................................................11
Temperature-Pressure Relief Valve ......................................................................................................................12
Filling the Water Heater ......................................................................................................................................13
Wiring............................................................................................................................................................13,14
Field Installed Wiring ..................................................................................................................................13,14
Wiring Diagram.................................................................................................................................................14
Venting ..........................................................................................................................................................15-22
Gas Piping......................................................................................................................................................22,23
Installation Checklist ...........................................................................................................................................24
Operating
Temperature Regulation
For Your Information
..........................................................................................................................................25-27
..................................................................................................28
......................................................................................................29,30
Start Up Conditions .............................................................................................................................................29
Condensation....................................................................................................................................................29
Smoke/Odor......................................................................................................................................................29
Thermal Expansion............................................................................................................................................29
Strange Sounds..................................................................................................................................................29
Operational Conditions ..................................................................................................................................29,30
Smelly Water................................................................................................................................................29,30
“Air” In Hot Water Faucet’s...............................................................................................................................30
High Temperature Limit Switch .........................................................................................................................30
Venting Manual Reset Switch ............................................................................................................................30
Not Enough or No Hot Water............................................................................................................................30
Water Is Too Hot...............................................................................................................................................30
Periodic Maintenance....................................................................................................31-33
Venting System Inspection...................................................................................................................................31
Burner Inspection ................................................................................................................................................31
Burner Cleaning ..................................................................................................................................................31
L.P. Gas Control Valve & Burner Assembly Replacement Information .................................................................32
Housekeeping .....................................................................................................................................................32
Anode Rod Inspection.........................................................................................................................................32
Temperature-Pressure Relief Valve Operation......................................................................................................32
Draining..............................................................................................................................................................33
Drain Valve Washer Replacement.......................................................................................................................33
Service ................................................................................................................................................................33
Leakage Checkpoints............................................................................................................34
Troubleshooting.......................................................................................................................35-37
Repair Parts
....................................................................................................................................38,39
4
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Introduction
WARNING
Thank You
for purchasing this water heater. Properly
installed and maintained, it should give you years of trouble free
service.
This gas-fired water heater is design certified by CSA
INTERNATIONAL
under
American
National
Standard/CSA Standard for Gas Water Heaters ANSI
Z21.10.1 • CSA 4.1 (current edition). The installation
must conform with this manual, Local Codes and with
the current edition of the National Fuel Gas Code, ANSI
Z223.1 / NFPA 54.
This publication is available from your local government
or public library, gas company, or by writing NFPA,
Batterymarch Park, Quincy, MA 02269.
Abbreviations Found In This Instruction Manual
CSA - Canadian Standards Association
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
Preparing for the New Installation
1. Read the “General Safety” section, pages 2 and 3 of this
manual first and then the entire manual carefully. If you
don’t follow the 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 the installation,
operation, and maintenance of the gas-fired water
heater. It also contains warnings through out the manu-
al that you must read and be aware of. All warnings and
all instructions are essential to the proper operation of
the water heater and your safety. Since we cannot put
everything on the first few pages, READ THE ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
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 fires.
Examine the location to ensure the water heater com-
plies with the “Locating the New Water Heater” section
in this manual.
5. For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during
an earthquake. See instructions for correct installation pro-
cedures. Instructions may be obtained from your local
dealer, wholesaler, public utilities or California Office of
the State Architect, 400 P Street, Sacramento, CA 95814.
2. The installation must conform with the instructions in
this manual; gas company rules; and Local Codes, or in
the absence of Local Codes, with the current edition of
the National Fuel Gas code, ANSI Z223.1, also referred
to as NFPA 54. This publication is available from your
local government or public library or gas company or
by writing NFPA, Batterymarch Park, Quincy, MA
02269.
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 SCAQMD rule #1121 and districts hav-
ing equivalent NOx requirements.
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.
5
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Typical Installation
VACUUM RELIEF REQUIRED BY SOME CODES
(REFER TO LOCAL CODES)
VENT TO
OUTDOORS
COLD WATER INLET
Some models are equipped with
circulating loop fittings.
*HOT (OUTLET) RECIRCULATING
LOOP CONNECTION CAN BE
INSTALLED WITHIN 360° RADIUS
TEMPERATURE-
PRESSURE RELIEF
VALVE
HOT WATER
OUTLET
DIRECTION
OF FLOW
CHECK VALVE
MARKED WITH
DIRECTION OF
FLOW ARROW
DISCHARGE PIPE
(Do not cap or plug)
ECIRCULAT-
CTION MUST
LY IN THE
ITION
PROVIDE A 6″ AIR GAP
BETWEEN THE END OF
THE DISCHARGE PIPE
AND DRAIN
GAS
SUPPLY
TEMPERED
WATER OUTLET
MIXING VALVE
DIRECTION
OF FLOW
HEAT TRAP
7' power cord
(Factory supplied)
*Certain models do not have these connection assemblies shipped with the water heater. They (Part #9001262) are available
through the manufacturer. See “Repair Parts” section for ordering information.
This appliance has been design certified as complying with American National Standard/CSA Standard for water heaters and
is considered suitable for:
Water (Potable) Heating: All models are “considered suitable for water (potable) heating.”
Water (Potable) Heating and Space Heating: Certain models are “considered suitable for water (potable) heating and space
heating.” Refer to the model and rating plate of the water heater.
WARNING
WARNING
This water heater shall not be connected to any heating
systems or component(s) previously used with a non-
potable water heating appliance.
When the system requires water at temperatures higher
than required for other uses, the hot water system may
require a means such as a mixing valve to be installed to
temper the water at certain points of use. Some people
are more likely to be permanently injured by hot water
than others; these include the elderly, children, the
infirm, or the physically/mentally handicapped. Before
immersing yourself or anyone else in hot water, be sure
to check the water temperature. WARNING: HOTTER
WATER INCREASES THE RISK OF SCALD INJURY. (Also
see “Temperature Regulation” section) Mixing valves
are available at plumbing supply or hardware stores.
Follow manufacturers instructions for installation of
these valves.
If this water heater is also used for space heating applica-
tions, all piping and components connected to the water
heater shall be suitable for use with potable water.
WARNING
Toxic chemicals such as used for treatment of boilers or
non-potable water heating appliances shall never be
introduced into a potable water space heating system.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric
unions or couplings be installed on this water heater when
connected to copper pipe.
6
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Locating the New Water Heater
Facts to Consider About the
Location
You should carefully choose an indoor location for the new
WARNING
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.
Do not use an extension cord. If there is not a suitable
receptacle and/or local codes prohibit use of a power cord,
field wiring must be provided.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must
be observed.
1. The location selected should be indoors as close as
practical to the vent termination point, and as central-
ized with the water piping system as possible. The water
heater, as all water heaters, will eventually leak. Do not
install without adequate drainage provisions where
water flow will cause damage.
2. 40,000 BTU/HR INPUT – If vented through an outside
wall or through the roof, using 3″ vent piping the total
vent run (vertical and horizontal) cannot exceed 115 feet
with one 90˚ elbow (50 feet with one 90° elbow if
optional 2″ vent piping is used). If more elbows are
required the venting distance must be reduced 5 feet for
every 90˚ elbow. See page 18 for vent charts.
CAUTION
WATER HEATERS EVENTUALLY LEAK: Installation of the
water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow
of water will not cause damage to the structure. For this
reason, it is not advisable to install the water heater in an
attic or upper floor. When such locations cannot be
avoided, a suitable drain pan should be installed under
the water heater. Drain pans are available at your local
hardware store. Such a drain pan must be not greater
1
than 1 ⁄2 inches deep, have a minimum length and width
of at least 2 inches greater than the water heater dimen-
sions and must be piped to an adequate drain. The pan
must not restrict combustion air flow.
ALL OTHER INPUTS HIGHER THAN 40,000 BTU/HR
–
6. The location selection must provide adequate clear-
ances for servicing and proper operation of the water
heater.
If vented through an outside wall or through the roof,
using 3″ vent piping the total vent run (vertical and hor-
izontal) cannot exceed 70 feet with one 90˚ elbow (110
feet with one 90° elbow if optional 4″ vent piping is
used). If more elbows are required the venting distance
must be reduced 5 feet for every 90˚ elbow. See page
18 for vent chart.
WARNING
INSTALLATION IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE AND UTILITY AREAS, ETC):
Flammable liquids (such as gasoline, solvents, propane (LP) or
butane, etc.) or other substances (such as adhesives, etc.), all
of which emit flammable vapors, may be improperly stored
or used in such areas. The gas water heater ignitor or main
burner can ignite such vapors. The resulting flashback and
fire can cause death or serious burns to anyone in the area, as
well as property damage.
If installation in such areas is your only option, then the
installation must be accomplished in a way that the ignitor
and main burner flame are elevated from the floor at least
18 inches. While this may reduce the chances of flammable
vapors from a floor spill being ignited, gasoline and other
flammable substances should never be stored or used in the
same room or area containing a gas water heater or other
open flame or spark producing appliance.
3. Vent piping cannot slope downward and horizontal runs
1
require ⁄8″ per five foot rise. All horizontal runs require
1
adequate support at 3 ⁄2 foot intervals and vertical runs
supported at 5 foot intervals.
4. The water heater requires its own (separate) venting sys-
tem. It cannot be connected to an existing vent pipe or
chimney. It must terminate to the outdoors. Whenever
possible terminate the vent on the leeward side of the
building if vented through an outside wall. Note:
Condensation may be created, at times, as the com-
bustion gases exit the vent cap and discoloration of sur-
faces in proximity to the vent cap may occur.
WARNING
The power vent water heater requires its own (separate) vent-
ing system. It cannot be connected to an existing vent pipe
or chimney. It must be terminated to the outdoors. Failure to
properly install the venting system can result in asphyxiation,
a fire or explosion and can cause DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE.
Also, the water heater must be located and/or protected so it
is not subject to physical damage by a moving vehicle.
NOTE: Flammable vapors may be drawn by air currents from
other areas of the structure to the appliance.
5. The water heater comes equipped with a 7 foot power
cord which can be used to connect to a 110/120 volt
power source if (1) local codes allow, and (2) there is a
three prong receptacle available.
7
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Locating the New Water Heater (cont’d)
WARNING
Facts to Consider About the
If this water heater will be used in beauty shops, barber
Location (cont’d)
shops, cleaning establishments, or self-service laundries
with dry cleaning equipment, it is imperative that the
water heater or water heaters be installed so that com-
bustion and ventilation air be taken from outside these
WARNING
areas. Refer to the “Locating The New Water Heater”
Propellants of aerosol sprays and volatile compounds,
section of this manual and also the current edition of
(cleaners, chlorine based chemicals, refrigerants, etc.) in
the National Fuel Gas Code, ANSI Z223.1, also referred
addition to being highly flammable in many cases, will also
to as NFPA 54 for specifics provided concerning air
change to corrosive hydrochloric acid when exposed to the
required.
combustion products of the water heater. The results can
be hazardous, and also cause product failure.
Combustion Air and Ventilation
When determining the installation location for a power
WARNING
vent water heater, snow accumulation and drifting should
be considered in areas where applicable.
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 inches (76.2mm) in any
direction, or if the appliance is installed in an alcove or clos-
et, the entire floor must be covered by the panel. Failure to
heed this warning may result in a fire hazard.
Venting Through an Outside Wall – Clearances
0″ clearance for 3″ (or optional 2″ and 4″) PVC, ABS, or CPVC
Schedule 40 piping from combustible surfaces.
•
18″ minimum in all directions from any obstruction that may
interfere.
•
12″ minimum from the ground, 9″ ceiling overhangs. Figure 2.
•
WARNING
The Power Vent outlet terminal shall terminate at least 36″
above any forced air inlet into the building located within 10
feet. Figure 3a.
•
Minimum clearances between the water heater and com-
bustible and non-combustible construction are: 0 inches
from sides, 0 inches from back, 5 inches from front of jack-
et to closet door and 14 inches from top of jacket to com-
bustible and non-combustible material. Minimum vent clear-
ance: 0 inches. Provide 24 inches front clearance for ser-
vicing and adequate clearance between the jacket top &
ceiling for servicing the flue area. (See Figure 1).
The Power Vent outlet terminal shall terminate at least 4 feet
below, 4 feet horizontally from or 1 foot above any door, win-
dow or gravity air inlet into the building. Figure 3a.
•
18″ minimum from other natural draft (gravity) direct vent,
•
power vent or power direct vent appliance inlet and/or outlet
vent(s) when directly above or 135° to either side of center line.
Figure 3c.
12" MAX.
0"
0"
24″ minimum from any appliance inlet and/or outlet vents
•
MIN.
MIN.
100 Sq In
Minimum
WATER
HEATER
WATER
HEATER
when directly below or 45° to either side of center line. Figure
3c.
VENTILATION
AIR
OPENINGS
5"
MIN.
0" MIN.
The location selection must provide clearances for servicing and
proper operation of the water heater. Figure 4.
•
DOOR
0" MIN.
TOP VIEW OF
100 Sq In
Minimum
TOP VIEW
OF CLOSET
WITH DOOR
ALCOVE
12" MAX.
DOOR
Vent termination must not be within 4 feet of any items such
as gas meters, gas valves or other gas regulating equipment.
•
FRONT VIEW
OF DOOR
RECTANGULAR AIR
DUCT
3" MIN.
Figure 1
The venting system must be installed in a manner which allows
•
AIR DUCT
inspection of the installation of the venting pipes and joints as
well as periodic inspection after installation as required by ANSI
Standards.
WARNING
A gas water heater cannot operate properly without the
correct amount of air for combustion. Do not install in a
confined area such a closet, unless you provide air as
shown in the “Locating The New Water Heater” section.
Never obstruct the flow of ventilation air. If you have
any doubts or questions at all, call your gas company.
Failure to provide the proper amount of combustion air
can result in a fire or explosion and can cause DEATH,
SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
WARNING
Vent termination must not be within 4 feet of any items such as
gas meters, gas valves or other gas regulating equipment.
WARNING
Failure to have required clearances between water heater
and combustible material will result in a fire hazard.
8
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Locating the New Water Heater (cont’d)
Must maintain
adequate service
and maintenance
accessibility.
9″ min. from
any overhang
C
Lof Flue
Range of degrees
available for vent
Figure 4
pipe installation.
12″ min.
Venting Through Roof – Clearances
0″ clearance for 3″ (or optional 2″ and 4″) PVC, ABS, or CPVC
Schedule 40 piping from combustible surfaces.
•
The Power Vent outlet terminal shall terminate at least 18 inch-
es above the roof surface. Figure 5.
•
Figure 2
The location selection must provide clearances for servicing
and proper operation of the water heater. Figure 4.
•
The venting system must be installed in a manner which
•
allows inspection of the installation of the venting pipes and
joints as well as periodic inspection after installation as
required by ANSI Standards.
IF “B” DIMENSION
IS LESS THAN 10’
48″ min.
45° VENT CAP
W/SCREEN
90° STREET ELL
48″ min.
36 min.
″
POWER VENT
TERMINAL
12″ min.
FORCED AIR
INLET INTO
BLDG.
18
″
Figure 3a
VENT TERMINAL
18″ TO WALL OR OTHER
OBSTRUCTIONS THAT
MAY INTERFERE WITH
VENTING.
18″ MIN.
VENT TERMINAL
Figure 5
18″ MIN.
CORNER OF BUILDING
Figure 3b
Combustion Air and Ventilation
for Appliances Located in
Unconfined Spaces
POWER VENT TERMINAL
Unconfined Space is a space whose volume is not less than 50
cubic feet per 1,000 Btu per hour of the aggregate input rating of
all appliances installed in that space. Rooms communicating
directly with the space in which the appliances are installed,
through openings not furnished with doors, are considered a part
of the unconfined space.
18″
NATURAL DRAFT (GRAVITY),
DIRECT VENT, POWER VENT
OR POWER DIRECT VENT
APPLIANCE INLET AND/OR
OUTLET VENT(S)
24″
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.),
additional air may need to be provided using the methods
described in Combustion Air and Ventilation for Appliances
Located in Confined Spaces.
45°
Figure 3c
9
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Locating the New Water Heater (cont’d)
Combustion Air and Ventilation
for Appliances Located in
Confined Spaces
Confined Space is a space whose volume is less than 50 cubic
feet per 1,000 Btu per hour of the aggregate input rating of all
appliances installed in that space.
2. When communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of 1
square inch per 4,000 BTU per hour of total input rating of
all equipment in the enclosure. (See Figure 8.)
a. ALL AIR FROM INSIDE BUILDINGS:
(See Page 8 Figure 1, and Figure 6 below)
VENTILATION LOUVERS
c)
The confined space shall be provided with two permanent
openings communicating directly with an additional room(s)
of sufficient volume so that the combined volume of all spaces
meets the criteria for an unconfined space. The total input of
all gas utilization equipment installed in the combined space
shall be considered in making this determination. Each open-
ing shall have a minimum free area of one square inch per
1,000 BTU per hour of the total input rating of all gas utiliza-
tion equipment in the confined space, but not less than 100
square inches. One opening shall commence within 12 inch-
es of the top and one commencing within 12 inches of the
bottom of the enclosure.
T THROUGH ROOF
AIR OUTLET
VENT TO
OUTDOORS
WATER
HEATER
INLET AIR DUCT
(ends 1″ above floor)
Figure 8
VENT THROUGH
ROOF
3. When communicating with the outdoors through horizon-
tal ducts, each opening shall have a minimum free area of
1 square inch per 2,000 BTU per hour of total input rating
of all equipment in the enclosure. (See Figure 9.)
VENT TO
OUTDOORS
VENT THROUGH
ROOF
OPENINGS
WATER
HEATER
VENT TO
OUTDOORS
Figure 6
OUTLET AIR DUCT
INLET AIR DUCT
b. ALL AIR FROM OUTDOORS: (see Figures 7-9)
The confined space shall be provided with two permanent
openings, one commencing within 12 inches of the top and
one commencing within 12 inches from the bottom of the
enclosure. The openings shall communicate directly, or by
ducts, with the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
Figure 9
4. When ducts are used, they shall be of the same cross-sec-
tional area as the free area of the openings to which they
connect. The minimum short side dimension of rectangular
air ducts shall not be less than 3 inches. (See Figure 9.)
VENTILATION LOUVERS
VENT THROUGH
ROOF
(each end of attic)
5. Louvers and Grilles: In calculating free area, consideration
shall be given to the blocking effect of louvers, grilles or
screens protecting openings. Screens used shall not be small-
1
er than ⁄4 inch mesh. If the free area through a design of lou-
VENT TO
OUTDOORS
ver or grille is known, it should be used in calculating the
size opening required to provide the free area specified. If
the design and free area is not known, it may be assumed
that wood louvers will be 20-25 percent free area and metal
louvers and grilles will have 60-75 percent free area. Louvers
and grilles shall be fixed in the open position or interlocked
with the equipment so that they are opened automatically
during equipment operation.
WATER
HEATER
INLET AIR
DUCT
Figure 7
VENTILATION LOUVERS
6. Special Conditions Created by Mechanical Exhausting or
Fireplaces: Operation of exhaust fans, ventilation systems,
clothes dryers or fireplaces may create conditions requiring
special attention to avoid unsatisfactory operation of
installed gas utilization equipment.
1. When directly communicating with the outdoors, each
opening shall have a minimum free area of 1 square inch
per 4,000 BTU per hour of total input rating of all equip-
ment in the enclosure. (See Figure 6.)
10
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Installing the New Water Heater
Water Piping
WARNING
HOTTER WATER CAN SCALD: Water heaters are intend-
ed to produce hot water. Water heated to a temperature
which will satisfy clothes washing, dish washing, and
other sanitizing needs can scald and permanently injure
you upon contact. Some people are more likely to be per-
manently injured by hot water than others. These include
the elderly, children, the infirm, or physically/mentally
handicapped. If anyone using hot water in your home fits
into one of these groups or if there is a local code or state
law requiring a certain temperature water at the hot
water tap, then you must take special precautions. In
addition to using the lowest possible temperature setting
that satisfies your hot water needs, some type of temper-
ing device, such as a mixing valve, should be used at the
hot water taps used by these people or at the water
heater. Mixing valves are available at plumbing supply or
hardware stores. Follow manufacturers instructions for
installation of the valves. Before changing the factory set-
ting on the thermostat, read the “Temperature
Regulation” section in this manual.
VENT TO
OUTDOORS
COLD INLET
WATER LINE
SHUTOFF
VALVE
TEMPERATURE-
PRESSURE RELIEF
VALVE
HOT OUTLET
TO HOUSE
This water heater shall not be connected to any heating
systems or component(s) used with a non-potable water
heating appliance.
If a water heater is installed in a closed water supply sys-
tem; such as one having a back-flow preventer, check
valve, water meter with a check valve, etc... in the cold
water supply; means shall be provided to control thermal
expansion. Contact the water supplier or plumbing con-
tractor on how to control this situation.
DISCHARGE PIPE
(Do not cap or plug)
GAS SUPPLY
PROVIDE A 6″ AIR
GAP BETWEEN THE
END OF THE
DISCHARGE PIPE
AND DRAIN
NOTE: To protect against untimely corrosion of hot and
cold water fittings, it is strongly recommended that dielec-
tric unions or couplings be installed on this water heater
when connected to copper pipe.
The illustration shows the attachment of the water piping to
3
the water heater. The water heater is equipped with /4 inch
water connections for 40 and 50 gallon models and 1 inch
water connections for 75 gallon models.
NOTE: If using copper tubing, solder tubing to an adapter
before attaching the adapter to the cold water inlet con-
nection. Do not solder the cold water supply line directly
to the cold water inlet or it will harm the dip tube.
NOTE: This water heater is insulated to minimize heat loss
from the tank. Further reduction in heat loss can be
accomplished by insulating the hot water lines from the
water heater.
11
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Installing the New Water Heater (cont’d)
Temperature-Pressure Relief Valve
WARNING
WARNING
The temperature-pressure relief valve must be manually
operated at least once a year. Caution should be taken
to ensure that (1) no one is in front of or around the out-
let of the temperature-pressure relief valve 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 com-
pletely reset and continues to release water, immedi-
ately close the cold water inlet to the water heater, fol-
low the draining instructions, and replace the tempera-
ture-pressure relief valve with a new one.
At the time of manufacture this water heater was provided
with a combination temperature-pressure relief valve certi-
fied by a nationally recognized testing laboratory that main-
tains periodic inspection of production of listed equipment
or materials, as meeting the requirements for Relief Valves
and Automatic Gas Shutoff Devices for Hot Water Supply
Systems, and the current edition of ANSI Z21.22 • CSA 4.4
and the code requirements of ASME. If replaced, the valve
must meet the requirements of local codes, but not less than
a combination temperature and pressure relief valve certi-
fied as meeting the requirements for Relief Valves and
Automatic Gas Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22 • CSA 4.4 by a nationally recognized
testing laboratory that maintains periodic inspection of pro-
duction of listed equipment or materials.
The valve must be marked with a maximum set pressure not
to exceed the marked hydrostatic working pressure of the
water heater (150 lbs./sq. in.) and a discharge capacity not
less than the water heater input rate as shown on the model
rating plate. (Electric heaters - watts divided by 1000 x 3412)
equal BTU/Hr. rate.
COLD
Your local jurisdictional authority, while mandating the use
of a temperature-pressure relief valve complying with ANSI
Z21.22 • CSA 4.4 and ASME, may require a valve model dif-
ferent from the one furnished with the water heater.
Compliance with such local requirements must be satisfied
by the installer or end user of the water heater with a local-
ly prescribed temperature-pressure relief valve installed in
the designated opening in the water heater in place of the
factory furnished valve.
For safe operation of the water heater, the relief valve must
not be removed from it’s designated opening or plugged.
The temperature-pressure relief valve must be installed
directly into the fitting of the water heater designated for
the relief valve. Position the valve downward and provide
tubing so that any discharge will exit only within 6 inches
above, or at any distance below the structural floor. Be cer-
tain that no contact is made with any live electrical part. The
discharge opening must not be blocked or reduced in size
under any circumstances. Excessive length, over 30 feet, or
use of more than four elbows can cause restriction and
reduce the discharge capacity of the valve.
TEMPERATURE-PRESSURE
RELIEF VALVE
DISCHARGE PIPE
(Do not cap or plug)
PROVIDE A 6″ AIR
GAP BETWEEN THE
END OF THE
DISCHARGE PIPE
AND DRAIN
No valve or other obstruction is to be placed between the
relief valve and the tank. Do not connect tubing directly to
discharge drain unless a 6″ air gap is provided. To prevent
bodily injury, hazard to life, or property damage, the relief
valve must be allowed to discharge water in quantities
should circumstances demand. If the discharge pipe is not
connected to a drain or other suitable means, the water flow
may cause property damage.
RELIEF VALVE OPENING
“THIS WATER HEATER IS PROVIDED WITH A COMBINATION TEMPER-
ATURE-PRESSURE RELIEF VALVE. FOR SAFE OPERATION OF THE
WATER HEATER, THE RELIEF VALVE(S) MUST NOT BE REMOVED
FROM ITS DESIGNATED POINT OF INSTALLATION OR PLUGGED.”
YOUR LOCAL JURISDICTIONAL AUTHORITY, WHILE MANDATING THE
USE OF A TEMPERATURE-PRESSURE RELIEF VALVE COMPLYING
WITH ANSI Z21.22 AND ASME, MAY REQUIRE A VALVE MODEL DIF-
FERENT FROM THE ONE FURNISHED WITH THE WATER HEATER.
COMPLIANCE WITH SUCH LOCAL REQUIREMENTS MUST BE SATIS-
FIED BY THE INSTALLER OR END USER OF THE WATER HEATER
WITH A LOCALLY PRESCRIBED TEMPERATURE-PRESSURE RELIEF
VALVE INSTALLED IN THE DESIGNATED OPENING IN THE WATER
HEATER.
The discharge pipe:
—Must not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restriction.
—Must not be plugged or blocked.
—Must be of material listed for hot water distribution.
—Must be installed so as to allow complete drainage of both
the temperature-pressure relief valve, and the discharge
pipe.
SEE MANUAL HEADING—“TEMPERATURE-PRESSURE RELIEF
VALVES” FOR INSTALLATION AND MAINTENANCE OF RELIEF VALVE,
DISCHARGE LINE AND OTHER SAFETY PRECAUTIONS.
—Must terminate at an adequate drain.
—Must not have any valve between the relief valve and tank.
12
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Installing the New Water Heater (cont’d)
Filling the Water Heater
CAUTION
WARNING
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
Do not use an extension cord. If there is not a suitable
receptacle and/or local codes prohibit use of a power cord,
field wiring must be provided.
You must provide all wiring of the proper size outside of
the water heater. You must obey local codes and electric
company requirements when you install this wiring.
To fill the water heater with water:
1. Close the water heater drain valve by turning the han-
dle to the right (clockwise). The drain valve is on the
lower front of the water heater.
If you are not familiar with electric codes and practices, or
if you have any doubt in your ability to connect the wiring
to this water heater, obtain the service of a competent elec-
trician. Contact a local electrical contractor and/or the local
electric utility.
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. To insure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run
until a constant flow is obtained. This will let air out of
the water heater and the piping.
WARNING
WATER HEATERS EQUIPPED FOR ONE TYPE VOLTAGE
ONLY: This water heater is equipped for 110/120 volts
only. DO NOT USE THIS WATER HEATER WITH ANY
VOLTAGE OTHER THAN THE ONE SHOWN ABOVE.
Failure to use the correct voltage can cause problems
which can result in DEATH, SERIOUS BODILY INJURY
OR PROPERTY DAMAGE. If you have any questions or
doubts consult your electric company.
4. Check all new water piping for leaks. Repair as needed.
Wiring
The water heater comes equipped with a 7 foot power cord
which can be used to connect to a 110/120 volt power
source if, (1) local codes allow, and (2) there is a three
prong grounded receptacle available. This unit must have
a grounded outlet to operate.
CAUTION
If wiring from the fuse box or circuit breaker box was alu-
minum for the old water heater, replace it with copper
wire. If you wish to reuse the existing aluminum wire, have
the connection at the water heater made by a competent
electrician. Contact a local electrical contractor and/or the
local electric utility.
7' MAXIMUM
CORD LENGTH
(Factory supplied)
OPTIONAL Field Installed Wiring
1. Provide a way to easily shut off the electric power when
working on the water heater. This could be with a cir-
cuit breaker or fuse block in the entrance box or a sepa-
rate disconnect switch.
2. Install and connect a circuit directly from the main fuse
or circuit breaker box. This circuit must be the right size
and have its own fuse or circuit breaker.
1
3. A standard ⁄2″ conduit opening has been made in the
water heater junction box for the conduit connection.
You must provide all wiring, (1) to a receptacle or, (2)
between the water heater and junction box when the
power cord is not used.
4. Use wire nuts and connect the power supply wiring to
the wires inside the water heaters junction box.
13
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Installing the New Water Heater (cont’d)
Wiring (cont’d)
WIRE NUTS
OPTIONAL Field Installed Wiring (cont’d)
5. The water heater must be electrically “grounded” by the
installer. A green ground screw has been provided on
the water heaters junction box. Connect ground wire to
this location. For complete grounding details and all
allowable exceptions, refer to local codes or in the
absence of local codes, with the National Electrical
Code, ANSI/NFPA 70 (current edition).
6. Replace the wiring junction cover using the screw
provided.
CONDUIT
GREEN
GROUND SCREW
WIRING DIAGRAM
CAUTION
Label all wires prior to disconnection when servicing con-
trols. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
14
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Installing the New Water Heater (cont’d)
Venting
WARNING
WARNING
Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
To insure proper venting of this gas-fired water heater, the
correct vent pipe diameter must be utilized. Do not install
any other gas appliances on the same vent with this water
heater as this will adversely affect the operation of the
water heater.
WARNING
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chem-
ical 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.
The combustion and ventilation air flow must not be
obstructed.
WARNING
The water heater outlet must be connected to a vent
which terminates to the outdoors. Never operate the
water heater unless it is vented to the outdoors and has
adequate air supply to avoid risks of improper opera-
tion, explosion or asphyxiation.
1
3 ⁄2
'
WARNING
STRAPPING
Obstructed or deteriorated vent systems may present
serious health risk or asphyxiation.
1
Horizontal runs must be securely supported at 3 ⁄2 foot
intervals and vertical runs supported at 5 foot intervals.
WARNING
1
The vent pipe from the water heater must slope upward ⁄8
inch per five linear feet for any horizontal run.
VENTING THROUGH AN OUTSIDE WALL
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR, 40 GALLON 50,000
BTU/HR MODELS ONLY
All vent gases must be completely vented to the outdoors of
the structure (dwelling).
(See rating plate for BTU/HR rating)
3″ PVC, ABS or CPVC Schedule 40 vent piping:
1. A 3″ PVC Schedule 40-45° vent cap with wire screen is
supplied with the water heater.
1
Min. rise
⁄8
″
2. A 3″ PVC, ABS or CPVC Schedule 40-90° street ell; used
to connect the vent pipe to the water heater when the
vent pipe is to be turned horizontally directly off the
blower (supplied locally).
per five feet
3. 3″ PVC, ABS or CPVC Schedule 40 pipe (must be sup-
plied locally).
3″ PVC, ABS OR CPVC
SCHEDULE 40
90° STREET ELBOW
WARNING
3″ PVC, ABS OR CPVC
Failure to have required clearances between water heater
and combustible material will result in a fire hazard.
VENT CAP
WITH SCREEN
SCHEDULE 40 PIPE
15
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Installing the New Water Heater (cont’d)
Venting (cont’d)
VENTING THROUGH AN OUTSIDE WALL (cont’d)
7. The water heater requires its own (separate) venting
system.
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR, 40 GALLON 50,000
BTU/HR MODELS ONLY
8. 4″ and 3″ PVC, ABS, or CPVC Schedule 40 piping and
fittings are acceptable materials for the vent system on
all 75 gallon 70,000 and 75,000 BTU/HR, 50 gallon
52,500, 55,000 and 62,500 BTU/HR models, 40 gallon
50,000 BTU/HR models.
4. The water heater requires its own (separate) venting
system.
5. 3″ PVC, ABS, or CPVC Schedule 40 piping and fittings
are acceptable materials for the vent system on all 75
gallon 70,000 and 75,000 BTU/HR, 50 gallon 52,500,
55,000 and 62,500 BTU/HR models, 40 gallon 50,000
BTU/HR models.
9. It cannot be connected to existing vent piping or
chimney.
10. It must terminate horizontally to the outdoors.
6. It cannot be connected to existing vent piping or
chimney.
ALL 40 AND 50 GALLON 40,000 BTU/HR MODELS ONLY
3″ PVC, ABS or CPVC Schedule 40 vent piping:
7. It must terminate horizontally to the outdoors.
1. A 3″ PVC Schedule 40-45° vent cap with wire screen is
supplied with the water heater.
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR, 40 GALLON 50,000
BTU/HR MODELS ONLY — OPTIONAL 4″ VENT PIPING
2. A 3″ PVC, ABS or CPVC Schedule 40-90° street ell; used
to connect the vent pipe to the water heater when the
vent pipe is to be turned horizontally directly off the
blower (supplied locally).
4″ PVC, ABS or CPVC Schedule 40 vent piping:
1. A wire screen to fit a 4″ PVC, ABS or CPVC Schedule
3. 3″ PVC, ABS or CPVC Schedule 40 pipe (must be sup-
40-45° vent cap is supplied with the water heater.
plied locally).
3″ PVC, ABS OR CPVC
SCHEDULE 40 90°
STREET ELBOW
2. A 4″ PVC, ABS or CPVC Schedule 40-45° vent cap
(elbow) (must be supplied locally).
3″ PVC, ABS OR CPVC
3. A 3″ PVC, ABS or CPVC Schedule 40 pipe, minimum
length of 3″ (must be supplied locally), to make vent
connection at the blower outlet.
SCHEDULE 40 PIPE
VENT CAP
WITH SCREEN
4. A 4″ to 3″ PVC, ABS or CPVC Schedule 40 reducer
(must be supplied locally).
5. A 4″ PVC, ABS or CPVC Schedule 40-90° street ell; used
to connect the vent pipe to the reducer when the vent
pipe is to be turned horizontally off the blower (supplied
locally).
4. The water heater requires its own (separate) venting
system.
5. 3″ PVC, ABS, or CPVC Schedule 40 piping and fittings
are acceptable materials for the vent system on all 40
and 50 gallon 40,000 BTU/HR models.
6. 4″ PVC, ABS or CPVC Schedule 40 pipe (must be sup-
plied locally).
6. It cannot be connected to existing vent piping or
chimney.
4″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
4″ PVC, ABS OR CPVC
SCHEDULE 40 90°
STREET ELBOW
7. It must terminate horizontally to the outdoors.
4″ VENT CAP
4″ TO 3″ PVC, ABS OR
WITH SCREEN
CPVC REDUCER
ALL 40 AND 50 GALLON 40,000 BTU/HR MODELS —
OPTIONAL 2″ VENT PIPING
3″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
(MINIMUM LENGTH 3″)
2″ PVC, ABS or CPVC Schedule 40 vent piping:
1. A wire screen to fit a 2″ PVC, ABS or CPVC Schedule
40-45° vent cap is supplied with the water heater.
2. A 2″ PVC, ABS or CPVC Schedule 40-45° vent cap
(elbow) (must be supplied locally).
16
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Installing the New Water Heater (cont’d)
3. A 3″ PVC, ABS or CPVC Schedule 40 pipe, minimum
length of 3″ (must be supplied locally), to make vent
connection at the blower outlet.
The vent piping may be installed as follows:
3 ELBOW
EXAMPLE
4. A 3″ to 2″ PVC, ABS or CPVC Schedule 40 reducer
(must be supplied locally).
1
MIN. RISE
⁄8
″
PER FIVE FEET
5. A 2″ PVC, ABS or CPVC Schedule 40-90° street ell; used
to connect the vent pipe to the reducer when the vent
pipe is to be turned horizontally off the blower (supplied
locally).
6. 2″ PVC, ABS or CPVC Schedule 40 pipe (must be sup-
plied locally).
3 ELBOW
EXAMPLE
2″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
2″ PVC, ABS OR CPVC
SCHEDULE 40 90°
STREET ELBOW
1
MIN. RISE
⁄8
″
PER FIVE FEET
VENT CAP
AND SCREEN
3″ TO 2″ PVC, ABS OR
CPVC REDUCER
3″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
(MINIMUM LENGTH 3″)
1
MIN. RISE
⁄8
″
PER FIVE FEET
7. The water heater requires its own (separate) venting
system.
3 ELBOW
EXAMPLE
1
MIN. RISE
⁄8
″
8. 2″ and 3″ PVC, ABS, or CPVC Schedule 40 piping and
fittings are acceptable materials for the vent system on
all 40 and 50 gallon 40,000 BTU/HR models.
PER FIVE FEET
9. It cannot be connected to existing vent piping or
chimney.
10. It must terminate horizontally to the outdoors.
1
MIN. RISE
⁄
8
″
NOTE: See pages 21 and 22 for vertical venting through a
roof.
PER FIVE FEET
VENTING SYSTEM EXAMPLE INSTALLATIONS FOR
ALL MODELS
The vent piping cannot under any circumstances be run
downhill.
1
1. Horizontal runs require a minimum ⁄8″ rise per five feet.
40 AND 50 GALLON MODELS 50,000 BTU/HR AND
HIGHER, 75 GALLON MODELS (3″ VENT)
SEE CHART ON PAGE 18 FOR MAX. LENGTH
16″ MIN.
1
1
13 ⁄2″ MIN.
MIN. RISE
⁄
8
″
12″ MIN.
PER FIVE FEET
17
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Installing the New Water Heater (cont’d)
Venting (cont’d)
VENTING THROUGH AN OUTSIDE WALL (cont’d)
ALL 40 and 50 GALLON 40,000 BTU/HR MODELS —
″
OPTIONAL 2 VENT PIPING
40 AND 50 GALLON 40,000 BTU/HR MODELS (3″ VENT)
″
2 DIA. VENT
NUMBER OF
90° ELBOWS*
MAX. LENGTH (FT.)
SEE CHART BELOW FOR MAX. LENGTH
50
45
40
35
30
25
1
2
3
4
5
6
4′ MIN.
1
1
MIN. RISE
⁄
8
″
15 ⁄2
″
MIN.
14″ MIN.
PER FIVE FEET
*NOTE: Two 45° elbows are equivalent to one 90° elbow.
One 90° elbow equals 5 feet of equivalent vent length.
95’ MAX.
2. The total vertical and horizontal vent run cannot
exceed the maximum length with the number of 90°
elbows as specified in the tables below. If more elbows
are required the venting distance must be reduced 5
feet for every 90˚ elbow:
1
MIN. RISE
⁄8
″
PER FIVE FEET
20’
(EXAMPLE)
ONE ELBOW
EXAMPLE
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR and 40 GALLON
50,000 BTU/HR MODELS ONLY
3″ VENT PIPE
3″ DIA. VENT
NUMBER OF
90° ELBOWS*
40 GALLON
40,000 BTU/HR
MODEL EXAMPLE
MAX. LENGTH (FT.)
70
65
60
55
50
45
1
2
3
4
5
6
3. Minimum vent length for all 40,000 BTU/HR input
models is 4 feet and 16 inches for all other models.
VENTING THROUGH AN OUTSIDE WALL WITH LOW
GROUND CLEARANCE
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON 52,500,
55,000 and 62,500 BTU/HR and 40 GALLON 50,000 BTU/HR
MODELS ONLY – OPTIONAL 4″ VENT PIPING
1. When the vent piping cannot pass through an outside
wall at a height greater than or equal to 12″ above the
ground (or above snow accumulation level), then the
installation can be modified as shown below.
″
4 DIA. VENT
NUMBER OF
90° ELBOWS*
MAX. LENGTH (FT.)
110
105
100
95
90
85
1
2
3
4
5
6
ALL 40 and 50 GALLON 40,000 BTU/HR MODELS ONLY
3″ DIA. VENT
NUMBER OF
90° ELBOWS*
12″ MIN. ABOVE
GROUND OR SNOW
ACCUMULATION LEVEL
MAX. LENGTH (FT.)
115
110
105
100
95
1
2
3
4
5
6
90
18
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Installing the New Water Heater (cont’d)
2. Refer to the tables below for maximum vent lengths for
low ground clearance installations. All installations
assume the use of two additional 90° elbows and the
standard 45° vent cap with screen outside of the exteri-
or wall.
Cementing PVC, ABS or CPVC Pipe and Fittings
Read and observe all safety information printed on primer,
cleaner, and cement containers.
DANGER
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR and 40 GALLON
50,000 BTU/HR MODELS ONLY
Primer, cleaner, and cements are extremely flammable.
They are harmful or fatal if swallowed. The vapors are
harmful. They may irritate eyes and skin and can be
absorbed through the skin.
″
3 DIA. VENT
NUMBER OF
90° ELBOWS* (inside bldg.)
MAX. LENGTH (FT.)
60
55
50
45
40
35
1
2
3
4
5
6
PRECAUTIONS
Always store primers, cleaner, and cements in cool, dry,
well ventilated places. Do not store them near heat,
sparks, or flames. Keep containers closed. Use them in
well ventilated areas. Wear impervious clothing while
handling. Do not smoke, eat, or drink while handling.
Wash thoroughly after handling and before eating. Wear
eye protection when handling. If swallowed, drink water,
do not induce vomiting, and call a physician or poison
control center immediately. If inhaled, get fresh air and
seek medical attention if ill feelings persist. In case of eye
and skin contact, immediately flush with plenty of water
for 15 minutes and seek medical attention if irritation
persists. KEEP OUT OF REACH OF CHILDREN.
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON 52,500,
55,000 and 62,500 BTU/HR and 40 GALLON 50,000 BTU/HR
MODELS ONLY – OPTIONAL 4″ VENT PIPING
4″ DIA. VENT
NUMBER OF
90° ELBOWS* (inside bldg.)
MAX. LENGTH (FT.)
100
95
90
85
80
75
1
2
3
4
5
6
All primers, cleaners, and cements must meet all local
codes and applicable standards of the American Society
For Testing Materials Standards.
Before using primers, cleaners, and cements, stir or shake,
making sure contents are liquid. Do not use if found to be
lumpy or jelly-like.
1. Cut pipe ends squarely removing all burrs and dirt.
2. Dry fit pipe and fittings to be connected for proper fit.
3. Clean pipe and fitting with a primer/cleaner.
ALL 40 and 50 GALLON 40,000 BTU/HR MODELS ONLY
3″ DIA. VENT
NUMBER OF
90° ELBOWS* (inside bldg.)
MAX. LENGTH (FT.)
4. Apply a thin coat of cement to fitting, avoiding puddling
105
100
95
90
85
1
2
3
4
5
6
inside.
5. Apply a liberal coat of cement to pipe leaving no voids.
6. QUICKLY assemble parts while cement is fluid! If you
wait too long, re-coat pipes.
7. Push pipe completely into socket of fitting, turning as it
goes until it bottoms.
80
8. Hold pipe and fitting together for 30 seconds. Then care-
fully clean off excess with a cloth. Allow connections a
sufficient time to cure before disturbing.
ALL 40 and 50 GALLON 40,000 BTU/HR MODELS —
OPTIONAL 2″ VENT PIPING
9. Remember that vent pipes must be adequately and
securely supported.
2″ DIA. VENT
NUMBER OF
90° ELBOWS* (inside bldg.)
MAX. LENGTH (FT.)
1
40
35
30
25
20
15
1
2
3
4
5
6
APPROXIMATE SETTING TIME FOR 2 ⁄2″ TO 4″ PIPE
JOINTS
MOVEMENT
COMPLETE
SET
8 hrs.
15 hrs.
18 hrs.
OF JOINT
3
90°F to 150°F
50°F to 90°F
0°F to 50°F
⁄4
hr.
1 hr.
*NOTE: Two 45° elbows are equivalent to one 90° elbow.
One 90° elbow equals 5 feet of equivalent vent length.
1
1 ⁄3 hr.
19
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Installing the New Water Heater (cont’d)
Venting (cont’d)
CUTTING OPENING THROUGH AN OUTSIDE WALL
INSTALLATION SHOWING USE OF PVC, ABS OR
CPVC PIPE
AND COLLAR INSTALLATION
After reading the manual and you have determined the
location of the opening in the wall, (using the drawing
EXTERIOR WALL
SILICONE
SEALER
1
1
below), cut a 2 ⁄2″ hole for 2″ vent piping, 3 ⁄2″ hole for 3″
1
vent piping or a 4 ⁄2″ hole for 4″ vent piping hole through an
exterior wall.
NOTE: When determining location of the opening in the
1
1
1 ⁄2″ MIN. EXTENSION
outside wall allow for the ⁄8″ rise per five feet that has
THROUGH
taken place in the horizontal run.
EXTERIOR WALL
SCREW
SCREW
C
L OF FLUE
1
MIN. RISE
⁄
8
″
14″ MIN. 40,000 BTU/HR
PER FIVE FEET
12″ MIN. ALL OTHER MODELS
SCREW
COLLAR
SCREW
COLLAR
SCREEN
VENT CAP MUST
BE POSITIONED
DOWNWARD
SILICONE SEALER
CONNECTING VENT TO BLOWER
40 GAL.– 60″
1
1. If making an immediate horizontal run of vent off the
blower, a 3″ PVC, ABS or CPVC Schedule 40 elbow
(supplied locally) is required. Place the elbow in the
required direction on the blower and using 3 sheet metal
screws, attach the elbow.
50 GAL.– 59 ⁄ ″
75 GAL.– 63″2
SEAL WITH RTV
SEALANT
The 3″ (or optional 2″ and 4″) PVC, ABS or CPVC Schedule
40 vent pipe can be run from the water heater through the wall
or from the wall to the water heater, whichever is most con-
1
venient. The vent pipe must extend a minimum of 1 ⁄2″ through
the exterior wall. Extending the vent cap as far as possible from
the surface of the exterior wall will help minimize discol-
oration of the wall in this area which may be caused by the
flue gases. Note that the inside collar must be slipped over
the vent piping before locating the pipe through the wall.
Before securing the inside and outside collars to the wall, use
a silicone sealer between pipe and opening to insure a water
and air tight seal.
2. If there is to be a vertical run of vent from the blower, the
3″ PVC, ABS or CPVC pipe must be attached to the blow-
er using 3 sheet metal screws.
SEAL WITH RTV
SEALANT
3. If the optional 2″ vent piping is to be used (40,000
BTU/Hr. models only), the 2″ street elbow, 3″ to 2″ reduc-
er and 3″ (minimum) section of 3″ PVC, ABS or CPVC
pipe must be supplied locally. The 3″ (minimum) section
of 3″ PVC, ABS or CPVC pipe must be attached to the
blower using 3 sheet metal screws.
20
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Installing the New Water Heater (cont’d)
4. If the optional 4″ vent piping is to be used (50,000
BTU/Hr. and higher models only), the 4″ street elbow, 4″
to 3″ reducer and 3″ (minimum) section of 3″ PVC, ABS
or CPVC pipe must be supplied locally. The 3″ (mini-
mum) section of 3″ PVC, ABS or CPVC pipe must be
attached to the blower using 3 sheet metal screws.
ALL 40 AND 50 GALLON 40,000 BTU/HR MODELS —
OPTIONAL 2″ VENT PIPING
2″ PVC, ABS or CPVC Schedule 40 vent piping:
1. A wire screen to fit a 2″ PVC, ABS or CPVC Schedule
40-45° vent cap is supplied with the water heater.
2. A 3″ PVC, ABS or CPVC Schedule 40 pipe, minimum
length of 3″ (must be supplied locally), to make vent
connection at the blower outlet.
VENTING THROUGH A ROOF
ALL MODELS
3. A 3″ to 2″ PVC, ABS or CPVC Schedule 40 reducer
3″ PVC, ABS or CPVC Schedule 40 vent piping:
(must be supplied locally).
1. A 3″ PVC Schedule 40-45° vent cap with wire screen is
4. 2″ and 3″ PVC, ABS, or CPVC Schedule 40 piping and
fittings are acceptable materials for the vent system on
all 40 and 50 gallon 40,000 BTU/HR models and must
be supplied locally.
supplied with the water heater.
2. 3″ PVC, ABS, or CPVC Schedule 40 piping and fittings
are acceptable materials for the vent system on all mod-
els and must be supplied locally.
2″ PVC, ABS OR CPVC
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR, 40 GALLON 50,000
BTU/HR MODELS ONLY — OPTIONAL 4″ VENT PIPING
SCHEDULE 40 PIPE
3″ TO 2″ PVC, ABS OR
CPVC REDUCER
4″ PVC, ABS or CPVC Schedule 40 vent piping:
3″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
(MINIMUM LENGTH 3″)
1. A wire screen to fit a 4″ PVC, ABS or CPVC Schedule
40-45° vent cap is supplied with the water heater.
2. A 3″ PVC, ABS or CPVC Schedule 40 pipe, minimum
length of 3″ (must be supplied locally), to make vent
connection at the blower outlet.
1. The water heater requires its own (separate) venting
system.
3. A 4″ to 3″ PVC, ABS or CPVC Schedule 40 reducer
(must be supplied locally).
2. It cannot be connected to existing vent piping or
chimney.
4. 4″ and 3″ PVC, ABS, or CPVC Schedule 40 piping and
fittings are acceptable materials for the vent system on
all 75 gallon 70,000 and 75,000 BTU/HR , 50 gallon
52,500, 55,000 and 62,500 BTU/HR, 40 gallon 50,000
BTU/HR models and must be supplied locally.
3. It must terminate vertically to the outdoors.
4. Typical installation(s) shown on page 22.
5. Refer to “Cementing PVC, ABS or CPVC Pipe and
Fittings” on page 19 and “Connecting Vent to Blower”
on pages 20 and 21.
4″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
4″ TO 3″ PVC, ABS OR
CPVC REDUCER
3″ PVC, ABS OR CPVC
SCHEDULE 40 PIPE
(MINIMUM LENGTH 3″)
21
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Installing the New Water Heater (cont’d)
VENTING THROUGH A ROOF (cont’d)
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON 52,500,
55,000 and 62,500 BTU/HR and 40 GALLON 50,000 BTU/HR
MODELS ONLY – OPTIONAL 4″ VENT PIPING
″
4 DIA. VENT
NUMBER OF
90° ELBOWS*
90˚ STREET
ELL
MAX. LENGTH (FT.)
45˚ VENT CAP
SEAL AROUND
FLASHING
110
105
100
95
90
85
1
2
3
4
5
6
SCREEN
VENT CAP MUST
BE POSITIONED
DOWNWARD
18″ MIN.
MAINTAIN LISTED
CLEARANCE
EACH VENT
45° ELBOW
ALL 40 and 50 GALLON 40,000 BTU/HR MODELS ONLY
″
3 DIA. VENT
NUMBER OF
90° ELBOWS*
MAINTAIN LISTED
CLEARANCE
MAX. LENGTH (FT.)
115
110
105
100
95
1
2
3
4
5
6
SUPPORT LATERALS
1
MIN. EVERY 3 /2
’
SUPPORT IF NECESSARY
POSITION FIRESTOP
90
MAINTAIN LISTED
CLEARANCE
ALL 40 and 50 GALLON 40,000 BTU/HR MODELS —
OPTIONAL 2″ VENT PIPING
EXHAUST VERTICAL
VENT
2″ DIA. VENT
NUMBER OF
90° ELBOWS*
MAX. LENGTH (FT.)
TOTAL VERTICAL
AND HORIZONTAL
RUNS - SEE ITEM 6.
CERTIFIED
WATER HEATER
50
45
40
35
30
25
1
2
3
4
5
6
*NOTE: Two 45° elbows are equivalent to one 90° elbow.
One 90° elbow equals 5 feet of equivalent vent length.
6. The total vertical and horizontal vent run cannot
exceed the maximum length with the number of 90˚
elbows as specified in the tables below and in the next
column. If more elbows are required the venting dis-
tance must be reduced 5 feet for every 90˚ elbow.
Gas Piping
WARNING
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
10.5 in. water column (2.6kPa) for natural gas or 13 in.
water column (3.2kPa) for propane (L.P.) gas. The mini-
mum inlet gas pressure listed on the rating plate is for the
purpose of input adjustment.
75 GALLON 70,000 and 75,000 BTU/HR, 50 GALLON
52,500, 55,000 and 62,500 BTU/HR and 40 GALLON
50,000 BTU/HR MODELS ONLY
3″ DIA. VENT
NUMBER OF
90° ELBOWS*
MAX. LENGTH (FT.)
WARNING
70
65
60
55
50
45
1
2
3
4
5
6
1
If the gas control valve is subjected to pressure exceeding /2
pound per square inch (3.5kPa), the damage to the gas con-
trol valve could result in a fire or explosion from leaking gas.
WARNING
If the main gas line shutoff serving all gas appliances is
used, also turn “OFF” the gas at each appliance. Leave all
gas appliances turned “OFF” until the water heater instal-
lation is complete.
22
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Installing the New Water Heater (cont’d)
A gas line of sufficient size must be run to the water heater. Consult
WARNING
the current edition of National Fuel Gas Code ANSI Z223.1, also
referred to as NFPA 54 and the gas company concerning pipe size.
Contaminant’s in the gas lines may cause improper
operation of the gas control valve that may result in fire
or explosion. Before attaching the gas line be sure that
all gas pipe is clean on the inside. To trap any dirt or
foreign material in the gas supply line, a drip leg (some-
times called a sediment trap) must be incorporated in
the piping. The drip leg must be readily accessible.
Install in accordance with the “Gas Piping” section.
Refer to the current edition of the National Fuel Gas
Code, ANSI Z223.1, also referred to as NFPA 54.
There must be:
—A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
—A drip leg (sediment trap) ahead of the gas control valve to help
prevent dirt and foreign materials from entering the gas control
valve.
—A flexible gas connector or a ground joint union between the
shutoff valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
flame. Rinse off soapy solution and wipe dry.
GAS PIPING WITH FLEXIBLE CONNECTOR
GAS SUPPLY PIPING
When installed at elevations above 2,000 feet, input ratings
should be reduced at the rate of 4 percent for each 1,000 feet
above sea level. Installations above 4,000 ft. require replace-
ment of the burner orifice in accordance with the National
Fuel Gas Code ANSI Z223.1 / NFPA 54.
MANUAL
SHUTOFF
VALVE
FLEXIBLE GAS CONNECTOR
LABELED AS COMPLYING
WITH ANSI STANDARDS
WARNING
Failure to replace the orifice could result in improper and
inefficient operation of the appliance, producing carbon
monoxide gas in excess of safe limits, which could result in
serious injury or death. Contact your gas supplier for any
specific changes which may be required in your area.
GROUND JOINT
UNION (OPTIONAL)
DRIP LEG
WARNING
GAS
(SEDIMENT
CONTROL
The appliance and its individual shutoff valve must be dis-
3″ MIN.
TRAP)
VALVE
connected from the gas supply piping system during any pres-
1
sure testing of that system at test pressures in excess of /2
CAP
pound per square inch (3.5kPa).
The appliance must be isolated from the gas supply piping sys-
tem by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test pres-
GAS PIPING WITH ALL BLACK IRON PIPE
TO GAS CONTROL
1
sures equal to or less than /2 pound per square inch (3.5kPa).
GAS SUPPLY PIPING
WARNING
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
MANUAL
SHUTOFF
VALVE
WARNING
Use pipe joint compound or teflon tape marked as being resis-
tant to the action of petroleum [Propane (L.P.)] gases.
SEDIMENT TRAP
A sediment trap shall be installed as close to the inlet of the
water heater as practical at the time or water heater instal-
lation. The sediment trap shall be either a tee fitting with a
capped nipple in the bottom outlet or other device recog-
nized as an effective sediment trap. If a tee fitting is used, it
shall be installed in conformance with one of the methods
of installation shown.
GROUND JOINT
UNION
BLACK PIPE
DRIP LEG
GAS
(SEDIMENT
TRAP)
3″ MIN.
CONTROL
VALVE
Connecting the gas piping to the gas control valve of the
water heater can be accomplished by either of the two
methods shown.
CAP
23
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Installing the New Water Heater (cont’d)
Installation Checklist
BEFORE OPERATING THE HEATER:
4. Is the water heater completely filled with water? See
“Filling the Water Heater” instructions in the “Installing
the New Water Heater” section.
5. Will a water leak damage anything? See the “Locating
the New Water Heater” section.
6. Is there proper clearance between the water heater and
anything that might catch fire? See the “Locating the
New Water Heater” section.
7. Do you have adequate ventilation so that the water
heater will operate properly? See “Combustion Air and
Ventilation” in the “Locating the New Water Heater”
section.
8. Is the vent piping properly secured? See “Venting”
instructions in the “Installing the New Water Heater”
section.
9. Is there proper clearance between the vent pipe and
anything that might catch fire? See “Venting” instruc-
tions in the “Installing the New Water Heater” section.
1. Check the gas line for leaks.
a. Use a soapy water solution. DO NOT test for gas
leaks using a match or open flame.
b. Brush the soapy water solution on all gas pipes,
joints and fittings.
c. Check for bubbling soap. This means you have a
leak. Turn “OFF” gas and make the necessary
repairs.
d. Recheck for leaks.
e. Rinse off soapy solution and wipe dry.
2. Is the new temperature-pressure relief valve properly
installed and piped to an adequate drain? See
“Temperature-Pressure Relief Valve” section.
3. Are the cold and hot water lines connected to the water
heater correctly? See “Water Piping” instructions in the
“Installing the New Water Heater” section.
10. Is the vent pipe properly sloped and does the vent ter-
minate outdoors? See “Venting” instructions in the
“Installing the New Water Heater” section.
VENT PIPE TO
OUTDOORS
11. Do you need to call your gas company to check the
gas pipe and its hookup?
SHUTOFF
VALVE
COLD
TEMPERATURE-PRESSURE
RELIEF VALVE
HOT
DISCHARGE PIPE
Do not cap or plug
(
)
MODEL RATING PLATE
SUITABLE FOR WATER (POTABLE)
HEATING AND SPACE HEATING
GAS SUPPLY
SHUTOFF VALVE
AUTOMATIC STORAGE WATER HEATER
ELECTRICAL RATING: VOLTS 115/HZ60/AMPS 2
TEE
DRIP LEG
(Sediment trap)
PIPE CAP
24
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Operating
This water heater is equipped with an electrically operated
venting system and electronic control. For the burner to
come on, the water heater thermostat must call for heat.
Then the system will begin sequencing, each section prov-
ing itself before gas is allowed to flow to the burner.
OPERATION
When the thermostat calls for heat, gas is allowed to flow
to a (N/O) pressure switch closing it. An electrical circuit is
then made to the blower, turning it on. When the blower
has achieved sufficient venting, the air pressure switch will
close. A 120 volt circuit will be completed through the
venting manual reset switch and on to the 120 volt gas
valve. The 120 volt gas valve will open allowing gas to
flow to the burner. The hot surface ignitor will establish a
main burner flame.
BEFORE THE WATER HEATER WILL OPERATE:
1. The control system must be connected to a grounded
110/120 volt power supply. The control system has an
overall rating of 2 amps. The water heater must be
securely and adequately grounded in accordance with
local codes and with the current edition of the National
Electrical Code ANSI/NFPA 70.
ALL 40 GALLON AND 50 GALLON 40,000 BTU/HR
MODELS ONLY
2. The ON/OFF rocker switch, located on the control box
above the thermostat must be in the “ON” position for
the electrical control system to operate allowing the gas
portion to operate (ignite burner).
BLOWER MOTOR
VENTING MANUAL
RESET SWITCH
3. The venting manual reset switch must be in the closed
position. See “Venting Manual Reset Switch” in the “For
Your Information” section.
4. There is a non-resettable hi-limit switch in the thermo-
stat, which must be good (closed) for the thermostat to
be operated. See “High Temperature Shut Off System”
in the “For Your Information” section.
DRAFT HOOD
DILUTION AIR
AIR PRESSURE
75 GALLON 70,000 AND 75,000 BTU/HR,
50 GALLON 52,500, 55,000 AND 62,500 BTU/HR,
AND 40 GALLON 50,000 BTU/HR MODELS ONLY
INTAKE
ON/OFF SWITCH
SWITCH
BLOWER MOTOR
VENTING MANUAL
RESET SWITCH
ALL MODELS
DRAFT HOOD
120V GAS VALVE
DILUTION AIR
INTAKE
BURNER
AIR PRESSURE
SWITCH
ON/OFF SWITCH
HOT SURFACE
IGNITOR
25
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Operating (cont’d)
3. The control module:
WARNING
BEFORE OPERATING [PROPANE (L.P.) GAS WATER
HEATERS]: Propane (L.P.) gas is heavier than air. Should
there be a leak in the system, the gas will settle near the
ground. Basements, crawl spaces, skirted areas under
manufactured (mobile) homes (even when ventilated),
closets and areas below ground level will serve as pock-
ets for the accumulation of this gas. Before attempting
to operate the water heater or turning a nearby electri-
cal light switch, be absolutely sure there is no accumu-
lated gas in the area. Search for odor of gas by sniffing
at ground level in the vicinity of the appliance. If odor
is detected, follow the steps indicated at “For Your
Safety” on the cover page of this manual, then leave the
premises.
a) Checks the pressure switch for an open circuit.
b) Energizes the blower.
c) Checks the pressure switch for a closed circuit to
prove draft.
d) Sends line voltage to the hot surface igniter with a
20-second warm up period.
e) Opens the gas valve and checks the sensing rod for
flame.
4. The burner heats the water to the desired thermostat
setting.
a) The resistance in the thermostat rises to the value
selected by the temperature control knob.
b) The control module closes the gas valve and 5
seconds later, removes power from the blower.
Operating instructions are located on front of the water
heater, above or to one side of the gas control valve. See
page 27.
5. Cycle is completed.
CONTROL SEQUENCE - HOT SURFACE DIRECT IGNITION
WARNING
AN ODORANT IS ADDED TO THE GAS USED BY
THIS WATER HEATER.
Pre-purge
5 sec.
20 sec.
4 sec.
1sec.
4 sec.
5 sec.
5 sec.
2
HSI Warm-up
Ignition Activation Period
Flame Recognition Period
Ignition Trial
FOR YOUR SAFETY
IF YOU SMELL GAS:
Interpurge
1. Do not try to light any appliance.
2. Do not touch any electrical switch; do not use any
phone in your building.
Post-purge
Retries
3. Immediately call you gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
4. If you cannot reach your gas supplier, call the fire
department.
Reset from Lockout
Flame Sensing (Nominal)
HSI Off/Run Mode
1 hr.
4.0 µ DC
CHECK FOR LEAKS
Be sure to check all your gas pipes for leaks before operat-
ing your water heater. Use a soapy water solution, not a
match or open flame. Check the factory gas fittings when
the main burner is turned “ON”.
WATER HEATING IGNITION SEQUENCE
(Make sure gas and electric power are connected properly)
1. The ignition control module is powered and monitors the
system, waiting for a call for heat from the thermostat.
2. The thermostat calls for heat by reading a resistance
value within a given range directly proportional to water
temperature.
26
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Operating (cont’d)
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss
of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
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.
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in the gas control but-
tons. Never use tools. If the control buttons will not
push in, don’t try to repair them, call a qualified ser-
vice technician. Force or attempted repair may
result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS:
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of
the control system and any gas control which has
been under water.
•
•
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 supplier’s instructions.
•
OPERATING INSTRUCTIONS
5. This appliance is equipped with a device which auto-
matically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
VACATION
6. Wait five (5) minutes to
If you then smell gas,
clear out any gas.
STOP! Follow “B” in
A
B
C
VERY
HOT
WARM
the safety information above on this label. If you don’t
COOLER
HOTTER
smell gas, go to the next step.
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control box to the “ON”
--------------
----------------------- ---------------------- ------------------------------
------------------------------------------------------
position.
* -----------------------------------------------------------------------
* ----------------------------------------------------------
9. Set the thermostat to desired setting by first pressing
--------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
* ------------------------------------------------------------------------
the COOLER
and holding for 1 second. Then press the HOTTER
button
and HOTTER
buttons together
-----------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------
.
10. WATER TEMPERATURE ADJUSTMENT
is
1.
STOP! Read the safety information above
on this label.
approximately 120˚F.
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
2. Set the ON/OFF switch on the control box to the “ON”
position.
3. Set the thermostat to the lowest setting by first press-
ing the COOLER
together and holding for 1 second. Then press the
COOLER button
appears.
and HOTTER
buttons
11. If the appliance will not operate, follow the instruc-
tions “TO TURN OFF GAS TO APPLIANCE” and
call your technician or gas supplier.
until the WARM indicator light
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING
4. Set the ON/OFF switch on the control box to the
“OFF” position.
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat to the lowest setting by first pressing
2. Set the ON/OFF switch on the control box to the
“OFF” position.
3. Turn off all electric power to the appliance if service
is to be performed.
the COOLER
and holding for 1 second. Then press the COOLER
button until the WARM indicator light appears.
and HOTTER
buttons together
27
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Temperature Regulation
changing the temperature setting. To change the tempera-
ture setting follow these instructions:
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30°F high-
er or lower at the point of use such as, bathtubs, showers,
sink, etc.
1. “Wake Up” the temperature indicators by holding down
both “COOLER” and “HOTTER” temperature adjust-
ment buttons at the same time for one second (See
Figure below). One or two of the temperature indicators
will light up. These indicators will only remain on for
30 seconds if no further buttons are pressed. After 30
seconds the control will go back to “Sleep” mode.
Any water heaters intended purpose is to heat water. Hot
water is needed for cleaning, (bodies, dishes, clothing). Hot
water will present a scald hazard. Depending on the time
element, and the people involved (normal adults, children,
toddlers, elderly, infirm, etc.) scalding may occur at differ-
ent temperatures.
2. Release both of the temperature adjustment buttons.
WARNING
A. To decrease the temperature press and release the
“COOLER” button until the desired setting is reached.
HOTTER WATER CAN SCALD: Water heaters are intend-
ed to produce hot water. Water heated to a temperature
which will satisfy clothes washing, dish washing, and other
sanitizing needs can scald and permanently injure you
upon contact. Some people are more likely to be perma-
nently injured by hot water than others. These include the
elderly, children, the infirm, or physically/mentally hand-
icapped. If anyone using hot water in your home fits into
one of these groups or if there is a local code or state law
requiring a certain temperature water at the hot water tap,
then you must take special precautions. In addition to
using the lowest possible temperature setting that satisfies
your hot water needs, some type of tempering device, such
as a mixing valve, should be used at the hot water taps
used by these people or at the water heater. Mixing valves
are available at plumbing supply or hardware stores. A
qualified plumber should be consulted. Follow manufac-
turers instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
b. To increase the temperature press and release the
“HOTTER” button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower
or raise the temperature setting. The button must be pressed
and released for each temperature change desired.
TEMPERATURE INDICATORS
WARNING
Never allow small children to use a hot water tap, or to
draw their own bath water. Never leave a child or hand-
icapped person unattended in a bathtub or shower.
TEMPERATURE ADJUSTMENT BUTTONS
The thermostat of this water heater has been factory set at
its lowest position, to reduce the risk of scald injury. It is
adjustable and must be reset to the desired temperature set-
ting. The mark ( ▼ ) (on temperature setting of gas valve)
indicative of approximately 120°F is preferred starting
point. Some states have a requirement for a lower setting. If
you need hotter water, follow directions for temperature
adjustment, but beware of the warnings in this section.
Time to Produce
2nd & 3rd Degree
Burns on Adult Skin
Display
▼ A B C
Temperature Setting
C - Flashing = approx. 160°F
C = approx. 150°F
● ● ● ● ● ● About 1/2 seconds
● ● ● ● ● ● About 1-1/2 seconds
● ● ● ● ● ● Less than 5 seconds
● ● ● ● ● ● About 30 seconds
● ● ● ● ● ● More than 5 minutes
● ● ● ● ● ● - - - - - - - - - - - - - - - -
B = approx. 140°F
A = approx. 130°F
▼ = approx. 120°F
●
Pressing the “COOLER”
button decreases temperature
●
WARM = approx. 80°F
and pressing the “HOTTER”
perature.
button increases the tem-
NOTE: Water temperature range of 120°–140°F recom-
mended by most dishwasher manufacturers.
To avoid any unintentional changes in water temperature
settings, the control has a tamper resistant feature for
WARNING
Should overheating occur or the gas supply fail to shut off,
turn “OFF” the manual gas control valve to the appliance.
28
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For Your Information
Start Up Conditions
CONDENSATION
Whenever the water heater is filled with cold water, a cer-
tain amount of condensation will form while the burner is
on. A water heater may appear to be leaking when in fact
the water is condensing. This usually happens when:
a. When a new water heater is filled with cold water for
the first time.
The water within the water heater tank expands as it is
heated and increases the pressure of the water system. If
the relieving point of the water heaters temperature-pres-
sure relief valve is reached, the valve will relieve the excess
pressure. The temperature-pressure relief valve is not
intended for the constant relief of thermal expansion. This
is an unacceptable condition and must be corrected.
b. When gas burns and water vapor is produced in water
heaters, particularly high efficiency models where flue
temperatures are lower.
It is recommended that any devices installed which could
create a closed system have a by-pass and/or the system
have an expansion tank to relieve the pressure built by ther-
mal expansion in the water system. Expansion tanks are
available for ordering through local plumbing supply hous-
es. Contact the local water supplier and/or plumbing
inspector for assistance in controlling these situations.
c. When you use large amounts of hot water in a short
time and the refill water is very cold.
Moisture from the products of combustion condenses on
the cooler tank surfaces and form drops of water which
may fall onto the burner or other hot surfaces and produce
a “sizzling” or “frying” noise.
Because of the suddenness and amount of water, conden-
sation water may be diagnosed as a “tank leak”. After the
water in the tank warms up (about 1-2 hours), the condition
should disappear.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do
not represent harmful or dangerous conditions.
Condensation causes sizzling and popping with the burn-
er area during heating and cooling periods and should be
considered normal. See “Condensation” in this section.
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 fami-
ly’s demands for hot water including dishwashers, wash-
ing machines and shower heads.
Excessive condensation may be noticed during the winter
and early spring months when incoming water tempera-
tures are at their lowest.
Operational Conditions
Good venting is essential for a gas fired water heater to
operate properly as well as to carry away products of com-
bustion and water vapor.
SMELLY WATER
In each water heater there is installed at least one anode
rod (see parts section) for corrosion protection of the tank.
Certain water conditions will cause a reaction between this
rod and the water. The most common complaint associat-
ed with the anode rod is one of a “rotten egg smell”. This
odor is derived from hydrogen sulfide gas dissolved in the
water. The smell is the result of four factors which must all
be present for the odor to develop:
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.
a. a concentration of sulfate in the supply water.
b. little or no dissolved oxygen in the water.
c. a sulfate reducing bacteria within the water heater.
(This harmless bacteria is non-toxic to humans.)
d. an excess of active hydrogen in the tank. This is
caused by the corrosion protective action of the
anode.
THERMAL EXPANSION
Water supply systems may, because of such events as high
line pressure, frequent cut-offs, the effects of water ham-
mer among others, have installed devices such as pressure
reducing valves, check valves, back flow preventers,
etc...to control these types of problems. When these
devices are not equipped with an internal by-pass, and no
other measures are taken, the devices cause the water sys-
tem to be closed. As water is heated, it expands (thermal
expansion) and closed systems do not allow for the expan-
sion of heated water.
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 hot water lines. Contact the local water heater sup-
plier for further information concerning an Anode
Replacement Kit #9000029 and this Chlorination
Treatment.
29
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For Your Information (cont’d)
HIGH TEMPERATURE LIMIT SWITCH
(Single-Use Type Energy Cut Off)
SMELLY WATER (cont’d)
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that continuous
chlorination and filtering conditioning equipment be con-
sidered to eliminate the water problem.
The thermostat has a built-in limit switch which will actu-
ate in case of excessive water temperatures. The heater can-
not be relit until the gas control valve is replaced. It is
important that a serviceman be called to determine the rea-
son for limit operation and thus avoid repeated thermostat
replacement. Lower the temperature adjustment setting on
new control.
Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
WARNING
Should overheating occur or the gas supply fail to shut
off, turn “off” the manual gas control valve to the
appliance.
“AIR” IN HOT WATER FAUCET’S
WARNING
NOT ENOUGH OR NO HOT WATER
HYDROGEN GAS: Hydrogen gas can be produced in a
hot water system that has not been used for a long peri-
od of time (generally two weeks or more). Hydrogen gas
is extremely flammable and explosive. To prevent the
possibility of injury under these conditions, we recom-
mend the hot water faucet be opened for several minutes
at the kitchen sink before any electrical appliances which
are connected to the hot water system are used (such as
a dishwasher or washing machine). If hydrogen gas is
present, there will probably be an unusual sound similar
to air escaping through the pipe as the hot water faucet is
opened. There must be no smoking or open flame near
the faucet at the time it is open.
1. Check the manual gas shut off valve to be sure it is open.
2. The ON/OFF switch on the control box must be “ON”.
3. The temperature button adjustment may be set too low.
See the “Temperature Regulation” section.
4. The gas company can check the gas input to see if it is
correct. An underfired water heater will not heat water as
quickly.
5. Look for leaking or open hot water faucet’s. Make sure
all are closed.
6. The cold water inlet temperature may be colder during
the winter months. It will take longer to heat the water
and seem like less hot water.
VENTING MANUAL RESET SWITCH
7. If you cannot find what is wrong, call the local gas util-
ity and/or plumbing contractor.
There is a venting manual reset switch located on the draft
hood. If the venting manual reset switch is activated, it will
not reset itself. Before resetting this venting manual reset
switch, check for flue blockage and propriety of the venting
system. To reset the venting manual reset switch, press the
red reset button.
WATER IS TOO HOT
1. The temperature adjustment setting may be set too high.
See the “Temperature Regulation” section.
VENTING MANUAL
NOTE: A period of time is necessary after an adjust-
ment has been made for the water temperature to
reach the new temperature setting.
VENTING MANUAL
RESET SWITCH
BLOWER
MOTOR
RESET SWITCH
2. If lower temperature settings will not lower the water
temperature, call the local gas utility.
O
DRAFT HOOD
30
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Periodic Maintenance
Venting System Inspection
If proper flame characteristics are not evident, check for
accumulation of lint or other foreign material that restricts
or blocks the air openings in the heater or burner. Also
check Combustion Air and Ventilation requirements.
At least once a year a visual inspection should be made of
the venting system. You should look for:
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be
obstructed.
2. Damage or deterioration which could cause improper
venting or leakage of combustion products.
3. Rusted flakes around top of water heater.
WARNING
Be sure the vent piping is properly connected to prevent
escape of dangerous flue gasses which could cause
deadly asphyxiation.
WARNING
Soot build-up indicates a problem that requires correc-
tion before further use. Turn “OFF” gas to water heater
and leave “OFF” until repairs are made, because failure
to correct the cause of the sooting can result in a fire.
WARNING
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Burner Cleaning
WARNING
NOTE: Burner assembly must be handled carefully to
avoid damaging the hot surface ignitor.
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chemi-
cal 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.
In the event your burner needs cleaning, use the following
instructions:
If inspection of the burner shows that cleaning is required,
turn the ON/OFF rocker switch located on the control box
to “OFF” position and allow the burner to cool.
Loose deposits on or around the burner can be removed by
carefully using the hose of a vacuum cleaner inserted
through the access door of the water heater. If the burner
needs to be removed for additional cleaning, call the local
gas utility or qualified service agent to remove and clean
the burner with a soft brush. Clean main burner orifice with
a suitable soft material. Correct the problem that required
the burner to be cleaned.
WARNING
If after inspection of the vent system you found sooting
or deterioration, something is wrong. Call the local gas
utility to correct the problem and clean or replace the
flue and venting before resuming operation of the water
heater.
Burner Inspection
WARNING
Flood damage to a water heater may not be readily visi-
ble or immediately detectible. However, over a period
of time a flooded water heater will create dangerous
conditions which can cause DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE. Contact a qualified
service technician or contractor to replace a flooded
water heater. Do not attempt to repair the unit! It must
be replaced!
Check main burner every 12 months for proper flame char-
acteristics. This is done by removing outer and inner doors
on heater. The main burner should provide complete com-
bustion of gas; ignite rapidly; give reasonably quiet opera-
tion; cause no excessive flame lifting from burner ports.
Make sure that the flow of combustion and ventilation air is
not blocked.
31
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Periodic Maintenance (cont’d)
L.P. Gas Control Valve & Burner
Assembly Replacement Information
Anode Rod Inspection
The anode rod is used to protect the tank from corrosion.
Most hot water tanks are equipped with an anode rod. The
submerged rod sacrifices itself to protect the tank. Instead
of corroding the tank, water ions attack and eat away the
anode rod. This does not affect the water’s taste or color.
The rod must be maintained to keep the tank in operating
condition.
WARNING
PROPANE (L.P.) GAS CONTROL VALVE AND BURNER
ASSEMBLY REPLACEMENT INFORMATION.
For Propane (L.P.) Gas Models Only:
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode
rod indicates high water conductivity and should be
checked and/or replaced more often than an anode rod that
appears to be intact. Replacement of a depleted anode rod
can extend the life of your water heater. Inspection should
be conducted by a qualified technician, and at a minimum
should be checked annually after the warranty period.
Your water heater is equipped with a Propane (L.P.) gas
control valve and a main burner assembly with left hand
threads for the following fittings and their connections.
(1) The connection between the manifold and the gas
control valve (A to B) are left hand threads.
(2) The connection between the main burner orifice
and the manifold (C to D) are left hand threads.
For ordering these replacement parts, please refer to the
“Repair Parts” section of this manual.
Temperature-Pressure Relief
Valve Operation
The temperature-pressure relief valve must be manually
operated at least once a year.
TEMPERATURE-PRESSURE
RELIEF VALVE
A
DISCHARGE PIPE
B
WARNING
C
When checking the temperature-pressure relief valve
operation, make sure that (1) no one is in front of or
around the outlet of the temperature-pressure relief valve
discharge line, and (2) that the water manually discharged
will not cause any property damage because the water
may be extremely hot.
D
If after manually operating the valve, it fails to complete-
ly reset and continues to release water, immediately close
the cold water inlet to the water heater, follow the drain-
ing instructions, and replace the temperature-pressure
relief valve with a new one.
Housekeeping
Failure to install and maintain a new properly listed tem-
perature-pressure relief valve will release the manufacturer
from any claim which might result from excessive tempera-
ture or pressure.
Vacuum around base of water heater for dust, dirt, and lint
on a regular basis.
WARNING
WARNING
INSTALLED IN SUITABLE AREA: To insure sufficient
ventilation and combustion air supply, proper clear-
ances from the water heater must be maintained. See
“Locating the New Water Heater” section. Combustible
materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or
adjacent to the water heater which can cause a fire.
If the temperature-pressure relief valve on the appliance
weeps or discharges periodically, this may be due to
thermal expansion. Your water heater may have a check
valve installed in the water line or a water meter with a
check valve. Consult the water supplier and/or plumbing
contractor for further information. Do not plug the tem-
perature-pressure relief valve.
32
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Periodic Maintenance (cont’d)
Draining
The water heater should be drained if being shut down dur-
ing freezing temperatures. Also periodic draining and clean-
ing of sediment from the tank may be necessary.
1. Turn “OFF” gas supply to water heater.
2. CLOSE the cold water inlet valve to the water heater.
3. OPEN a nearby hot water faucet and leave open to
allow for draining.
4. Connect a hose to the drain valve and terminate to an
adequate drain.
5. OPEN the water heater drain valve to allow for tank
draining.
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 ter-
minate to an adequate drain.
6. Close the drain valve.
7. Follow instructions in the “Filling The Water Heater”
section.
8. Follow the lighting instructions in the “Lighting” section
to restart the water heater.
Drain Valve Washer
Replacement
NOTE: For replacement, use a ⁄32″ x ⁄64″ x ⁄8″ thick washer
available at your nearest hardware store. For ordering
replacement washers, refer to the “Repair Parts” section.
17
13
1
1. Turn “OFF” gas supply to water heater.
2. Follow “Draining” instructions.
3. Turning counter clockwise, remove the hex cap below
the screw handle.
4. Remove the washer and put the new one in place.
5. Screw the handle and cap assembly back into the drain
valve and retighten using a wrench. DO NOT OVER
TIGHTEN.
6. Follow instructions in the “Filling The Water Heater”
section.
7. Check for leaks.
8. Follow the lighting instructions in the “Lighting” section
to restart the water heater.
HANDLE AND
CAP ASSEMBLY
WASHER
Service
If a condition persists or you are uncertain about the oper-
ation of the water heater, let a qualified person check it out.
Call the local utility and/or plumbing contractor
.
33
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Leakage Checkpoints
Use this guide to check a “Leaking” water heater. Many sus-
pected “Leakers” are not leaking tanks. Often the source of
the water can be found and corrected.
CAUTION
Read this manual first. Then before checking the water
heater make sure the gas supply has been turned “OFF”,
and never turn the gas “ON” before the tank is com-
pletely full of water.
If you are not thoroughly familiar with gas codes your water
heater, and safety practices, contact the gas utility to check
the water heater.
CAUTION
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
A
Water at the vent pipe is water vapor which has con-
A
densed out of the combustion products. This is
caused by a problem in the vent. Contact the gas
utility.
C
B
* Condensation may be seen on pipes in humid
weather or pipe connections may be leaking.
B
B
* The primary anode rod fitting may be leaking.
C
E
D
Small amounts of water from temperature-pressure
relief valve may be due to thermal expansion or high
water pressure in your area.
D
* The temperature-pressure relief valve may be leak-
ing at the tank fitting.
E
Water from a drain valve may be due to the valve
opened slightly.
F
* The drain valve may be leaking at the tank fitting.
G
Combustion products contain water vapor which
H
can condense on the cooler surfaces of the tank.
Droplets form and drip into the fire or run on the
floor. This is common at the time of startup after
installation and when incoming water is cold.
Water in the water heater bottom or on the floor may
I
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.
H
G
F
Leakage from other appliances, water lines, or
ground seepage should also be checked.
I
* To check where threaded portion enters tank, insert cotton swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions in the “Installing the New Water Heater” section.
34
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Troubleshooting
WARNING
WARNING
This troubleshooting guide has been supplied for use by
qualified service personnel who have a complete under-
standing of both electricity and gas.
Label all wiring before disconnecting any wiring; to
ensure correct reconnection. Failure to follow this
instruction could cause improper and possible danger-
ous operation, resulting in DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE.
THERMOSTAT AND GAS SUPPLY CHECK
Is gas being supplied to the
thermostat?
No
Yes
Turn “ON” gas supply.
Is thermostat calling for heat?
Run (hot) water from heater and
set adjustment button higher.
Check using a manometer at
thermostat pressure tap.
Yes
Is there a minimum gas pressure
4″ W.C. for natural gas or 10″
W.C. for propane (L.P.) gas?
Call gas company to increase
gas pressure.
No
Yes
GO TO SYSTEMS CHECK
SECTION, PAGE 36
35
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Troubleshooting (cont’d)
SYSTEMS CHECK
WARNING
Please check guidelines below. For your safety, water heater
service should be performed only by a qualified service
technician.
DO NOT BY-PASS ANY CONTROLS TO MAKE HEATER
OPERATE. OPERATE ONLY AS WIRED FROM FACTORY.
LED STATUS
A B C
● ● ● ● ● ●
PROBLEM
SOLUTION
An open earth ground circuit to the
ignition system.
1. Check that the earth ground connection is
properly connected.
2. Check that the ground conductor on the
water heater is properly connected.
▼
Wiring error or a high resistance to
earth ground.
1. Check for proper connection of line neutral
and hot wires.
2. Check that the water heater is securely
connected to earth ground.
A B C
● ● ● ● ● ●
▼
Pressure switch remained closed longer
than 5 seconds after the call for heat
began.
1. Pressure switch wiring is incorrect.
2. Replace pressure switch.
A B C
● ● ● ● ● ●
▼
Pressure switch remained opened longer
than 5 seconds after the combustion
blower was energized.
1. Pressure switch wiring is incorrect.
2. Pressure switch tubing not connected
correctly.
A B C
● ● ● ● ● ●
▼
3. Air intake or exhaust obstructed.
A B C
● ● ● ● ● ●
Error in the hot surface ignitor circuit.
System in lockout.
1. Check that all wiring is correct and secure.
2. Replace hot surface ignitor.
▼
1. Gas supply is off or too low to operate.
2. Hot surface ignitor not positioned correctly.
3. Low voltage to the water heater.
4. Electric polarity to unit is incorrect - test
and correct.
A B C
● ● ● ● ● ●
▼
Problem in the gas valve driver circuit.
Problem with the internal circuit.
Problem with the internal circuit.
1. Turn power to the water heater off for
10 seconds and then back on.
A B C
● ● ● ● ● ●
▼
2. Replace gas control valve.
1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
A B C
● ● ● ● ● ●
▼
1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
A B C
● ● ● ● ● ●
▼
A B C
● ● ● ● ● ●
Flame signal sensed out of proper
sequence.
1. Replace gas control valve.
▼
A B C
● ● ● ● ● ●
▼
ECO activated.
1. Replace gas control valve.
A B C
● ● ● ● ● ●
One of the temperature adjust buttons
stuck closed.
1. Press and release each of the buttons once.
2. Replace gas control valve.
▼
Water temperature sensor is either
open or short circuited.
1. Check that all wiring is correct and secure.
2. Replace gas control valve.
A B C
● ● ● ● ● ●
▼
36
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Troubleshooting (cont’d)
PROBLEM
CAUSE
Blower will not run.
A) “ON/OFF” control switch turned off. Turn switch to the “ON” position.
SOLUTION
B) Blower unplugged.
C) No power at outlet.
D) Thermostat defective.
E) Control harness defective.
F) High limit control circuit open.
G) Blower motor defective.
Thermostat problems.
Plug blower back into 115 VAC. outlet.
Repair service to outlet.
Replace thermostat.
Replace control harness.
Replace ECO.
NOT ENOUGH
HOT WATER
Replace Blower Assembly.
A) Thermostat set too low.
B) Thermostat or ECO defective.
Others
Set temperature control higher.
Replace thermostat or ECO as required.
A) Heater undersized.
B) Low gas pressure.
Reduce hot water use.
Contact dealer.
C) Incoming water is unusually cold.
D) Leaking hot water pipes or fixtures.
A) Not enough dilution air to mix with
flue gases.
Allow more time for heater to reheat.
Have plumber check and repair leaks.
Proper dilution air must be provided for dilution
of flue temp. Refer to “INSTALLING THE NEW
WATER HEATER” section.
Check for heat sources around and/or blockage
of dilution air intake at draft hood. (See page 25).
Install correct orifice.
Turn off heater and gas, clean burner head.
Check dilution air intake exhaust venting, and
air openings in bottom base pan for obstructions
or blockage.
Check dilution air intake for obstructions or
blockage.
VENT PIPE TOO HOT
(ABOVE 170˚F)
B) Dilution air too hot for mixing with
flue gases.
C) Wrong burner orifice.
A) Dirt in burner ports
B) Combustion air path restricted.
YELLOW FLAME
CONDENSATION
WATER LEAKS
C) Not enough dilution air for proper
combustion.
A) Water on the floor under heater.
B) Water dripping from blower assembly. Provide drip “TEE” to catch condensation from
horizontal section of exhaust vent close to
See “CONDENSATION” section.
blower assembly.
Tighten threaded connections.
Improperly sealed, hot or cold supply
connections, relief valve, drain valve
or thermostat threads.
Leakage from other appliances or water Inspect other appliances near water heater.
lines.
Condensation of flue products.
Thermal expansion in closed water
system.
See “CONDENSATION” section.
Install thermal expansion tank (DO NOT plug
T&P valve).
LEAKING T&P
Improperly seated valve.
Check relief valve for proper operation
(DO NOT plug T&P valve).
HOT WATER ODORS
(Refer to SMELLY WATER)
High sulfate or mineral content in
water supply.
Drain and flush heater thoroughly then refill.
Bacteria in water supply.
Thermostat set too high.
WATER HEATER SOUNDS Condensation dripping on burner.
Chlorinate water supply.
WATER TOO HOT
Refer to TEMPERATURE REGULATION.
See “CONDENSATION” section.
Clean sediment from tank. Refer to DRAINING
instruction in Maintenance section of manual.
Refer to COMBUSTION AIR AND VENTILATION
on pages 9, 10 and 11.
SIZZLING-RUMBLING
Sediment at bottom of heater tank.
SOOTING
Improper combustion.
HEATER LIGHTS BUT
GOES OUT IN 4-5
SECONDS
Outlet polarity is reversed.
Test polarity and correct.
37
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Repair Parts
1
2
3
PVC, ABS or CPVC items for all
models supplied locally
4
5
6
7
8
8
Blower/Draft Hood Assembly
for 40,000 Btu/Hr Models Only
OR
9
9
28
27
11
10
12
25
24
26
21
14
20
13
15
23
29
17
18
19
22
30
16
or
38
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Repair Parts (cont’d)
KEY PART
NO. DESCRIPTION
KEY PART
NO. DESCRIPTION
19. Manifold (Natural)
19. Manifold (L.P.)
20. Gas Thermostat (Natural)
20. Gas Thermostat (L.P.)
21. Wiring Harness
22. Manifold Cover
23. Control Cover
24. On/Off Switch
25. Pressure Switch
26. Power Cord
1. Vent Cap w/Screen (PVC)
2. Wall Collar
3. PVC, ABS or CPVC Schedule 40
Vent Pipe (supplied locally)
4. 90° PVC, ABS or CPVC Schedule 40
Elbow (supplied locally)
5. Vent/Blower Adapter
6. Blower
7. Blower Gasket
8. Venting Manual Reset Switch
9. Draft Hood Assembly
10. Dip Tube
11. Anode Rod
12. Temperature-Pressure Relief Valve
13. Drain Valve
27. Flue Baffle
28. Restrictor Ring
29. Drain Pan
30. Water Heater Stand
14. Drain Valve Washer
17
13
1
( /32″ x /64″ x /8″ thick)
15. Inner Door
16. Hot Surface Ignition Assembly
17. Burner Assembly (Natural)
17. Burner Assembly (L.P.)
18. Orifice (Natural)
18. Orifice (L.P.)
Now that you have purchased this Water Heater, should a need ever exist for repair parts or service, simply contact the com-
pany it was purchased from or the manufacturer listed on the model rating plate on the water heater.
Be sure to provide all pertinent facts when you call or visit.
Selling prices will be furnished on request or parts will be shipped at prevailing price and you will be billed accordingly.
The model number of your Gas Water Heater will be found on the model rating plate located above the gas control valve.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION:
MODEL NUMBER
SERIAL NUMBER
(TYPE GAS) NATURAL OR PROPANE (L.P.)
PART DESCRIPTION
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
39
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