AO Smith Water Heater Residential Power Vent Gas Water Heaters with Hot Surface Ignition User Guide

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 6air 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 (contd)  
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 6AIR 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 3vent piping the total  
vent run (vertical and horizontal) cannot exceed 115 feet  
with one 90˚ elbow (50 feet with one 90° elbow if  
optional 2vent 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 3vent 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 4vent 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 ⁄8per 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 (contd)  
WARNING  
Facts to Consider About the  
If this water heater will be used in beauty shops, barber  
Location (contd)  
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  
0clearance for 3(or optional 2and 4) PVC, ABS, or CPVC  
Schedule 40 piping from combustible surfaces.  
18minimum in all directions from any obstruction that may  
interfere.  
12minimum from the ground, 9ceiling 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.  
18minimum 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"  
24minimum 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 (contd)  
Must maintain  
adequate service  
and maintenance  
accessibility.  
9min. from  
any overhang  
C
Lof Flue  
Range of degrees  
available for vent  
Figure 4  
pipe installation.  
12min.  
Venting Through Roof – Clearances  
0clearance for 3(or optional 2and 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’  
48min.  
45° VENT CAP  
W/SCREEN  
90° STREET ELL  
48min.  
36 min.  
POWER VENT  
TERMINAL  
12min.  
FORCED AIR  
INLET INTO  
BLDG.  
18  
Figure 3a  
VENT TERMINAL  
18TO WALL OR OTHER  
OBSTRUCTIONS THAT  
MAY INTERFERE WITH  
VENTING.  
18MIN.  
VENT TERMINAL  
Figure 5  
18MIN.  
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 (contd)  
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 1above 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 6AIR  
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 (contd)  
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