185885-001 Water Heater

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Ii M

Keep thIs Manual In the pocKet on heater for future reference

whenever MaIntenance adjustMent or servIce Is requIred.

power dIrect vented Gas Models

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

all technIcal and warrantY questIons: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS

PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER

resIdentIal Gas water heaters

f Y sy AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

GAMA certification applies

to all residential gas water

heaters with capacities of 20

to 100 gallons with input rating

of 75,000 BTU/Hr. or less.

PRINTED 1007 185885-00

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2

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IMportant defInItIons

Qualied Installer: Aqualiedinstallermusthaveabilityequivalenttoalicensedtradesmanintheeldsofplumbing,airsupply,venting,andgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGasCodeasit

relatestotheinstallationofgasredwaterheaters.Thequaliedinstallermustalsobefamiliarwiththedesignfeaturesanduseofammablevaporignitionresistantwaterheaters,andhaveathoroughunderstandingofthisinstructionmanual.

si agy: Aserviceagencyalsomusthaveabilityequivalenttoalicensedtradesmanintheeldsofplumbing,airsupply,venting,andgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGasCodeasitrelatestotheinstallationofgasredwaterheaters.Theserviceagencymustalsohaveathoroughunderstandingofthisinstructionmanual,andbeabletoperformrepairsstrictlyinaccordancewiththeserviceguidelines

providedbythemanufacturer.

Gas Supplier: TheNaturalGasorPropaneUtilityorservicewhosuppliesgasforutilizationbythegasburningapplianceswithinthisapplication.ThegassuppliertypicallyhasresponsibilityfortheinspectionandcodeapprovalofgaspipinguptoandincludingtheNaturalGasmeterorPropanestoragetankofabuilding.Manygassuppliersalso

offerserviceandinspectionofapplianceswithinthebuilding.

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General safetY

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tk Yforpurchasingthiswaterheater.Properlyinstalledand

maintained,itshouldgiveyouyearsoftroublefreeservice.

AbbreviationsFoundInThisInstructionManual:

CSA-CanadianStandardsAssociation

ANSI-AmericanNationalStandardsInstitute

NFPA-NationalFireProtectionAssociation

ASME-AmericanSocietyofMechanicalEngineers

GAMA-GasApplianceManufacturersAssociation

Thisgas-redwaterheaterisdesigncertiedbyCSAInternational

underAmerican National Standard/CSA Standard for Gas Water

HeatersANSIZ21.10.1CSA4.1(currentedition).

preparInG for the InstallatIon

1. ReadtheGeneralSafetysection,page3ofthismanualrstand

thentheentiremanualcarefully.Ifyoudontfollowthesafetyrules,

thewaterheaterwillnotoperateproperly.ItcouldcauseDEATH,

SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

Thismanualcontainsinstructionsfortheinstallation,operation,

andmaintenanceofthegas-redwaterheater.Italsocontains

warningsthroughoutthemanualthatyoumustreadandbeaware

of. All warnings and all instructions are essential to the proper

operationofthewaterheaterandyoursafety. read the entIre

Manual Before atteMptInG to Install or operate

the water heater.

2.Theinstallationmustconformwiththeseinstructionsandthelocalcodeauthorityhavingjurisdiction.Intheabsenceoflocalcodes,installationsshallcomplywiththeNationalFuelGasCodeANSI

Z223.1/NFPA 54 and the National Electrical Code, NFPA 70.ThesepublicationsareavailablefromTheNationalFireProtectionAssociation,1BatterymarchPark,Quincy,MA02269.

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

4.Ifafterreadingthismanualyouhaveanyquestionsordonotunderstandanyportionoftheinstructions,callthelocalgasutilityorthemanufacturerwhosenameappearsontheratingplate.

5.Carefully planyour placement of the waterheater. Correctcombustion, ventaction, andvent pipeinstallation are veryimportant in preventingdeath frompossiblecarbon monoxidepoisoningandres,seeFigures1and2.

ExaminethelocationtoensurethewaterheatercomplieswiththeLocatingtheNewWaterHeatersectioninthismanual.

6.For Californiainstallation thiswater heater mustbe braced,anchored, orstrapped toavoidfalling ormovingduring anearthquake.Seeinstructionsforcorrectinstallationprocedures.InstructionsmaybeobtainedfromCaliforniaOfceoftheStateArchitect,400PStreet,Sacramento,CA95814.

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

8.ComplieswithSCAQMDrule#1121anddistrictshavingequivalentNOxrequirements.

IntroductIon

taBle of contents

SAFE INSTALLATION, USE AND SERVICE....................... ........... 2

GENERAL SAFETY................. .............. ............... .............. ............ 3

TABLE OF CONTENTS ............. ............... .............. ............... ......... 4

INTRODUCTION ............................................................................ 4

Preparing for the New Installation.............. .............. ............... .... 4

INSTALLATIONREQUIREMENTSFORTHE

COMMONWEALTH OF MASSACHUSETTS ............... .............. .... 5

TYPICAL INSTALLATION ............................................................... 6

MIXING VALVE USAGE ............... .............. ............... .............. ....... 7

LOCATING THE NEW WATER HEATER .............. .............. ...... 8-11

FactstoConsiderAboutLocation............................................ 8-9

CombustionAirandExhaustTerminationClearances........... 9-10

Wire Fence .............. .............. ............... .............. ............... ....... 10

AirforVentilationforAppliancesLocatedinConnedSpaces .... 10

InsulationBlankets............... .............. ............... .............. ..... 10-11

INSTALLING THE NEW WATER HEATER ..................... ........ 12-22

Water Piping .............. ............... .............. ............... .............. 12-13

Temperature-PressureReliefValve.......................................... 13

Gas Piping .............. ............... .............. ............... .............. ........ 14

SedimentTraps......................................................................... 15

Filling the Water Heater .............. ............... .............. ............... .. 15

BlowerAssemblyInstallation .................................................... 15

VentConnectionstoBlowerAssembly ..................................... 16

Venting and Installation........................................................ 16-17

Venting Through an Outside Wall .............. ............... ........... 17-18

VentingSystemExampleInstallationforAllModels................. 18

Vent Pipe Separation ............. ............... .............. ............... ....... 18

Cutting Openings Through an Outside

Wall and Collar Installation .................................................. 18-19

Installation Showing Use of PVC, ABS or CPVC Pipe

for Inlet and Outlet Vent Piping ................................................. 19

Connecting Vent to Blower ....................................................... 19

InstallationShowingUseof(optional)

DeluxeHorizontalVentKit ................................................... 19-20

Venting Through a Roof ............. .............. ............... .............. .... 20Vent Pipe Preparation ..........................................................20-22

LIGHTING & OPERATING LABEL .............. ............... .............. .... 23

TEMPERATURE REGULATION ............. .............. ............... ........ 24

FOR YOUR INFORMATION ............... .............. ............... ............. 25

Start Up Conditions............... .............. ............... .............. ......... 25

Operational Conditions .............. .............. ............... .............. .... 25

PERIODIC MAINTENANCE .................................................... 26-28

VentingSystemInspection ....................................................... 26

Burner Operation and Inspection .............................................. 26

Burner Cleaning ........................................................................ 26

Housekeeping........................................................................... 26

Anode Rod ............. ............... .............. ............... .............. ......... 27

Temperature-PressureReliefValveOperation ......................... 27

Draining ...............................................................................27-28 DrainValveWasherReplacement............................................ 28

Service...................................................................................... 28

LEAKAGECHECKPOINTS.......................................................... 29

REPAIR PARTS LIST ............... .............. ............... .............. ......... 30

TROUBLESHOOTING GUIDELINES......................................31-33

WARRANTY ............................................................................34-35

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Forallsidewallterminated,horizontallyventedpowervent,directvent,andpowerdirectventgasfueledwaterheatersinstalled

ineverydwelling,buildingorstructureusedinwholeorinpartforresidentialpurposes,includingthoseownedoroperatedby

theCommonwealthandwherethesidewallexhaustventterminationislessthanseven(7)feetabovenishedgradeinthe

areaoftheventing,includingbutnotlimitedtodecksandporches,thefollowingrequirementsshallbesatised:

InstallatIon of carBon MonoXIde detectorsAt thetimeof installationofthesidewallhorizontalventedgas

fueledequipment,theinstallingplumberorgasttershallobservethatahardwiredcarbonmonoxidedetectorwithanalarm

andbatteryback-upisinstalledontheoorlevelwherethegasequipmentistobeinstalled.Inaddition,theinstallingplumber

orgasttershallobservethatabatteryoperatedorhardwiredcarbonmonoxidedetectorwithanalarmisinstalledoneach

additionallevelofthedwelling,buildingorstructureservedbythesidewallhorizontalventedgasfueledequipment.Itshall

betheresponsibilityofthepropertyownertosecuretheservicesofqualiedlicensedprofessionalsfortheinstallationofhard

wiredcarbonmonoxidedetectors.

Intheeventthatthesidewallhorizontallyventedgasfueledequipmentisinstalledinacrawlspaceoranattic,thehardwired

carbonmonoxidedetectorwithalarmandbatteryback-upmaybeinstalledonthenextadjacentoorlevel.

Intheeventthattherequirementsofthissubdivisioncannotbemetatthetimeofcompletionofinstallation,theownershall

haveaperiodofthirty(30)daystocomplywiththeaboverequirementsprovidedthatduringsaidthirty(30)dayperiod,abat-

teryoperatedcarbonmonoxidedetectorwithanalarmshallbeinstalled.

approved carBon MonoXIde detectorsEachcarbonmonoxidedetectorasrequiredinaccordancewiththeabove

provisionsshallcomplywithNFPA720andbeANSI/UL2034listedandCSAcertied.

sIGnaGe Ametalorplasticidenticationplateshallbepermanentlymountedtotheexteriorofthebuildingataminimumheight

ofeight(8)feetabovegradedirectlyinlinewiththeexhaustventterminalforthehorizontallyventedgasfueledheatingappli-

anceorequipment.Thesignshallread,inprintsizenolessthanone-half(1/2)inchinsize,Gas vent dIrectlY Below.

Keep clear of all oBstructIons.

InspectIon Thestateorlocalgasinspectorofthesidewallhorizontallyventedgasfueledequipmentshallnotapprovethe

installationunless,uponinspection,theinspectorobservescarbonmonoxidedetectorsandsignageinstalledinaccordance

withtheprovisionsof248CMR5.08(2)(a)1through4.

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

1.TheequipmentlistedinChapter10entitledEquipmentNotRequiredToBeVentedinthemostcurrenteditionofNFPA54

asadoptedbytheBoard;and

2.ProductApprovedsidewallhorizontallyventedgasfueledequipmentinstalledina roomorstructureseparatefromthe

dwelling,building,orstructureusedinwholeorinpartforresidentialpurposes.

Manufacturer requIreMents - Gas equIpMent ventInG sYsteM provIdedWhenthemanufacturerofProduct

Approvedsidewallhorizontallyventedgasequipmentprovidesaventingsystemdesignorventingsystemcomponentswith

theequipment,theinstructionsprovidedbythemanufacturerforinstallationoftheequipmentandtheventingsystemshall

include:

1.Detailedinstructionsfortheinstallationoftheventingsystemdesignortheventingsystemcomponents;and

2.Acompletepartslistfortheventingsystemdesignorventingsystem.

Manufacturer requIreMents - Gas equIpMent ventInG sYsteM not provIdedWhenthemanufacturerofaProductApprovedsidewallhorizontallyventedgasfueledequipmentdoesnotprovidethepartsforventingtheuegases,

butidentiesspecialventingsystems,thefollowingrequirementsshallbesatisedbythemanufacturer:

1.The referencedspecialventing systeminstructionsshall be includedwith theappliance or equipmentinstallation

instructions;and

2.ThespecialventingsystemsshallbeProductApprovedbytheBoard,andtheinstructionsforthatsystemshallincludea

parts list and detailed installation instructions.

AcopyofallinstallationinstructionsforallProductApprovedsidewallhorizontallyventedgasfueledequipment,allventing

instructions,allpartslists forventinginstructions,and/orallventing designinstructionsshallremainwiththe applianceor

equipmentatthecompletionoftheinstallation.

InstallatIon requIreMents for the coMMonwealth of Massachusetts

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tYpIcal InstallatIonGet to Know Your water heater - Gas Models

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*cautIon: 115 vac

control harness

InsIde outer jacKet

* all pIpInG MaterIals to Be supplIed BY custoMers.

** located under the Blower asseMBlY.

*** not pIctured

tYpIcal hot surface IGnIter & MaIn Burner

hot

surface

IGnIter

flaMe

sensor

teMperature IndIcators

teMperature adjustMent Buttons

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MIXInG valve usaGe

fIGure 2.

ThisappliancehasbeendesigncertiedascomplyingwithAmericanNational Standard/CSA Standard for water heaters and is consideredsuitablefor:

w (pb) hig s hig:All modelsareconsideredsuitableforwater(potable)heatingandspaceheating.

HOTTERWATERCANSCALD:

Water heaters are intended to produce hot water. Water heated to a

temperaturewhichwillsatisfyspaceheating,clotheswashing,dish

washing,andothersanitizingneedscanscaldandpermanentlyinjure

youuponcontact.Somepeoplearemorelikelytobepermanently

injuredbyhotwaterthanothers.Theseincludetheelderly,children,

theinrm,orphysically/mentallydisabled.Ifanyoneusinghotwate

inyourhometsintooneofthesegroupsorifthereisalocalcodeor

statelawrequiringacertaintemperaturewateratthehotwatertap

thenyoumusttakespecialprecautions.Inadditiontousingthelowes

possibletemperaturesettingthatsatisesyourhotwaterneeds,a

meanssuchasa*MixingValve,shouldbeusedatthehotwater

tapsusedbythesepeopleoratthewaterheater.Mixingvalvesare

availableatplumbingsupplyorhardwarestores.ConsultaQualied

Installer or ServiceAgency. Followmixing valve manufacturers

instructionsforinstallationofthevalves.Beforechangingthefactory

settingonthethermostat,readtheTemperatureRegulationsection

inthismanual,seeFigure31.

suGGested pIpInG arranGeMent for top connectIons

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facts to consIder aBout the locatIon

Carefullychooseanindoorlocationforthenewwaterheater,because

theplacementisaveryimportantconsiderationforthesafetyofthe

occupantsinthebuildingandforthemosteconomicaluseofthe

appliance. ti i i m

(mbi) m ii.

Whether replacing an old water heater or putting the water heater in

anewlocation,thefollowingcriticalpointsmustbeobserved:

1. Selectalocationindoorsascloseaspracticaltotheventterminalor

locationtowhichthewaterheaterventpipingisgoingtobeconnected,

andascentralizedwiththewaterpipingsystemaspossible.

2.Selectedlocationmustprovideadequateclearancesforservicing

and proper operation of the water heater.

Installationof the waterheatermust be accomplished in sucha

mannerthatifthetankoranyconnectionsshouldleak,theowwillnot

causedamagetothestructure.Forthisreason,itisnotadvisableto

installthewaterheaterinanatticorupperoor.Whensuchlocations

cannotbeavoided,asuitabledrainpanshouldbeinstalledunderthe

waterheater.Drainpansareavailableatyourlocalhardwarestore.

Suchadrainpanmusthaveaminimumlengthandwidthofatleast

2(5.1cm)greaterthatthewaterheaterdimensionsandmustbe

pipedtoanadequatedrain.Drainpandepthmustallowforaccesstotheouterdoorsforservicingtheignitorandburner.

Waterheaterlifedependsuponwaterquality,waterpressureandthe

environmentinwhichthewaterheaterisinstalled.Waterheatersare

sometimesinstalledinlocationswhereleakagemayresultinproperty

damage,evenwiththeuseofadrainpanpipedtoadrain.However,

unanticipateddamagecanbereducedorpreventedbyaleakdetector

orwatershut-offdeviceusedinconjunctionwithapipeddrainpan.

Thesedevicesareavailablefromsomeplumbingsupplywholesalers

andretailers,anddetectandreacttoleakageinvariousways:

Sensorsmountedinthedrainpanthattriggeranalarmorturnoffthe

incomingwatertothewaterheaterwhenleakageisdetected.

Sensorsmountedinthedrainpanthatturnoffthewatersupplytotheentirehomewhenwaterisdetectedinthedrainpan.

Water supply shut-offdevicesthat activatebased onthe water

pressuredifferentialbetweenthecoldwaterandhotwaterpipes

connected to the water heater.

Devicesthatwillturnoffthegassupplytoagaswaterheaterwhile

atthesametimeshuttingoffitswatersupply.

INSTALLATIONSIN AREASWHERE FLAMMABLELIQUIDS

(VAPORS)ARELIKELYTOBEPRESENTORSTORED(GARAGES,

STORAGEANDUTILITYAREAS,ETC.):Flammableliquids(suchas

gasoline,solvents,propane(LPorbutane,etc.)andothersubstances

(suchasadhesives,etc.)emitammablevaporswhichcanbeignited

locatInG the new water heaterbyagaswaterheatershotsurfaceigniterormainburner.Theresulting

ashbackandrecancausedeathorseriousburnstoanyoneinthearea

andpropertydamage.ThiswaterheaterisequippedwithaFVsensor

fordetectingthepresenceofammablevapors,seeFigure3.Whenthe

sensordetects thosevapors,theunitwillshutdownandnotoperate.

Shouldthishappen,pleaserefertotroubleshootingguideinthismanual.

Eventhoughthiswaterheaterisaammablevaporsignitionresistant

waterheaterandisdesignedtoreducethechancesofammablevapors

beingignited,gasolineandotherammablesubstancesshouldneverbestoredorusedinthesamevicinityorareacontainingagaswater

heaterorotheropenameorsparkproducingappliance.

fIGure 3.

Also,thewaterheatermustbelocatedand/orprotectedsoitisnot

subjecttophysicaldamagebyamovingvehicle.

This water heatermust notbe installed directlyon carpeting.

Carpetingmustbeprotectedbymetalorwoodpanelbeneaththe

applianceextendingbeyondthefullwidthanddepthoftheappliance

byatleast3(7.6cm)inanydirection,oriftheapplianceisinstalled

inanalcoveorcloset,theentireoormustbecoveredbythepanel.

Failuretoheedthiswarningmayresultinarehazard.

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Minimum clearancesbetween the waterheater andcombustible

constructionare0inchatthesidesandrear,6(15.2cm)fromthe

frontofthejacket,and12(30.5cm)fromthetop(standardclearance).

Ifclearancesstatedontheheaterdifferfromstandardclearances,

install water heater according to clearances stated on the heater.

Adequateclearanceforservicingthisapplianceshouldbeconsidered

beforeinstallation,suchaschangingtheanodes,etc.

Aminimumclearanceof5(12.7cm)fromthefrontofthejacketmust

beallowedforaccesstoreplaceablepartssuchasthethermostats,

drainvalveandreliefvalve.Provide24(61cm)frontclearancefor

servicingandadequateclearancebetweenthejackettopandceiling

forservicingtheuearea.

Wheninstallingtheheater,considerationmustbegiventoproper

location. Locationselectedshouldbe asclose tothe wall as

practicable andas centralized withthe water pipingsystem as

possible.

fIGure 4.

Donotinstallinaconnedareasuchasacloset,unlessyouprovide

ventilationairasshowninthe"LocatingTheNewWaterHeater"

sectionandFigure5.Neverobstructtheowofventilationair.Ifyou

haveanydoubtsorquestionsatall,callyourgascompany.Failureto

provideventilationaircanresultinareorexplosionandcancause

DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

fIGure 5.

Ifthiswaterheaterwillbe used inbeauty shops,barbershops

cleaningestablishments,orself-servicelaundrieswithdrycleaning

equipment,itisimperativethatthewaterheaterorwaterheater

beinstalledsothatcombustionandventilationairbetakenfrom

outside these areas.

Propellantsofaerosolspraysandvolatilecompounds,(cleaners

chlorine basedchemicals,refrigerants,etc.) in addition to being

highlyammableinmanycases,willalsoreacttoformcorrosive

hydrochloricacid when exposedto thecombustionproducts o

thewaterheater.Theresultscanbehazardous,andalsocause

product failure.

coMBustIon aIr and eXhaust terMInatIon

clearances

vig tg oi w - c, fig 7.

0"clearancefor3"PVC,ABS,orCPVCSchedule40pipingfrom

combustiblesurfaces.

Thelocationselectionmustprovideclearancesforservicingand

proper operation of the water heater, see Figure 8.

fIGure 6.

Theventingsystemmustbeinstalledinamannerwhichallows

inspectionoftheinstallationoftheventingpipesandjointsa

wellasperiodicinspectionafterinstallationas requiredbythe

National Fuel Gas Code ANSI Z223.1.

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fIGure 7.

vent terMInatIon clearances

wIre fence

Whenthewaterheateroutletterminalislowenoughtobetouched

accidentally,orisaccessibletosmallchildren,awiremeshchain

linkfence(asshowninFigure8)maybeused.Careshouldbe

takentomaintainadequateventilationaroundtheoutletterminal.

Ifachainlinkfenceisinstalled,itmustnotbeusedasastorage

areaforitemsthatmayblockproperventilation.

fIGure 8.

vig tg r - c

0"clearancefor3"PVC,ABS,orCPVCSchedule40pipingfrom

combustibleandnoncombustiblesurfaces.

Theventexhaustoutletandairinletterminalsshallterminateat

least18"(45.7cm)abovetheroofsurface,seeFigure9.

fIGure 9.

aIr for ventIlatIon for applIances located In

confIned spaces

Airforventilationshouldbeprovidedifinstalledinaconnedspace.

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

InsulatIon BlanKets

Insulationblanketsareavailabletothegeneralpublicforexternal

useongaswaterheatersbutarenotnecessarywiththeseproducts.

Thepurposeofaninsulationblanketistoreducethestandbyheat

lossencountered with storagetankheaters.Your water heater

meetsorexceedstheNationalApplianceEnergyConversationAct

standardswithrespecttoinsulationandstandbylossrequirements,

makinganinsulationblanketunnecessary.

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Shouldyouchoosetoapplyaninsulationblankettothisheater,you

shouldfollow theseinstructions (Foridentication of components

mentionedbelow,seeFigure1).Failuretofollowtheseinstructions

canrestricttheairowrequiredforpropercombustion,potentially

resultinginre,asphyxiation,seriouspersonalinjury,ordeath.

Do notapplyinsulationtothetopofthewaterheater,asthiswi

interfere with safe operation of the water heater.

Do notcovertheouterdoor,thermostat,temperature&pressur

reliefvalveorFVSensor.

Do not let insulation around the gas water heater get within 8 inches

oftheoor(accessforservicingtheburner).

Do not covertheinstructionmanual. Keepit ontheside ofthe

waterheaterornearbyforfuturereference.

Doobtainnewwarningandinstructionlabelsfromthemanufacturer

forplacementontheblanketdirectlyovertheexistinglabels.

Doinspecttheinsulationblanketfrequentlytomakecertainit

doesnotsag,therebyobstructingaccesstoburner.

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therMal eXpansIon

Aswaterisheated,itexpands(thermalexpansion).Inaclosed

systemthevolumeofwaterwillgrowwhenitisheated.Asthe

volumeofwatergrowstherewillbeacorrespondingincreasein

waterpressureduetothermalexpansion.Thermalexpansioncan

causeprematuretankfailure(leakage).Thistypeoffailureisnot

coveredunderthelimitedwarranty.Thermalexpansioncanalso

cause intermittent temperature-pressure relief valve operation:waterdischargedfromthevalveduetoexcessivepressurebuild

up.Thisconditionisnotcoveredunderthelimitedwarranty.The

temperature-pressurereliefvalveisnotintendedfortheconstant

reliefofthermalexpansion.

Aproperly sized thermalexpansion tankshouldbe installed

onall closed systemsto controlthe harmfuleffects ofthermal

expansion.Contactalocalplumbingserviceagencytohavea

thermalexpansiontankinstalled.

note:t gi imy i

water ttings, it is strongly recommended that dielectric unions

ig b i i

i.

Allgaspipingmustcomplywithlocalcodesandordinancesorwiththe

NationalFuelGasCode(ANSIZ223.1/NFPA-54)whicheverapplies.

Copperandbrasstubingandttings(excepttinlinedcoppertubing)

shallnotbeused.

fIGure 10.

Figure10showsthetypicalattachmentofthewaterpipingtothewater heater. The water heater is equipped with 3/4 inch NPT waterconnections.

water pIpInG

HOTTERWATERCANSCALD:

Water heaters are intended to produce hot water. Water heated to

a temperaturewhich will satisfy space heating,clothes washing,

dish washing, cleaning and othersanitizing needscan scald and

permanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludethe

elderly,children,theinrm,orphysically/mentallydisabled.Ifanyone

usinghotwaterinyourhometsintooneofthesegroupsorifthere

isalocalcodeorstatelawrequiringacertaintemperaturewaterat

thehotwatertap,thenyoumusttakespecialprecautions.Inaddition

tousingthelowestpossibletemperaturesettingthatsatisesyour

hotwaterneeds,ameanssuchasamixingvalveshouldbeusedat

thehotwatertapsusedbythesepeopleoratthewaterheater,see

Figure2.Valvesforreducingpointofusetemperaturebymixingcold

andhotwaterarealsoavailable.

ConsultaQualiedInstallerorServiceAgency.Followmanufacturers

instructionsforinstallationofthevalves.Beforechangingthefactory

settingonthethermostat,readtheTemperatureRegulationsection

inthismanual.

Thiswaterheatershallnotbeconnectedtoanyheatingsystemsor

component(s)usedwithanon-potablewaterheatingappliance.

All pipingcomponentsconnectedto this unit forspace heating

applicationsshallbesuitableforusewithpotablewater.

Toxicchemicals,suchasthoseusedforboilertreatmentshallnotbe

introducedintothissystem.

Whenthesystemrequireswaterforspaceheatingattemperatures

higherthanrequiredfordomesticwaterpurposes,atemperingvalve

must beinstalled. Pleasereferto Figure2 forsuggested piping

arrangement.

Watersupplysystemsmay,becauseofcoderequirementsorsuch

conditionsas high line pressure, among others,have installed

devicessuchaspressurereducingvalves,checkvalves,andback

owpreventers.Devicessuchasthesecausethewatersystemto

beaclosedsystem.

InstallInG the new water heater

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13

note:I ig big, big b

ig i i. d

y i iy i.

I i m i b mg k.

t & p v pi Ii (i i)

RemoveinsulationforT&Pvalveandpipeconnectionsfromcarton.

fIGure 11.

Fitpipeinsulationovertheincomingcoldwaterlineandthehotwater

line.Makesurethattheinsulationisagainstthetopcoveroftheheater.

FitT&Pvalveinsulationovervalve.Makesurethattheinsulation

doesnotinterferewiththeleveroftheT&Pvalve.

Secure all insulation using tape.

teMperature-pressure relIef valve

Thisheateris provided witha properlycertifiedcombinationtemperature-pressurereliefvalvebythemanufacturer.

Thevalveiscertiedbyanationallyrecognizedtestinglaboratory

thatmaintainsperiodicinspectionofproductionoflistedequipmentof

materialsasmeetingtherequirementsforReliefValvesforHotWater

SupplySystems,ANSIZ21.22CSA4.4,andthecoderequirements

of ASME.

Ifreplaced,thevalvemustmeettherequirementsoflocalcodes,but

notlessthanacombinationtemperatureandpressurereliefvalve

certiedasindicatedintheaboveparagraph.

Thevalvemustbemarkedwithamaximumsetpressurenotto

exceedthemarkedhydrostaticworkingpressureofthewaterheater

(150psi=1,035kPa)andadischargecapacitynotlessthanthewate

heaterinputrateasshownonthemodelratingplate.

Forsafeoperationofthewaterheater,thereliefvalvemustnotb

removedfromitsdesignatedopeningnorplugged.

Thetemperature-pressurereliefvalvemustbeinstalleddirectlyinto

thettingofthewaterheaterdesignedforthereliefvalve.Positionthe

valvedownwardandprovidetubingsothatanydischargewillexitonly

within6inches(15.2cm)aboveanadequatedrainoroutsideofthe

buildingorstructure.Becertainthatnocontactismadewithanylive

electricalpart.Thedischargeopeningmustnotbeblockedorreducedinsizeunderanycircumstances.Excessivelength,over30feet(9.14

m),oruseofmorethanfourelbowscancauserestrictionandreduce

thedischargecapacityofthevalve,seeFigures10or14.

Novalveorotherobstructionistobeplacedbetweenthereliefvalv

andthetank.Donotconnecttubingdirectlytodischargedrainunless

a6(15.2cm)airgapisprovided.Topreventbodilyinjury,hazardt

life,orpropertydamage,thereliefvalvemustbeallowedtodischarge

waterinquantitiesshouldcircumstancesdemand.Ifthedischarg

pipeisnotconnectedtoadrainorothersuitablemeans,thewate

owmaycausepropertydamage.

TheDischargePipe:

Shallnotbesmallerinsizethantheoutletpipesizeofthevalve,or

haveanyreducingcouplingsorotherrestrictions.

Shallnotbepluggedorblocked.

Shallbeofmateriallistedforhotwaterdistribution.

Shallbeinstalledsoastoallowcompletedrainageofboththe

temperature-pressurereliefvalve,andthedischargepipe.

Shallterminateatanadequatedrain.Shallnothaveanyvalvebetweenthereliefvalveandtank.

Thetemperature-pressurereliefvalvemustbemanuallyoperateda

leastonceayear.Cautionshouldbetakentoensurethat(1)noone

isinfrontofor aroundtheoutletofthetemperature-pressurerelie

valvedischargeline,and(2)thewatermanuallydischargedwillnot

causeanybodilyinjuryorpropertydamagebecausethewatermay

beextremelyhot.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetand

continuesto release water, immediatelyclose the coldwater inle

to the water heater, follow the draining instructions, and replace the

temperature-pressurereliefvalvewithanewone.

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Gas pIpInG

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

Allgaspipingmustcomplywithlocalcodesandordinancesorwith

theNationalFuelGasCode(ANSIZ223.1/NFPA-54)whicheverapplies.Copperandbrasstubingandttings(excepttinlinedcoppertubing)shallnotbeused.

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

IfthemaingaslineShut-offservingallgasappliancesisused,alsoturnoffthegasateachappliance.Leaveallgasappliancesshutoffuntilthewaterheaterinstallationiscomplete.

Agaslineofsufcientsizemustberuntothewaterheater.Consultthe current edition of National Fuel Gas Code ANSI Z223.1/NFPA54andyourgassupplierconcerningpipesize.

Theremustbe: Areadilyaccessiblemanualshutoffvalveinthegassupplyline

servingthewaterheater,and Adripleg(sedimenttrap)aheadofthegascontrolvalvetohelp

preventdirtandforeignmaterialsfromenteringthegascontrolvalve.

Aexiblegasconnectororagroundjointunionbetweentheshutoffvalveandthegascontrolvalvetopermitservicingoftheunit.

Besuretocheckallthegaspipingforleaksbeforelightingthewaterheater.Useasoapywatersolution,notamatchoropename.Rinseoffsoapysolutionandwipedry.

Wheninstalledatelevationsabove7,700feet(2,347meters),input

ratingshouldbereducedattherateof4percentforeach1,000feet(305meters)abovesealevelwhichrequiresreplacementofthe

burneroriceinaccordancewithTheNationalFuelGasCode

ANSIZ223.1/NFPA54.Contactyourlocalgassupplierforfurther

information.

Failuretoreplacethestandardoricewithahighaltitudeoricewheninstalled couldresult in improper andinefcientoperationof the

appliance,producingcarbonmonoxidegasinexcessofsafelimits,

whichcouldresultinseriousinjuryordeath.Contactyourgassupplierforanyspecicchangeswhichmayberequiredinyourarea.

UsepipejointcompoundorTeontapemarkedasbeingresistant

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

Theapplianceanditsgasconnectionmustbeleaktestedbefore

placing the appliance in operation.

TheapplianceanditsindividualShut-offvalveshallbedisconnected

fromthegassupplypipingsystemduringanypressuretestingof

that systemat test pressuresin excessof 1/2 psi (14 inchesof

watercolumnor3.5kPa).Itshallbeisolatedfromthegassupply

pipingsystembyclosingitsindividualmanualShut-offvalveduring

anypressuretestingofthegassupplypipingsystemattestpressures

equal to or less than 1/2psi(14inchesofwatercolumnor3.5kPa) .

Connectingthegas piping tothegas controlvalve ofthe waterheatercanbeaccomplishedbyeitherofthetwomethodsshownin

Figures 12 and 13.

fIGure 12. Gas pIpInG wIth

fleXIBle connector.

fIGure 13. Gas pIpInG wIth all

BlacK Iron pIpe to Gas control.

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sedIMent traps

Asedimenttrapshallbeinstalledasclosetotheinletofthewater

heater aspractical atthe timeof water heaterinstallation. The

sedimenttrapshallbeeitherateettingwithacappednippleinthe

bottomoutletorotherdevicerecognizedasaneffectivesediment

trap.Ifateettingisused,itshallbeinstalledinconformancewith

oneofthemethodsofinstallationshowninFigures12and13.

Contaminantsinthegaslinesmaycauseimproperoperationofthegas

controlvalvethatmayresultinreorexplosion.Beforeattachingthe

gaslinebesurethatallgaspipeiscleanontheinside.Totrapanydirtorforeignmaterialinthegassupplyline,adripleg(sometimescalled

asedimenttrap)mustbeincorporatedinthepiping.Thedriplegmust

bereadilyaccessible.InstallinaccordancewiththeGasPiping

section. Refer to the current edition of the National Fuel Gas Code,

ANSI Z223.1/NFPA 54.

fIGure 14.

fIllInG the water heater

Neverusethiswaterheaterunlessitiscompletelyfullofwater.Topreven

damagetothetank,thetankmustbelledwithwater.Watermustow

fromthehotwaterfaucetbeforeturningONgastothewaterheater.

Tollthewaterheaterwithwater:

1. Closethewaterheaterdrainvalveby turningthehandletothe righ

(clockwise).Thedrainvalveisonthelowerfrontofthewaterheater.

2.Openthecoldwatersupplyvalvetothewaterheater.

note: t y m b

i i .

3. Toinsurecompletellingofthetank,allowairtoexitbyopeningthe

nearesthotwaterfaucet.Allowwatertorununtilaconstantowiobtained.Thiswillletairoutofthewaterheaterandthepiping.

4. Check allwaterpiping andconnections forleaks.Repair as

needed.

Blower asseMBlY InstallatIon

sequence of InstallatIon

1. This powerdirectventwater heater comeswiththebloweassemblyinstalled.

2 Aftertheunitissetinplace,makesuretheblowerassemblyisstimountedsecurely,andmakesurethereisnodamagetotheblower

3. Makesurethereisnopackingmaterialinthedischargeoftheblowerortheintake,seeFigure15.

4. Makesurethattherubbertubingisstill attachedfrom the aipressureswitchtotheportontheblowerhousing.Makesuretherubbertubingisnotfoldedanywherebetweenthepressureswitchandtheblowerhousing.

5. MakesuretheON/OFFswitchisinthe OFFpositionandthathewiringharnessisconnectedfromtheblowercontrolboxtotheconnectoronthebottomsideofthegascontrolvalve.

6. Ifthewiringharnessisnotfactoryinstalled,makesuretheONOFF switch is in the OFF position and then connect the wiringharness from the blowercontrolboxto the connectoron thebottomsideofthegascontrolvalve.

7. Thiswaterheateris apolaritysensitiveapplianceandwillnooperateifthepowersupplypolarityisreversed.Thepowersupploroutlet providing powerto this water heatermustbe wired

properly(correctpolarity).

8. DonotpluginpowercorduntilventsystemiscompletelyinstalledThispowerdirectventheateroperateson110-120Vac,thereforeagroundedoutletmustbewithinreachofthesix(6)foot(1.8m

exiblepowercordsuppliedwiththeunit,seeFigure2.Ensurethepolarityattheoutletiscorrect.Thepowercordsuppliedmaybeusedonlywherelocalcodespermit.Iflocalcodesdonotpermtheuseofaexiblepowersupplycord:

a.)Makesuretheunitisunpluggedfromwalloutlet.Removescrewsandremovecontrolbox.

b.)Cuttheexiblepowercord,leavingenoughtobeabletomakeconnections,theremovethestrainreliefttingfrombox.

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

d.)Spliceeldwiringintoexisting wiringusingcode authorizedmethod(wirenuts,etc.).

e.)Becertainthatneutralandliveconnectionsarenotreversedwhenmakingtheseconnections.

f.) Replacecontrolbox,makesurethatcontrolboxissecuredshut

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16

vent connectIons to Blower asseMBlY

Figure15showsthetypicalventconnections.

fIGure 15.

ventInG and InstallatIon

Planthelayoutoftheventsystemfromtheventterminationtothewater

heaterconsideringallofthe90and45elbowsplusthenumberoffeet

ofpipethatwouldbeneededtoinstallthetotalventsystem.Thewater

heatermustbeventedtotheoutdoorsasdescribedintheseinstructions.

DONOTconnectthiswaterheatertoanexistingventorchimney.Itmustbeventedseparatelyfromallotherappliances.Thettings,other

thanthesuppliedVentTerminationshouldbeequivalenttothefollowing:

PVC(Schedule40,DWV,ASTMD-2665),CPVC(Schedule40,DWV,

ASTMF-438),ABS(Schedule40DWV,ASTMD-2661).

Thecementusedshould beas recommendedby the vent

pipe manufacturer. Seethe instructionsin theVENTPIPE

PREPARATIONsectionofthismanualforthepropermethodof

cuttingandcementingthePVCpipeandttings.

Allventgasesmustbecompletelyventedtotheoutdoorsofthe

structure(dwelling).Whendeterminingtheinstallationlocationfor

apowerdirectventwaterheater,snowaccumulationanddrifting

shouldbeconsideredinareaswhereapplicable.

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17

fIGure 16.

Horizontalrunsmust besecurelysupportedat 31/2 foot (1m)

intervalsandverticalrunssupportedat5foot(1.5m)intervals.

fIGure 17.

ventInG throuGh an outsIde wall

a. a 75 G M

Inthecartonissupplied:

1.Two3inletandoutletPVCSchedule40-45ventcaps.

2. One3CPVCSchedule80-90elbow;usedtoconnectthe

ventpipetothewaterheaterwhentheventpipeistobe

turnedhorizontallydirectlyofftheblower.

3. One5(1.5m)sectionof3CPVCSchedule40ventpipe

(Moremayberequiredandmustbepurchasedlocally.)

fIGure 18.

1. Thewaterheaterrequiresitsown(separate)ventingsystem.

2. oy3CPVCSchedule40pipingandttingsareacceptablematerialsontherstvefeetoftheventsystem.

3. 3PVC,ABS,orCPVCSchedule40 piping and ttingsareacceptablematerialsfortheiventsystemandfortheventsystemaftertherstvefeet.

4. Theunitcannotbeconnectedtoexistingventpipingorchimney

5. Whenventingthroughanoutsidewall,theventsmustterminatehorizontallytotheoutdoors.

B. a 50 G 65,000 Btu/hr MInthecartonissupplied:

1. Two3i and PVCSchedule40-45ventcaps.

2. One3ABSSchedule40-90streetelbow;usedtoconnecttheventpipetothewaterheaterwhentheventpipeitobeturnedhorizontallydirectlyofftheblower.

3. One5(1.5m)sectionof3ABSSchedule40ventpipe

(Moremayberequiredandmustbepurchasedlocally.)

fIGure 19.

1. Thewaterheaterrequiresitsown(separate)ventingsystem.

2. oy3CPVCorABSSchedule40pipingandttingsareacceptablematerialsontherstvefeetofthe ventsystem.

3. 3PVC,ABS,orCPVCSchedule40 piping and ttingsareacceptablematerialsfortheiventsystemandfortheventsystemaftertherstvefeet.

4. Theunitcannotbeconnectedtoexistingventpipingorchimney

5. Whenventingthroughanoutsidewall,theventsmustterminatehorizontallytotheoutdoors.

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18

c. a 40 50 G 40,000 Btu/hr MInthecartonissupplied:

1. Two3inletandoutletPVCSchedule40-45ventcaps.Allotherpipingmustbesuppliedbythesupplier.

fIGure 20.

* Ifmakinganimmediatehorizontalrunofventofftheblower,two

3PVCorABSschedule40streetelbowsarerequired.

ventInG sYsteM eXaMple InstallatIons for

all Models

Theventpipingcannotunderanycircumstancesberundownhill.

fIGure 21.

c ii iig:

1. Horizontalrunsrequireaminimum1/8(3.2mm)risepervefeet

of length.

fIGure 22.

2. The totalvertical and horizontal ventrunscannot exceed the

maximumlengthwiththenumberof90elbowsasspeciedinthetablebelow.Ifmoreelbowsarerequired,theventingdistancemustbereduced5feet(1.5m)forevery90elbow:

Thenumberof90elbowsshowninthetableisforboththeintake

airandventpipes.IE:Theventpipecancontainthree90elbows,

theintakeairpipecanalsocontainthree90elbows.

3" dIa. vents MaX.

lenGth (ft.)

nuMBer of 90

elBows*

45 1

40 2

35 3

*NOTE:Two45elbowsareequivalenttoone90elbow.One90

elbowequals5feet(1.5m)ofequivalentventlength.

fIGure 23.

3. Minimumventlengthforallmodelsis18inches(46cm).

vent pIpe separatIon

Theinletandoutletventpipesmustbeseparatedbyaminimum

distance of6 1/2 inches(16.5 cm)upto 24inches (61 cm)maximum.

fIGure 24.

cuttInG openInGs throuGh an outsIde wall

and collar InstallatIon

Afterreadingthe manualanddeterminingthe location forthe

openingin the wall,cut one 31/2(9 cm) diameterholeforthe

inletventpipingandone31/2(9cm)diameterholefortheoutlet

ventpipingthroughanexteriorwall,seeFigure25.

n: w miig i ig i

outside wall, allow for the 1/8 (3.2 mm) rise per ve feet (1.5

m) g i i iz .

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19

fIGure 25.

The3 PVC,ABS,or CPVC Schedule 40ventpipecan berun

fromthewaterheaterthroughthewallorfromthewalltothewater

heater,whicheverismostconvenient.Theventpipemustextenda

minimumof11/2(4cm)throughtheexteriorwall.Extendingthe

vent cap asfaras possiblefromthesurfaceofthe exteriorwall

willhelpminimizediscolorationofthewall.Notethattheinsideue

mounting adaptors mustbe slippedoverthe vent pipingbefore

locating the pipe through the wall. Before securing the inside and

outsidecollarstothewall,useasiliconesealerbetweenpipeand

opening to insure a water and air tight seal.

InstallatIon showInG use of pvc, aBs or

cpvc pIpe for Inlet and outlet vent pIpInG

Inletpipingthroughanytypewall.

fIGure 26.

connectInG vent to Blower

1. Ifmakinganimmediatehorizontalrunofventofftheblower,one

3PVCinletandone3 PVC (CPVCfor75gallonmodelsand

ABSfor50gallon65,000Btu/Hrmodels)outletSchedule40street

elbowsarerequired.Placetheelbowintherequireddirectionon

theblowerandattachtheelbowwith3sheetmetalscrews.

fIGure 27.

2. Ifthereistobeaverticalrunofventfromtheblower,the3PVC

inletandthe3PVC(CPVCfor75gallonmodelsandABSfo

50gallon65,000Btu/Hrmodels)outletpipesmustbeattachedtotheblowerandventinghoodusing6sheetmetalscrews.

fIGure 28.

InstallatIon showInG use of (optIonal

deluXe horIZontal vent KIt

Typicalinstallation.

fIGure 29a.

oi 3 pvc hiz v Ki:

fIGure 29B.

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20

Ifthisconcentrictermination,throughthewalltypeofventingsystemispreferred,theconcentricventkitcanbeorderedfromtheServicePartsDepartmentunderkit#9002749.Installationinstructionsareprovidedwiththekit.

ventInG throuGh a roof

Two3inletandoutletPVCSchedule40-45ventcapsaresupplied.

A5 (1.5m) sectionof 3CPVC Schedule40outletventpipe issuppliedwith75gallonmodelsanda5(1.5m)sectionof3ABSSchedule40outletventpipeissuppliedwith50gallon65,000Btu/Hrmodels.Moremayberequiredandmustbepurchasedlocally.

1. Thewaterheaterrequiresitsown(separate)ventingsystem.2. Only3"ABS Schedule 40pipingand ttingsare acceptable

materialsontherstvefeetoftheoutletventsystemonthe50gallon65,000BTU/HRmodelsand3"CPVCSchedule40pipingandSchedule80ttingsareacceptablematerialsontherstvefeetoftheoutletventsystemon75gallonmodels.

3. 3PVC,ABS,orCPVCSchedule40 piping and ttings areacceptablematerialsfortheinletventsystemandfortheoutletventsystemaftertherstvefeet(1.5m).

4. Theunitcannotbeconnectedtoexistingventpipingorchimney.5. Ventingmustterminateverticallytotheoutdoors.6. The total verticalandhorizontalventruns cannotexceedthe

maximumlengthwithamaximumnumberof90elbowsas

speciedinthetablebelow.Ifmoreelbowsarerequired,theventingdistancemustbereduced5feetforevery90elbow.

Thenumberof90elbowsshowninthetableisforboththeintakeairandventpipes.IE:Theventpipecancontainthree90elbows,theintakeairpipecanalsocontainthree90elbows.

3" dIa. vents MaX.

lenGth (ft.)

nuMBer of 90

elBows*

45 1

40 2

35 3

*NOTE:Two45elbowsareequivalenttoone90elbow.One90

elbowequals5feet(1.5m)ofequivalentventlength.

fIGure 30.

vent pIpe preparatIon

1. InItIal preparatIon

A. Makesurethesolventcementyouareplanningtouseis

designedforthespecicapplicationyouareattempting.

B. K no w the p hysi ca l a nd ch emical ch ar acte ri st ics a nd

limitationsofthePVC,ABSandCPVCpipingmaterialsthatyouareabouttouse.

C. Knowthereputationofyourmanufacturerandtheirproducts.

D. Knowyourownqualicationsorthoseofyourcontractor.The

solventweldingtechniqueofjoiningPVC,ABSandCPVCpipe

isaspecializedskilljustasanyotherpipettingtechnique.

E. Closelysupervisetheinstallationandinspectthenished

jobbeforestart-up.

F. Contactthemanufacturer,supplier,orcompetentconsulting

agencyifyouhaveanyquestionsabouttheapplicationorinstallation of PVC, ABS and CPVC pipe.

G. Takethetimeandefforttodoaprofessionaljob.Shortcutswillonlycauseyouproblemsanddelaysinstart-up.Byfar,

themajorityoffailuresinPVC,ABSandCPVCsystemsare

theresultofshortcutsand/orimproperjoiningtechniques.

2. selectIon of MaterIals

CuttingDevice-SaworPipeCutter

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

Brush-PureBristle

Rag-Cotton(NotSynthetic)

PrimerandCleaner

SolventCement- PVCforPVCComponents and CPVCfor

CPVCComponentsandABSforABScomponents.

Containers-MetalorGlasstoholdPrimerandCement.Select

thetypeofPVC,ABSorCPVCmaterialstobeusedonthebasis

oftheirapplicationwithrespecttochemicalresistance,pressurerating,temperaturecharacteristics,etc.

InsertionTool - Helpful forlarger diameter pipeand ttings6

inches(15.2cm)andabove.

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prIMer

ItisrecommendedthatTetrahydrofuran(THF)beusedtopreparethe

surfacesofpipeandttingsforsolventwelding.Donotusewater,

rags,gasolineoranyothersubstitutesforcleaningPVC,ABSor

CPVCsurfaces.AchemicalcleanersuchasMEKmaybeused.

ceMent

Thecementshouldbeabodiedcementofapproximately500to

1600centipoiseviscositycontaining10-20%(byweight)virginPVC

material solvated withtetrahydrofuran(THF). Smallquantities of

dimethylformamide(DMF)maybeincludedtoactasaretarding

agenttoextendcuringtime.Selectthepropercement;Schedule40

cementshouldbeusedforSchedule40pipe.Neveruseall-purpose

cements,commercialgluesandadhesivesorABScementtojoin

PVCorCPVCpipeandttings.

applIcators

Selectasuitablepurebristletypepaintbrush.Useaproperwidth

brushorrollertoapplytheprimerandcement(seechartbelow).

Speedyapplication ofcement isimportant due toits fast drying

characteristics.

recoMMended Brush* sIZe for prIMer

and ceMent applIcatIons

nmi pi (Ips) siz B wi (Ins.)

3 1-1/2 2-1/2

*use onlY natural BrIstle

3. MaKInG the joInt

a. cig

Pipemustbesquarelycuttoallowfortheproperinterfacingofthe

pipeendandthettingsocketbottom.Thiscanbeaccomplished

withamiterboxsaworwheeltypecutter.Wheeltypecuttersare

notgenerallyrecommendedforlargerdiameterssincetheytendtoarethecornerofthepipeend.Ifthistypeofcutterisused,

theareontheendmustbecompletelyremoved.

NOTE:Powersawsshouldbespecicallydesignedtocutplastic

pipe.

step a

B. dbig

Useaknife,plasticpipedeburringtool,orletoremoveburrs

fromtheendofsmalldiameterpipe.Besuretoremoveallburrs

fromaroundtheinsideaswellastheoutsideofthepipe.Aslight

chamfer(bevel)ofabout10-15shouldbeaddedtotheend

topermiteasierinsertionofthepipeintotheendofthetting

Failuretochamfertheedgeofthepipemayremovecementfrom

thettingsocket,causingthejointtoleak.

step B

C. Test dry t of the joint

Taperedttingsocketsaredesigned sothataninterfaced

shouldoccurwhenthepipeisinsertedabout1/3to2/3ofthe

wayintothesocket.Occasionally,whenpipettingdimensions

areatthetoleranceextremes,itwillbepossibletofullyinserdrypipetothebottomofthettingsocket.Whenthishappens,

asufcientquantityofcementmustbeappliedtothejointtoll

thegapbetweenthepipeandtting.Thegapmustbelledto

obtainastrong,leak-freejoint.

d. Ii, ig, imig

Visuallyinspecttheinsideofthe pipe andtting sockets and

removealldirt,greaseormoisturewithacleandryrag.Ifwiping

failstocleanthesurfaces,achemicalcleanermustbeused.

Checkforpossibledamagesuchassplitsorcracksandreplace

ifnecessary.

d--y

MarkingthedepthofentryisawaytocheckifthepipehasreachedthebottomofthettingsocketinStepF.Measure

thettingdepthandmarkthisdistanceonthepipeO.D.You

maywanttoaddseveralinchestothedistanceandmakea

secondmarkastheprimerandcementwillmostlikelydestroy

yourrstone.

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22

Applyprimertothesurfaceofthepipeandttingsocketwitha

naturalbristlebrush.ThisprocesssoftensandpreparesthePVC,

ABSorCPVCforthesolventcementingstep.Movequicklyand

withouthesitationtothecementingprocedurewhilethesurfaces

arestillwetwithprimer.

e. aii m

Applythesolventcementevenlyandquicklyaroundtheoutsideofthe

pipeatawidthalittlegreaterthanthedepthofthettingsocket.

Applyalightcoatofcementevenlyaroundtheinsideofthe

ttingsocket.Avoidpuddling. Applyasecondcoatofcementtothepipeend.

step e

f. ji mby

Workingquickly,insertthepipeintothettingsocketbottomand

givethepipeorttinga1/4turntoevenlydistributethecement.

Donotcontinuetorotatethepipeafterithashitthebottomofthe

ttingsocket.Agoodjointwillhavesufcientcementtomakea

beadallthewayaroundtheoutsideofthettinghub.Thetting

willhaveatendencytoslidebackwhilethecementisstillwet

soholdthejointtogetherforabout15seconds.

step f

G. c i mm

Removeallexcesscementfromaroundthepipeandttingwitha

drycottonrag.Thismustbedonewhilethecementisstillsoft.

Thejointshouldnotbedisturbedimmediatelyafterthecementing

procedure,andsufcienttimeshouldbeallowedforpropercuringofthejoint.Exactdryingtimeisdifcultto predictbecauseit

dependsonvariablessuchastemperature,humidityandcement

integrity.Formorespecicinformation,youshouldcontactyour

solventcementmanufacturer.

step G

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Due tothenatureof the typical gas waterheater, the water

temperatureincertainsituationsmayvaryupto30F(16.7C)

higherorloweratthepointofusesuchas,bathtubs,showers,

sink,etc.

Itisrecommendedthatlowerwatertemperaturesbeusedtoavoid

theriskofscalding.Itisfurtherrecommended,inallcases,that

thewatertemperaturebesetforthelowesttemperaturewhichsatisesyourhotwaterneeds.Thiswillalsoprovidethemost

energyefcientoperationofthewaterheater.

HOTWATERCANSCALD:Waterheatersareintendedtoproduce

hotwater.Waterheatedtoatemperaturewhichwillsatisfyspace

heating,clothes washing, dishwashing,and other sanitizing

needscanscaldandpermanentlyinjureyouuponcontact.Some

peoplearemorelikelytobepermanentlyinjuredbyhotwater

than others.These includetheelderly, children,the inrm,or

physically/mentallydisabled.Ifanyoneusinghotwaterinyour

hometsintooneofthesegroupsorifthereisalocalcodeor

statelawrequiringacertaintemperaturewateratthehotwater

tap,thenyoumusttakespecialprecautions.Inadditiontousing

thelowestpossibletemperaturesettingthatsatisesyourhot

waterneeds,ameanssuchasamixingvalveshouldbeusedat

thehotwatertapsusedbythesepeopleoratthewaterheater.

Mixingvalvesareavailableatplumbingsupplyorhardwarestores,

seeFigure2.Followmanufacturersinstructionsforinstallationof

thevalves.Beforechangingthefactorysettingonthethermostat,

see Figure 31.

Neverallowsmallchildren tousea hotwater tap, orto draw

theirownbathwater.Neverleaveachildorhandicappedperson

unattendedinabathtuborshower.

Thewaterheatershouldbelocatedinanareawherethegeneralpublicdoesnothaveaccess.Ifasuitableareaisnotavailable,

a cover should be installedover thethermostat to prevent

tampering.

The watertemperature setting was factory set at thelowest

temperature; Pressingthe COOLER buttondecreases

temperatureandpressingtheHOTTER buttonincreases

thetemperature.

Settingthewaterheatertemperatureat120F(49C)(Approx.

markontemperaturesettingofgascontrolvalve)willreduce

theriskofscalds.Somestatesrequiresettingsatspeciclower

temperatures.

teMperature reGulatIonToavoidanyunintentionalchangesinwatertemperaturesettings,

thegascontrolvalvehasatamperresistantfeatureforchanging

thetemperaturesetting.Tochangethetemperaturesettingfollow

theseinstructions:

1.WakeUpthetemperatureindica torsbyholdingdownboth

COOLERandHOTTERtemperatureadjustmentbuttons

atthesametimeforonesecond,seeFigure31.Oneortwoofthetemperatureindicatorswilllightup.Theseindicators

willonlyremainonfor30secondsifnofurtherbuttonsare

pressed.After30secondsthecontrolwillgobacktoSleep

mode.

2.Releasebothofthetemperatureadjustmentbuttons.

a.TodecreasethetemperaturepressandreleasetheCOOLER

buttonuntilthedesiredsettingisreached.

b.ToincreasethetemperaturepressandreleasetheHOTTER

buttonuntilthedesiredsettingisreached.

NOTE:Holdingdownthebuttonwillnotcontinuetolowerorraisethetemperaturesetting.Thebuttonmustbepressedandreleased

foreachtemperaturechangedesired.

Shouldoverheatingoccurorthegassupplyfailtoshutoff,turn

offthemanualgascontrolvalvetotheappliance.

Gas control valve - front vIew

tm sig

diy

A B C

tim p 2

3 dg B

a ski

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

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

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

A=approx.130F(54C) About30seconds

=approx.120F(49C) Morethan5minutes

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

fIGure 31.

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25

for Your InforMatIonstart up condItIons

condensate

Whenever the waterheater isfi l led with cold water, some

condensatewillformwhiletheburnerison.Awaterheatermay

appeartobeleakingwheninfactthewateriscondensate.This

usuallyhappenswhen:

a. Anewwaterheaterislledwithcoldwaterforthersttime.

b. Burninggasproduceswatervaporinwaterheaters,particularly

highefciencymodelswhereuetemperaturesarelower.

c. Largeamountsofhotwaterareusedinashorttimeandtherell

waterinthetankisverycold.

Moisturefromtheproductsofcombustioncondenseonthecooler

tanksurfacesandformdropsofwaterwhichmayfallontotheburner

orotherhotsurfacestoproduceasizzlingorfryingnoise.

Becauseofthesuddennessandamountofwater,condensatewater

maybediagnosedasatankleak.Afterthewaterinthetankwarms

up(about1-2hours),theconditionshoulddisappear.

Donotassume the waterheater isleakinguntil therehasbeenenoughtimeforthewaterinthetanktowarmup.

Anundersizedwaterheaterwillcausemorecondensation.Thewater

heatermustbesizedproperlytomeetthefamilysdemandsforhot

waterincludingdishwashers,washingmachinesandshowerheads.

Excessivecondensate maybe noticed duringthe winter and

early spring months whenincoming watertemperaturesare at

their lowest.

Goodventingisessentialforagasredwaterheatertooperate

properlyaswellastocarryawayproductsofcombustionandwater

vapor.

sMoKe/odor

Itisnotuncommontoexperienceasmallamountofsmokeandodor

duringtheinitialstart-up.Thisisduetoburningoffofoilfrommetal

parts, and will disappear in a short while.

closed water sYsteMs

Watersupplysystemsmay,becauseofcoderequirementsorsuch

conditionsas highline pressure,among others, haveinstalled

devicessuchaspressurereducingvalves,checkvalves,andback

owpreventers.Devicessuchasthesecausethewatersystemto

beaclosedsystem.

therMal eXpansIon

Aswaterisheated,itexpands(thermalexpansion).Inaclosed

systemthevolumeofwaterwillgrowwhenitisheated.Asthe

volumeofwatergrowstherewillbeacorrespondingincreasein

waterpressureduetothermalexpansion.Thermalexpansioncan

causeprematuretankfailure(leakage).Thistypeoffailureisno

coveredunderthelimitedwarranty.Thermalexpansioncanalso

causeintermittenttemperature-pressurereliefvalveoperation

waterdischargedfromthevalveduetoexcessivepressurebuild

up.Thisconditionisnotcoveredunderthelimitedwarranty.The

temperature-pressurereliefvalveisnotintendedfortheconstanreliefofthermalexpansion.

Aproperlysized thermal expansion tankshould be installed

onallclosedsystemstocontroltheharmfuleffectsofthermal

expansion.Contactalocalplumbingserviceagencytohavea

thermalexpansiontankinstalled.

stranGe sounds

Possiblenoisesduetoexpansionandcontractionofsomemeta

partsduringperiodsofheat-upandcool-downdonotnecessarily

representharmfulordangerousconditions.

Condensationcausessizzlingandpoppingwithintheburnerareaduringheatingandcoolingperiodsandshouldbeconsiderednormal

SeeCondensateinthissection.

operatIonal condItIons

aIr In hot water faucets

HYDROGEN GAS: Hydrogen gascanbe produced ina ho

watersystemthathasnotbeenusedforalongperiodoftime

(generally twoweeks or more). Hydrogengas isextremely

flammableand explosive.Topreventthe possibilityof injury

under these conditions, werecommend thehot water faucet

located farthest away, beopenedfor several minutes before

anyelectricalapplianceswhichareconnectedtothehotwate

systemareused(suchasadishwasherorwashingmachine).Ifhydrogengasispresent,therewillprobablybeanunusualsound

similartoairescapingthroughthepipeasthehotwaterfauce

isopened.Theremustbenosmokingoropenflamenearthe

faucetatthetimeitisopen.

hIGh water teMperature shut off sYsteM

This water heateris equipped with anautomaticgas shut-of

system.Thissystemworkswhenhighwatertemperaturesare

present.TurnOFFtheentiregassupplytothewaterheater

Thehightemperatureshut-offisbuiltintothegascontrolvalve.

Itisnon-resettable.Ifthehightemperatureshut-offactivates,the

gascontrolvalvemustbereplaced.Contactyourgassupplier

orserviceagency.

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26

ventInG sYsteM InspectIon

Atleastonceayearavisualinspectionshouldbemadeoftheventing

system.Youshouldlookfor:

1.Obstructionswhich couldcause improper venting. The

combustionandventilationairowmustnotbeobstructed.

2.Damageordeteriorationwhichcouldcauseimproperventingor

leakageofcombustionproducts.

Besuretheventpipingisproperlyconnectedtopreventescapeof

dangerousuegasseswhichcouldcausedeadlyasphyxiation.

Obstructionsanddeterioratedventsystemsmaypresentserious

healthriskorasphyxiation.

Chemicalvaporcorrosionoftheueandventsystemmayoccur

ifairforcombustioncontainscertainchemicalvapors.Spraycan

propellants, cleaning solvents,refrigeratorand air conditioner

refrigerants,swimmingpoolchemicals,calciumandsodiumchloride,

waxes,bleachandprocesschemicalsaretypicalcompoundswhich

arepotentiallycorrosive.

Ifafterinspectionoftheventsystemyoufoundsootingor

deterioration, somethingis wrong. Callthe localgas utilityto

correcttheproblemandcleanorreplacetheueandventingbefore

resumingoperationofthewaterheater.

Burner operatIon and InspectIon

Flooddamageto awaterheatermaynot bereadilyvisible or

immediatelydetectable.However,overaperiodoftimeaooded

water heater will create dangerous conditions which can cause

DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

Contacta qualified installer orserviceagency toreplacea

oodedwaterheater.Donotattempttorepairtheunit!Itmustbe

replaced!

Atleastoncea year avisualinspectionshould bemadeof the

mainburnerandthehotsurfaceigniterassemblyforproperame

perIodIc MaIntenancecharacteristicsandignitionsequences.Thiscanbedonebyviewing

themainburneroperationthroughtheViewportontheOuterDoor,

seeFigure1.Themainburnershouldprovidecompletecombustion

ofgas,igniterapidly,givereasonablyquietoperation,andcause

noexcessiveameliftingfromtheburnerports.Iftheproperame

characteristicsarenotevidentasinFigure32,makesurethatthe

owofcombustionandventilationairisnotblockedintheventing

system.

Youshouldalsocheckforsooting.Sootisnotnormalandwillimpair

propercombustion.AvisualinspectionofthemainburnerandHSI

igniterassembly shouldalsobe doneat least once ayear, see

Figure 32.

Sootbuild-upindicatesaproblemthatrequirescorrectionbefore

furtheruse.TurnOFFgastowaterheaterandleaveoffuntilrepairs

aremade,becausefailuretocorrectthecauseofthesootingcan

resultinarecausingdeath,seriousinjury,orpropertydamage.

fIGure 32.

Burner cleanInG

Intheeventyourburnerorburnerairopeningsrequirecleaning,turntheblowerswitchtotheOFFpositionandallowtheburnertocool.

Callaserviceagencytoremoveandcleantheburnerandcorrect

theproblemthatrequiredtheburnertobecleaned.

houseKeepInG

Vacuumaroundbaseofwaterheaterfordust,dirt,andlintona

regularbasis.

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anode rod

Eachwaterheatercontainsatleastoneanoderod,whichwillslowly

deplete whileprotectingthe glass-linedtank fromcorrosion and

prolonging the life of the water heater. Once the anode is depleted,

thetankwillstarttocorrode,eventuallydevelopingaleak.Certain

waterconditionswillcauseareactionbetweenthisrodandthewater.

Themostcommoncomplaintassociatedwiththeanoderodisa

"rotteneggsmell"producedfromthepresenceofhydrogensulde

gasdissolvedinthewater.IMPORTANT:Donotremovethisrod

permanentlyasitwillvoidanywarranties.Thepartslistincludes

aspecialanodethatcanbeorderedifwaterodorordiscolorationoccurs.NOTE:Thisrodmayreducebutnoteliminatewaterodor

problems.Thewatersupplysystemmayrequirespecialaeration

or chlorination equipmentfrom a waterconditioning company to

successfullyeliminateallwaterodorproblems.

Theuseofawatersoftenermaydecreasethelifeofthewaterheater

tank.Theanoderodshouldberemovedfromthewaterheatertank

every3yearsforinspection.Thefollowingaretypical(butnotall)

signsofadepletedanoderod:

Themajorityoftherod'sdiameterislessthan3/8".

Signicantsectionsofthesupportwire(approx.1/3ormoreof

theanoderod'slength)arevisible.

Iftheanoderodshowssignsofeitherorbothitshouldbereplaced.

NOTE:Whetherre-installingorreplacingtheanoderod,checkfor

anyleaksand immediatelycorrect iffound.In situations where

clearanceabovethewaterheaterislimiteditmaybenecessaryto

bendtheanoderodforremoval.Flexibleanoderodsareavailable

forreplacement.

Inreplacingtheanode:

1. Turnoffgassupplytothewaterheater.

2. Shutoffthewatersupplyandopenanearbyhotwaterfaucetto

depressurizethewatertank.

3. Drainapproximately5gallonsofwaterfromthetank(Referto

the"DrainingandFlushing"sectionforproperprocedures).Close

drainvalve.

4. Removeoldanoderod.

5. UseTeontapeorapprovedpipesealantonthreadsandinstall

new anode rod.

6. Turnonwatersupplyandopennearbyhotwaterfaucettopurge

air from water system.Check foranyleaksandimmediately

correctanyiffound.

7. Restartthewaterheaterasdirected underthe"OperatingYou

WaterHeater"section.Seethe"RepairPartsIllustration"section

for anode rod location.

teMperature-pressure

relIef valve operatIon

Thetemperature-pressurereliefvalvemustbemanuallyoperated

atleastonceayear.

fIGure 33.

Whenchecking the temperature-pressure reliefvalve operation

makesurethat(1)nooneisinfrontoforaroundtheoutletofthe

temperature-pressurereliefvalvedischargeline,and(2)thatthe

waterdischargewillnotcauseanypropertydamage,asthewater

maybeextremelyhot,seeFigure33.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetand

continuestoreleasewater,immediatelyclosethecoldwaterinle

to the water heater, follow the draining instructions, and replace the

temperature-pressurereliefvalvewithanewone.

Ifthetemperature-pressurereliefvalveontheapplianceweepsor

dischargesperiodically,thismaybeduetothermalexpansion.You

mayhaveacheckvalveinstalledinthewaterlineorawatermete

withacheckvalve.Consultyourlocalwatersupplierorservice

agencyforfurtherinformation.Donotplugthetemperature-pressure

reliefvalve.

draInInG

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28

Thewaterheatershouldbedrainedifbeingshutdownduringfreezing

temperatures.Alsoperiodicdrainingandcleaningofsedimentfrom

thetankmaybenecessary.

1.SettheblowerswitchtotheOFFposition.

2.CLOSEthecoldwaterinletvalvetothewaterheater.

3.OPEN a nearbyhot water faucet andleaveopento allow for

draining.

4.Connectahosetothedrainvalveandterminatetoanadequate

drain.

5.OPENthewaterheaterdrainvalvetoallowfortankdraining.

note: I i gig b i

x i, i b i

ig mi

i.

6.CLOSEthedrainvalve.

7.FollowinstructionsintheFillingTheWaterHeatersection.

8.Followthelightinginstructionsonthelabelorseepage23under

LightingInstructionstorestartthewaterheater.

draIn valve washer replaceMent

(SeeFigure34)

1.TurnOFFgassupplytowaterheater.

2.FollowDraininginstructions.

3.Turningcounterclockwise( ),removethehexcapbelowthe

screw handle.

4.Removethewasherandputthenewoneinplace.

5.Screwthehandleandcapassemblybackintothedrainvalveand

retighten using a wrench. DO NOT OVER TIGHTEN.

6.FollowinstructionsintheFillingTheWaterHeatersection.

7.Checkforleaks.

8.FollowthelightinginstructionsintheLightingsectiontorestart

the water heater.

fIGure 34.

servIce

Ifaconditionpersistsoryouareuncertainabouttheoperationofthe

waterheatercontactaserviceagency.

UsethisguidetocheckaLeakingwaterheater.Manysuspected

Leakersarenotleakingtanks.Oftenthesourceofthewatercan

befoundandcorrected.

Ifyouarenotthoroughlyfamiliarwithgascodes,yourwaterheater,

andsafetypractices,contactyourgassupplierorqualiedinstaller

tocheckthewaterheater.

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29

leaKaGe checKpoIntsReadthismanualrst.Thenbeforecheckingthewaterheatermake

surethegassupplyhasbeenturnedOFF,andneverturnthegas

ONbeforethetankiscompletelyfullofwater.

Neveruse this waterheaterunless itis completelylledwith

water.Topreventdamagetothetank,thetankmustbelledwith

water.Watermustowfromthehotwaterfaucetbeforeturning

ONgastothewaterheater.

A. Waterattheblowerassemblyiswatervaporwhichhascondensed

outofthecombustionproducts.Thisiscausedbyaproblemin

thevent.Contactthegasutility.

B.*Condensationmaybeseenonpipesinhumidweatherorpipe

connectionsmaybeleaking.

C.*Theanoderodttingmaybeleaking(anodeislocatedunde

theBlowerAssembly).

D.Smallamountsofwaterfromtemperature-pr essurereliefvalve

maybeduetothermalexpansionorhighwaterpressurein

yourarea.

E.*Thetemperature-pressurereliefvalve may beleakingat the

tanktting.

F.Waterfromadrainvalvemaybeduetothevalvebeingslightly

opened.

G.*Thedrainvalvemaybeleakingatthetanktting.

H.Co mb u sti o n p r o d u cts co n ta i n wa te r va p o r wh i ch ca n

condenseonthecoolersurfacesofthetank.Dropletsform

anddripontotheburnerorrunonthefloor.Thisiscommon

atthetimeofstart-upafterinstallationandwhenincoming

water is cold.

I. Waterinthe waterheater bottomor onthefloormaybe

fromcondensation,loose connections, orthe relief valve

DO NOT replace the water heater until a full inspection o

allpossiblewatersourcesismadeandnecessarycorrective

stepstaken.

Leakage fromother appliances,water lines,or ground seepage

shouldalsobechecked.

* Tocheckwhere threadedportionenters tank, insertcotton

swabbetweenjacketopeningandtting.Ifcottoniswet,follow

DraininginstructionsinthePeriodicMaintenancesection

andthenremovetting.PutpipedopeorTeontapeonthethreadsandreplace.ThenfollowFillingtheWaterHeater

instructionsintheInstallingtheNewWaterHeatersection.

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30

repaIr parts lIst

Ky n. p dii

1 v c /s

2 a, f Mig

3 5' aBs s 40 v pi (50 g. 65,000)

3 5' cpvc s 40 v pi (75 g.)

4 90 aBs s 40 eb (50 g. 65,000)

4 90 cpvc s 80 eb (75 g. )

5 v/B a

6 B

7 f a Gk (6' x 10.102")

8 B Gk

9 vig; M r si

10 v h amby

11 ji Bx

12 t & p v

13 di tb

14 a r

15 fv s Bk

16 di p

17 h s Igi i amby

18 Orice

19 B amby

20 I d

21 di v

22 Mi

23 rig a d /Gk

24 l a d /Gk

25a a d ci (2)

25B jk/a d ci (6)26 fv s

27 G c v

28 p si (ai)

29 Flue Bafe Assembly

30 Bafe Adaptor Collar Assembly

31 oi (dx) hiz v Ki

32 otinal (3") pvc hrizntal vent Kit (75 Galln only)

Nowthatyouhavepurchasedthiswaterheater,shouldaneedeverexistforrepairpartsorservice,simplycontactthecompanyitwaspurchasedfromordirectfromthemanufacturerlistedontheratingplate on the water heater.

Besuretoprovideallpertinentfactswhenyoucallorvisit.

sig i i b i i bi iig i y i b bi igy.

ThemodelnumberofyourGasWaterHeaterwillbefoundontheratingplatelocatedabovethegascontrolvalve.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THEFOLLOWINGINFORMATION:

MODELNUMBER

TYPEGAS(NATURALORPROPANE(L.P.)

SERIALNUMBER

PARTDESCRIPTION

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

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31

trouBleshootInG GuIdelInesTheseguidelinesshouldbeutilizedbyaqualiedserviceagent.Whencallingforservicenotifytheserviceagent

thatthisisaFlammableVaporIgnitionResistantProduct.

# led status proBleM solutIon

1Thegascontrolvalvehassensed

inadequate or no earth ground.

1 Ensurethewalloutlet(powersupply)isproperly

grounded.

2 Ensure all ground connections/wires on the water

heateraresecurelyconnected.

2

Thegascontrolvalvehassensed

reversedpolarityinthe120VAC

powersupply.

1 Ensurethewalloutlet/powersupplyisproperlywired.

2 Ensure all internal 120 VAC wiring connections and

wiringharnesshavenoreversedwires.120VAC"hot"

wiremustconnecttotheon/offswitch.

3

Pressureswitchcircuitremaining

closedformorethan5seconds

afterheatingcyclebegins.

B my i i

ii.

1 Ensure air pressure switch circuit wiring is correct and

theairpressureswitchisnotjumpered.

2 Replace the air pressure switch.

4

Pressureswitchcircuitremains

open longer than 5 seconds after

theblowerisenergized.

B my iy i

i ii.

1 Ensuretheairpressureswitchsensingtubeisproperlyconnectedatbothendsandisnotkinkedordamaged.

2 Ensurethecorrectsizeofventandintakeairpipe(direct

ventproducts)wasusedpertheinstallationinstructions

inthemanualthatcamewiththewaterheater.

3 Ensuremaximumnumberofelbowsormaximum

equivalentfeetofventorintakeairpipehasnotbeen

exceededpertheinstallationinstructionsinthemanual

thatcamewiththewaterheater.

4 Ensuretherearenoobstructionsintheventorintake

air pipe.

5Thegascontrolvalvehasdetected

an open igniter circuit.

1 Checkwiringtothehotsurfaceigniterassembly-

replaceigniterassemblyifwiringisdamagedorworn.

2 Checkresistanceoftheigniteratigniterassemblyplug

-shouldbebetween11and18ohms-replaceigniterif

open or shorted.

3 Checkigniterassemblyplugandthesocketonthe

bottomofthegascontrolvalveforgoodconnection.

4 Replaceigniterassemblyiftheplugiswornor

damaged.

5 Replacethegascontrolvalveiftheigniterassembly

socketonthebottomofthecontroliswornordamaged.

6

Ignition/amefailure.

Thegascontrolvalvehasreached

themaximumnumberorretries(3)

forignitionandiscurrentlylocked

out for one hour.

Cyclethepowertothewaterheater

off and on to reset.

1 Gassupplyisturnedoff-pressureistoolow.

2 Ensuretheamesensorisclean-usenesteelwool

tocleantheamesensor.

3 Manifoldgaspressuretotheburneristoolow.

4 Checkigniterassemblyplugandthesocketonthebottom

ofthegascontrolvalveforgoodconnection.Replace

igniterassemblyiftheplugiswornordamagedreplace

thegascontrolvalveifsocketiswornordamaged.

5 Replaceigniterassembly.

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trouBleshootInG GuIdelInestrouBleshootInG GuIdelInesTheseguidelinesshouldbeutilizedbyaqualiedserviceagent.Whencallingforservicenotifytheserviceagent


# led status proBleM solutIon

7

8

9

Thegascontrolvalvehasdetected

aproblemwiththegasvalvedriver

circuit,internalmicroprocessor,or

other internal circuits.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 Ifanyoftheseerrorcodespersistorcannotbecleared

-replacethegascontrolvalve.

10

Thegascontrolvalvehassensed

mainburnerameoutofproper

sequence.



2 Replacethegascontrolvalveifthiserrorcodepersists.

11


excessivewatertemperatureinthe

tankandhasactivatedtheECO

(energycutoff)hightemperature

limit.



2 Replacethegascontrolvalveiftheerrorcodepersists.

12 Thegascontrolvalvehasdetectedthatoneorbothofthetemperature

adjustbuttonsarestuck.

1 Pressandreleasebothtemperatureadjustbuttons

severaltimes-cyclewaterheaterpoweroffandon.


13


thewatertemperaturesensor

(locatedinthecontrolvalve's

immersionprobe)iseitheropenor

shorted.




14


theFV(ammablevapor)sensoris

either open or shorted.

1 Ensure all FV sensor wiring is correct and the igniter

assemblyplugandsocketconnectionsonthebottom

ofthegascontrolvalvearemakinggoodcontact.

2 Replace the FV sensor.

15


thepresenceofammablevapors

fromtheFV(ammablevapor)

sensor.

1 Donottouchanyelectricalswitch,donotuseany

phoneinyourbuilding,anddonottrytolightanyappliance.

2 Smellaroundthewaterheatertoensurethereareno

gasleaksatthegascontrolvalve,inthesupplygas

line(s),oranyothertypeofammablevapor(s)inthe

area.

3 Carefullyinspecttheareasurroundingthewaterheater

foranysubstancessuchasgasoline,paint,paint

thinners,varnish,orcleanersthatcouldemitammable

vapors.Removeanythingthatcanpotentiallyemit

ammablevaporsfromtheareaandstoreitproperlyin

a different location.

4 Callthetechnicalinformationsupportphonenumbershownonthewaterheaterlabelingforfurther

assistance.

16


the air pressure switch circuit is

openingrepeatedlyduringone

heatingcycle.

LDO(Lint,Dust,andOil)lockout

condition.

1 Onmodelsequippedwithadilutionairintakescreenon

theblowerassembly-check/cleanthisscreen.

2 Onmodelsequippedwithacombustionairintake

screenonthebasering(bottom)ofthewaterheater

-check/cleanthescreen.

3 Ensureintakeairscreen(s)onmodelssoequippedare

notobstructed.

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33

Theseguidelinesshouldbeutilizedbyaqualiedserviceagent.Whencallingforservicenotifytheserviceagent


proBleM cause solutIon

not enouGh or

no hot water

1. Blower will not run.

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

B) Blowerunplugged. Plugblowerbackinto115vac.outlet.

C) Nopoweratoutlet. Repairservicetooutlet.

D) Thermostatdefective. Replacethermostat.

E) Controlharnessdefective. Replace control harness.

F) Highlimitcontrolcircuitopen. Replace ECO.

G) Blowermotordefective. Replaceblowerassembly.

3. Thermostatproblems

A) Thermostatsettoolow. Turntemperaturecontrolhigher.

B) T he rmo st at o r ECO de fe ct ive . Re pl ac e th ermo st at o r ECO as req uired .

4. Others

A) Heaterundersized. Reduce hot water use.

B) L ow g as p re ss ure. Contact dealer.

C) Incomingwaterisunusuallycold. Allowmoretimeforheatertoreheat.

D) Leakinghotwaterpipesorxtures. Haveplumbercheckandrepairleaks.

vent pIpe too hot

(aBove 170 f)

Defectiveairowrestrictor.Ta ke u ni t o ut o f se rvic e i mmed iat el y; c all a s ervi cerepresentative.

Notenoughdilutionairtomixwithuegasesininletelbow.

Properdilutionairmustbeprovidedforcombustionanddilutionof

uetemperature.Refertothe"INSTALLINGTHENEWWATER

HEATER"sectioninthemanual.

Dilutionairtoohotformixingwithuegases.Supply airis toohot. Check forheat sourcesaroundintake

terminalandblockageofdilutionairleg.

Wrongburnerorice. Installcorrectorice.

Yellow flaMe

Dirtinburnerports. Turnoffheaterandgas,cleanburnerhead.

Combustionairpathrestricted. Checkintakeventingarrangementforobstructions.

Notenoughdilutionairforpropercombustion. Checkintakeventingarrangementforobstructions.

condensatIon

Wat er on the oorunder heater. See"CONDENSATION"sect ion.

Waterdrippingfromblowerassembly.Providedrip"TEE"tocatchcondensationfromhorizontalsection

ofexhaustventclosetoblowerassembly.

water leaKs

Improperly sealed hot or cold supply connections, relief

valve,drainvalveorthermostatthreads.Tighten threaded connections.

Leakagefromotherappliancesorwaterlines. Inspect other appliances near water heater.

Condensation of ueproduct s. See"CONDENSATION"sect ion.

leaKInG t & p valve

Thermalexpansioninclosedwatersystem. Installthermalexpansiontank(DONOTplugT&Pvalve).

Improperlyseatedvalve.Checkreliefvalveforproperoperation(DONOTplugT&P

valve).

hot water odors (r

cathodIc protectIon)

Highsulfateormineralcontentinwatersupply. Drainandushheaterthoroughlythenrell.

Bacteriainwatersupply. Chlorinatewatersupply.

water too hot Thermostatset too high. Ref er to"TEMPERATUREREGULATION"sect ion.

water heater sounds

sIZZlInG - ruMBlInG

Co nde ns at io n drip pi ng on b urner. Se e "CON DEN SATI ON" se ct io n.

Sedimentatbottomofheatertank.Cleansedimentfromtank.Referto"DRAINING"instructionsin

the"MAINTENANCE"section.

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

heater lIGht Goes out

In 45 secondsOutletpolarityisreversed. Testpolarityandcorrect.

vent Gas odors

Lackofairsupply.

Immediatelyshutdownthewaterheaterandcontactaservice

agencytodeterminecause.

Improperlyinstalledventpiping.

Downdraft.

PoorCombustion.

trouBleshootInG GuIdelInestrouBleshootInG GuIdelInes

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resIdentIal Gas warrantY

Thiswarrantyshallapplyonlywhentheheateris:

ownedbytheoriginalpurchaser; installedforindooroperationonly; used attemperaturesnotexceeding the maximum calibratedsettingofitsthermostat; used at waterpressurenot exceeding theworking pressureshownontheheater; lledwithpotablewater,freetocirculateatalltimesand withthetankfreeofdamagingwatersedimentorscale deposits; u s ed i n a n o n- c o rr o si v e a n d n o n- c on t am i na t ed atmosphere; usedwithfactoryapprovedanode(s)installed; initsoriginalinstallationlocation; intheUnitedStates,its territories orpossessions, and

Canada; sizedin accordancewithproper sizing techniquesfor residentialwaterheaters; bearingaratingplatewhichhasnotbeenaltered,defaced orremovedexceptasrequiredbythewarrantor; usedinanopensystemorinaclosedsystemwith a properlysizedandinstalledthermalexpansiontank; operatedwithproperlyinstalleddripleginthegassupply line; redwiththefuelforwhichitwasfactorybuilt; redatthefactoryratedinput; operatedwith the innerandouter combustionchamber doors in placeandal l factorysealstocombustion

chamberintact. installed withno attempted,noractualmodicationor alterationof the waterheatersdesign in anyway, including but not l imited to,theattachment ofnon-

companyapprovedappliancesorequipment.

Anyaccidenttothewaterheateroranypartthereof(includingfreezing, re, oods,or lightning), anymisuse,abuseoralteration ofit,any operation ofit ina modiedform, anyoperation of thewater heateron desalinated(deionized)water, or anydamage causedby attemptsto repairtankleaksor parts, willvoidthiswarranty. This warranty doesnotcoverwaterheatersreplacedforcosmeticreasonsorforreasonsofnoise,taste,odor,discoloredand/orrustywater.

Thiswarrantydoesnotapplytowaterheatersusedtoheatpools,whirlpoolsorhottubsorusedforspaceheatingwhereitssizingdoesnotconformwithspecicationsoftheheatingcomponentmanufacturer.

Thiswarrantygives you specic legal rights,and youmayhaveotherrightswhichvaryunderthelawsofeachprovince.Ifanyprovisionofthiswarrantyisprohibitedorinvalidunderapplicableprovincelaw,thatprovisionshallbeineffectivetotheextentof theprohibitionor invaliditywithoutinvalidatingtheremainderoftheaffectedprovisionortheotherprovisionsofthiswarranty.

THIS WARRANTY IS APPLICABLE TO THE ORIGINAL

OWNER ONLY,in accordancewiththewarrantytermsand

conditionsspeciedbelow.

StateWaterHeaters(thewarrantor)willfurnishtheORIGINAL

OWNER,1)areplacementStatewaterheaterofequivalent

sizeand current model ifthe glass-lined tankin thiswater

heaterleaksand,2)areplacementpartforanycomponent

part which fails.

THE STATE WATER HEATERS REPLACEMENT MODEL OR

PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED

PORTIONOF THEORIGINALWARRANTY. Thewarranty

periodwillbedeterminedbytheoriginaldateofpurchaseofthe

waterheater,orintheabsenceofaBillofSaleverifyingsaid

date,fromthedateofmanufactureindicatedonratingplateafxedtothiswaterheater.Thiswarrantyisnottransferrable

andappliestomodelslistedbelow:

Whenthewaterheaterhasbeenusedforotherthansingle

familyresidentialapplication;

1.Thetankwarrantyshallbereducedto1yearfor6year

models.

2. Theparts warranty shallbe reducedto 1 year forall

models.

condItIons and eXceptIons

This warranty shall applyonlywhen thewaterheater is

installedandoperatedinaccordancewith1)alllocalfire

codesandplumbingcodes,ordinancesandregulations,2)

theprinted instructionsprovidedwith it,3) goodindustry

practices,and4)propersafetypracticessuchasbutnot

limitedtoaproperlysizeddrainpanifinstalledinanarea

whereleakagefromthetankoritsconnectionswouldresult

indamagetotheareaadjacenttotheheater.Inaddition,a

newtemperatureandpressurereliefvalve,certifiedbythe

CanadianGasAssociationmusthavebeenproperlyinstalled

and piped to the nearest drain.

serIes tk p

s 6-Y M 6-y 6-y

Gs6

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35

servIce and laBor responsIBIlItY

UNDER THIS LIMITED WARRANTY, THE WARRANTOR

WILL PROVIDE ONLY A REPLACEMENT WATER HEATER

OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR

ALLOTHERCOSTS.Suchcostsmayincludebutarenot

limitedto:

a. Labor chargesfor service,removal, or reinstallationofthe water heater or part thereof.

b. Shippinganddeliverychargesforforwardingthenewwater

heateror replacement partfrom thenearest distributor

andreturningtheclaimeddefectiveheaterorparttosuch

distributor.

c. Al l costnecessary or incidental for handl ing and

administrativecharges,and foranymaterialsand/or

permitsrequiredforinstallationofthereplacementheater

or part.

lIMItatIon

Documents

185885-001 Water Heater