Instruction Manual for
Residential
Power Direct Vent
Gas Water Heaters
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
COMPANY 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, alter-
ation, service or maintenance can cause
DEATH, SERIOUS BODILY INJURY, OR
PROPERTY DAMAGE. Refer to this manual
for assistance or consult 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.
WARNING
• 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.
READ THE GENERAL SAFETY SECTION
BEGINNING ON INSIDE COVER AND THEN
THIS ENTIRE MANUAL BEFORE INSTALLING
OR OPERATING THIS WATER HEATER.
184333-001
11-03
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General Safety (cont’d)
WARNING
WARNING
Obstructed or deteriorated vent systems may present a serious
health risk or asphyxiation.
This water heater must not be installed directly on carpeting.
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 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
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chlo-
ride, waxes, bleach, and process chemicals are typical compounds
which are potentially corrosive.
WARNING
Do not install in a confined area such as a closet, unless you provide
ventilation 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
ventilation air can result in a fire or explosion and can cause
DEATH, SERIOUS BODILY 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, 6 inches from front of jacket to closet door and 12
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 and 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 clean-
ing equipment, it is imperative that the water heater or water
heaters be installed so that combustion and ventilation air be
taken from outside 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 direct vent water heater requires its own (separate)
venting 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 IN-
JURY, OR PROPERTY DAMAGE.
WARNING
WARNING
INSULATING JACKETS: When installing an external water heater
insulation jacket on a 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.
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.
c. DO NOT put insulation over the gas control valve or gas control
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 (access for servicing 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 dis-
connected from the gas supply piping system during any pres-
sure testing of the gas system at test pressures in excess of
1
⁄2
pound per square inch (3.5kPa).
2. The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at test
WARNING
1
pressures equal or less than ⁄2 pound per square inch
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!
(3.5kPa).
WARNING
Soot build-up indicates a problem that requires correction be-
fore further use. Turn “OFF” gas to water heater and leave “OFF”
until repairs are made, because failure to correct the cause of
the sooting can result in a fire or explosion causing DEATH, SE-
RIOUS 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 connec-
tions 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 have a minimum length
and width of at least 2 inches greater than the water heater dimensions
and must be piped to an adequate drain. Drain pan depth must allow for
access to the outer doors for servicing the ignitor and burner.
WARNING
The water heater must be properly vented outdoors. Never op-
erate the water heater unless it is vented to the outdoors and
has adequate air supply to avoid risks of improper operation, ex-
plosion or asphyxiation.
WARNING
Vent termination must not be within 4 feet of any items such as
gas meters, gas valves or other gas regulating equipment.
3
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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
......................................................................7-9
Facts to Consider About Location.......................................................................................................................7-8
Combustion Air and Ventilation .........................................................................................................................8-9
Venting Clearances ..........................................................................................................................................8-9
Air for Ventilation for Appliances Located in Confined Spaces ..............................................................................9
Installing the New Water Heater
................................................................10-20
Water Piping .......................................................................................................................................................10
Temperature-Pressure Relief Valve ......................................................................................................................11
Filling the Water Heater ......................................................................................................................................12
Wiring............................................................................................................................................................12-13
Optional Field Installed Wiring ....................................................................................................................12-13
Wiring Diagram.................................................................................................................................................13
Venting ..........................................................................................................................................................13-18
Gas Piping......................................................................................................................................................18-19
Installation Checklist ...........................................................................................................................................20
Operating
Temperature Regulation
For Your Information
..........................................................................................................................................21-23
..................................................................................................24
......................................................................................................25-26
Start Up Conditions .............................................................................................................................................25
Condensation....................................................................................................................................................25
Smoke/Odor......................................................................................................................................................25
Thermal Expansion............................................................................................................................................25
Strange Sounds..................................................................................................................................................25
Operational Conditions..................................................................................................................................25-26
Smelly Water.....................................................................................................................................................25
"Air” In Hot Water Faucets ................................................................................................................................26
Venting Manual Reset Switch ............................................................................................................................26
High Temperature Limit Switch .........................................................................................................................26
Not Enough or No Hot Water............................................................................................................................26
PeWriaoterdIs iTcoo HMot..a....i..n....t..e....n....a....n....c....e.............................................................................................................26
....................................................................................................27-29
Venting System Inspection...................................................................................................................................27
Burner Inspection ................................................................................................................................................27
Burner Cleaning ..................................................................................................................................................27
L.P. Gas Control Valve & Burner Assembly Replacement Information .................................................................28
Housekeeping .....................................................................................................................................................28
Anode Rod Inspection.........................................................................................................................................28
Temperature-Pressure Relief Valve Operation......................................................................................................29
Draining..............................................................................................................................................................29
Drain Valve Washer Replacement.......................................................................................................................29
Service ................................................................................................................................................................29
Leakage Checkpoints............................................................................................................30
Troubleshooting.......................................................................................................................31-33
Repair Parts
....................................................................................................................................34-37
4
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Introduction
Thank You
for purchasing this water heater. When
WARNING
installed according to State and Local Codes and main-
tained according to the manufacturers instructions, 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.
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.
3. If after reading this manual you have any questions or
do not understand any portion of the instructions, call
the local gas utility or the manufacturer whose name
appears on the rating plate.
4. Carefully plan the place where you are going to put the
water heater. Correct combustion, vent action, and
intake air and exhaust 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 writ-
ing 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 having
equivalent NOx requirements.
5
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Typical Installation
INTAKE FOR
COMBUSTION
Vacuum Relief required
by some codes
(refer to local codes)
AIR
EXHAUST
VENT TO
OUTDOORS
AIR INTAKE PIPE
COLD WATER INLET
Some models are equipped with
circulating loop fittings.
FLUE PRODUCTS
DISCHARGE PIPE
*HOT (OUTLET) RECIRCULATING
LOOP CONNECTION CAN BE
INSTALLED WITHIN 360° RADIUS
SHUTOFF VALVE
HOT WATER OUTLET
TEMPERATUR
PRESSURE REL
VALVE
DIRECTION
OF FLOW
TEMPERED
WATER OUTLET
CHECK VALVE
MARKED WITH
DIRECTION OF
FLOW ARROW
MIXING
VALVE
DISCHARG
ECIRCULAT-
CTION MUST
LY IN THE
SITION
(Do not cap
PROVIDE A 6″
BETWEEN THE
THE DISCHA
AND DR
GAS
SUPPLY
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.
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.
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 peo-
ple 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 hard-
ware stores. Follow manufacturers instructions for
installation of these valves.
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
6. The location selection must provide adequate clearances
Facts to Consider About the
Location
for servicing and proper operation of the water heater.
WARNING
You should carefully choose an indoor location for the new water
heater, because the placement is a very important consideration
for the safety of the occupants in the building and for the most
economical use of the appliance. This water heater is not for use
in manufactured (mobile) homes or outdoor installation.
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 flash-
back 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.
Whether replacing an old water heater or installing 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 centralized with the water pip-
ing system as possible. The water heater, as all water heaters, will
eventually leak. Do not install without adequate drainage provi-
sions where water flow will cause damage.
2. If vented through an outside wall or through the roof using 3″ vent
piping, the total vent run (vertical and horizontal) cannot exceed
a total of 45 feet with one elbow. If more elbows are required,
the venting distance must be reduced 5 feet for every 90° elbow.
See page 15 for vent chart.
3. Vent piping cannot slope downward and horizontal runs require
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.
1
⁄
8″ per five foot rise. All horizontal runs require adequate support
1
at 3 ⁄2 foot intervals and vertical runs supported at 5 foot intervals.
4. The water heater requires its own (separate) venting system. 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 through an outside wall. Note:
Condensation may be created, at times, as the combustion gases
exit the vent cap and discoloration of surfaces in proximity to
the vent cap may occur.
WARNING
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
change to corrosive hydrochloric acid when exposed to the
combustion products of the water heater. The results can
be hazardous, and also cause product failure.
WARNING
The power direct vent water heater requires its own (separate)
venting 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 IN-
JURY, OR PROPERTY DAMAGE.
WARNING
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.
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.
WARNING
WARNING
Minimum clearances between the water heater and combustible
and non-combustible construction are: 0 inches from sides, 0
inches from back, 6 inches from front of jacket to closet door
and 12 inches from top of jacket to combustible and non-com-
bustible material. Minimum vent clearance: 0 inches. Provide 24
inches front clearance for servicing and adequate clearance
between the jacket top and ceiling for servicing the flue area.
Do not use an extension cord. If there is not a suitable recepta-
cle with ground and/or local codes prohibit use of a power cord,
field wiring must be provided.
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. When such locations cannot be avoid-
ed, 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 have a minimum length and width of at
least 2 inches greater than the water heater dimensions and must
be piped to an adequate drain. Drain pan depth must allow for
access to the outer doors for servicing the ignitor and burner.
Figure 1
7
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Locating the New Water Heater (cont’d)
Facts to Consider About the
Location (cont’d)
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 the
National Fuel Gas Code ANSI Z223.1.
WARNING
•
Do not install in a confined area such a closet, unless you
provide ventilation air as shown in the “Locating The New
Water Heater” section. Never obstruct the flow of ventila-
tion air. If you have any doubts or questions at all, call your
gas company. Failure to provide ventilation 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
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry clean-
ing equipment, it is imperative that the water heater or water
heaters be installed so that combustion and ventilation air be
taken from outside these areas. Refer to the “Locating The New
Water Heater” section of this manual and also the current edi-
tion of the National Fuel Gas Code, ANSI Z223.1, also referred
to as NFPA 54 for specifics provided concerning air required.
WARNING
Failure to have required clearances between water heater
and combustible material will result in a fire hazard.
9″ min. from
any overhang
Combustion Air and Exhaust
C
Lof Flue
12″ min.
WARNING
When determining the installation location for a power direct
vent water heater, snow accumulation and drifting should be
considered in areas where applicable.
Venting Through an Outside Wall – Clearances
0″ clearance for 3″ PVC, ABS, or CPVC Schedule 40 piping from
•
Figure 2
combustible surfaces.
18″ minimum in all directions from any obstruction, such as a wall,
•
that may interfere.
12″ minimum from the ground and corners, 9″ ceiling overhangs.
•
Figure 2.
The Power Direct Vent outlet terminal shall terminate at least 36″
•
above any forced air inlet located within 10 feet. Figure 3.
The Power Direct Vent outlet terminal of 50,000 BtuH input mod-
•
els or less shall terminate at least 9″ below, 9″ horizontally from or
9″ above any door, window or gravity air inlet into the building.
Figure 3.
PDV
The Power Direct Vent outlet terminal of over 50,000 BtuH input
•
TERMINAL
A
models shall terminate at least 12″ below, 12″ horizontally from or
12″ above any door, window or gravity air inlet into the building.
Figure 3.
“B”
A
A
36″ min. IF “B” DIMENSION
PDV
IS LESS THAN 120″
18″ minimum from other natural draft (gravity) direct vent, power
•
TERMINAL
vent or power direct vent appliance inlet and/or outlet vent(s) when
directly above or 135° to either side of center line. Figure 4, page 9.
12″ min.
FORCED AIR
INLET
24″ minimum from any appliance inlet and/or outlet vents when
•
directly below or 45° to either side of center line. Figure 4, page 9.
Figure 3
CORNER INSTALLATION
OF INLET AND OUTLET
The location selection must provide clearances for servicing and
proper operation of the water heater. Figure 5.
•
A - 9″ min. (50,000 BtuH
NOT RECOMMENDED
input models or less)
A - 12″ min. (over 50,000
BtuH input models)
Vent termination must not be within 4 feet of any items such as gas
meters, gas valves or other gas regulating equipment.
•
8
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Locating the New Water Heater (cont’d)
1
6 ⁄2″ MIN.
Venting Through Roof – Clearances
VENT OUTLET
AIR INTAKE
24″ MAX.
0″ clearance for 3″ PVC, ABS, or CPVC Schedule 40 piping
•
•
•
from combustible and noncombustible surfaces.
The vent exhaust outlet and air inlet terminals shall terminate at
least 18 inches above the roof surface. Figure 7.
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.
24″
NATURAL DRAFT (GRAVITY)
45˚
DIRECT VENT, POWER
VENT, OR POWER DIRECT
VENT APPLIANCE INLET
AND/OR OUTLET VENT(S).
90° STREET ELL
45° VENT CAP
W/SCREEN
Figure 4
Must maintain
adequate service
and maintenance
accessibility.
18″
Range of degrees
available for vent
pipe installation.
Figure 5
WIRE FENCE
When the water heater outlet terminal is low enough to be
touched accidentally, or is accessible to small children, a
wire mesh chain link fence (as shown in Figure 6) may be
used. Care should be taken to maintain adequate ventila-
tion around the outlet terminal. If a chain link fence is
installed, it must not be used as a storage area for items that
may block proper ventilation.
Air for Ventilation for
Appliances Located in
Confined Spaces
Air for ventilation should be provided if installed in a confined
space. Refer to the National Fuel Gas Code, ANSI Z223.1.
NOT TO BE USED AS
A STORAGE AREA
Figure 6
9
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Installing the New Water Heater
Water Piping
INTAKE FOR
WARNING
COMBUSTION
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
permanently injured by hot water than others. These
include the elderly, children, the infirm, or physical-
ly/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 instruc-
tions for installation of the valves. Before changing the
factory setting on the thermostat, read the “Temperature
Regulation” section in this manual.
AIR
EXHAUST VENT
TO OUTDOORS
AIR INTAKE
PIPE
SHUTOFF
VALVE
COLD INLET
WATER LINE
FLUE PRODUCTS
DISCHARGE PIPE
This water heater shall not be connected to any heating
systems or component(s) used with a non-potable water
heating appliance.
TEMPERATURE-
PRESSURE RELIEF
VALVE
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.
HOT OUTLET
TO HOUSE
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.
DISCHARGE PIPE
(Do not cap or plug)
PROVIDE A 6″ AIR
GAP BETWEEN THE
END OF THE
DISCHARGE PIPE
AND DRAIN
The illustration shows the attachment of the water piping to
3
GAS
SUPPLY
the water heater. The water heater is equipped with /4 inch
water connections.
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.
10
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Installing the New Water Heater (cont’d)
Temperature-Pressure Relief Valve
WARNING
WARNING
At the time of manufacture this water heater was provided
The temperature-pressure relief valve must be manually oper-
with a combination temperature-pressure relief valve certi-
ated at least once a year. Caution should be taken to ensure
fied by a nationally recognized testing laboratory that main-
that (1) no one is in front of or around the outlet of the tem-
tains periodic inspection of production of listed equipment
perature-pressure relief valve discharge line, and (2) the water
or materials, as meeting the requirements for Relief Valves
manually discharged will not cause any bodily injury or prop-
and Automatic Gas Shutoff Devices for Hot Water Supply
erty damage because the water may be extremely hot.
Systems, and the current edition of ANSI Z21.22 and the
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater, follow the draining instruc-
tions, and replace the temperature-pressure relief valve with
a new one.
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 by a nationally recognized testing
laboratory that maintains periodic inspection of production
of listed equipment or materials.
The valve must be marked with a maximum set pressure not
to exceed the marked hydrostatic working pressure of the
water heater (150 lbs./sq. in.) and a discharge capacity not
less than the water heater input rate as shown on the model
rating plate. (Electric heaters - watts divided by 1000 x
3412) equal BTU/Hr. rate.
COLD
HOT
Your local jurisdictional authority, while mandating the use
of a temperature-pressure relief valve complying with ANSI
Z21.22 and ASME, may require a valve model different from
the one furnished with the water heater.
Compliance with such local requirements must be satisfied
by the installer or end user of the water heater with a local-
ly prescribed temperature-pressure relief valve installed in
the designated opening in the water heater in place of the
factory furnished valve.
TEMPERATURE-
PRESSURE RELIEF
VALVE
TEMPERED
WATER
OUTLET
For safe operation of the water heater, the relief valve must
not be removed from it’s designated opening or plugged.
The temperature-pressure relief valve must be installed
directly into the fitting of the water heater designated for
the relief valve. Position the valve downward and provide
tubing so that any discharge will exit only within 6 inches
above, or at any distance below the structural floor. Be cer-
tain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in
size under any circumstances. Excessive length, over 30
feet, or use of more than four elbows can cause restriction
and reduce the discharge capacity of the valve.
DISCHARGE PIPE
(Do not cap or plug)
PROVIDE A 6″ AIR
GAP BETWEEN THE
END OF THE
DISCHARGE PIPE
AND DRAIN
No valve or other obstruction is to be placed between the
relief valve and the tank. Do not connect tubing directly to
RELIEF VALVE OPENING
″
discharge drain unless a 6 air gap is provided. To prevent
"THIS WATER HEATER IS PROVIDED WITH A COMBINATION TEMPERA-
TURE-PRESSURE RELIEF VALVE. FOR SAFE OPERATION OF THE WATER
HEATER, THE RELIEF VALVE(S) MUST NOT BE REMOVED FROM ITS DES-
IGNATED POINT OF INSTALLATION OR PLUGGED."
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.
YOUR LOCAL JURISDICTIONAL AUTHORITY, WHILE MANDATING THE USE
OF A TEMPERATURE-PRESSURE RELIEF VALVE COMPLYING WITH ANSI
Z21.22 AND ASME, MAY REQUIRE A VALVE MODEL DIFFERENT FROM THE
ONE FURNISHED WITH THE WATER HEATER.
The discharge pipe:
—Must not be smaller in size than the outlet pipe size of
the valve, or have any reducing couplings or other restric-
tion.
COMPLIANCE WITH SUCH LOCAL REQUIREMENTS MUST BE SATISFIED
BY THE INSTALLER OR END USER OF THE WATER HEATER WITH LOCAL-
LY PRESCRIBED TEMPERATURE-PRESSURE RELIEF VALVE INSTALLED IN
THE DESIGNATED OPENING IN THE WATER HEATER.
—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
SEE MANUAL HEADING—"TEMPERATURE-PRESSURE RELIEF VALVES"
FOR INSTALLATION AND MAINTENANCE OF RELIEF VALVE. DISCHARGE
LINE AND OTHER SAFETY PRECAUTIONS.
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.
11
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Installing the New Water Heater (cont’d)
You must provide all wiring of the proper size outside of
Filling the Water Heater
the water heater. You must obey local codes and electric
company requirements when you install this wiring.
CAUTION
If you are not familiar with electric codes and practices, or
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
if you have any doubt in your ability to connect the wiring
to this water heater, obtain the service of a competent elec-
trician. Contact a local electrical contractor and/or the local
electric utility.
WARNING
To fill the water heater with water:
1. Close the water heater drain valve by turning the han-
dle to the right (clockwise). The drain valve is on the
lower front of the water heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open
when the water heater is in use.
3. To insure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run
until a constant flow is obtained. This will let air out of
the water heater and the piping.
WATER HEATERS EQUIPPED FOR ONE TYPE VOLTAGE
ONLY: This water heater is equipped for 110/120 volts only.
DO NOT USE THIS WATER HEATER WITH ANY VOLTAGE
OTHER THAN THE ONE SHOWN ABOVE. Failure to use the
correct voltage can cause problems which can result in DEATH,
SERIOUS BODILY INJURY OR PROPERTY DAMAGE. If you
have nay questions or doubts consult your electric company.
CAUTION
If wiring from the fuse box or circuit breaker box was aluminum
for the old water heater, replace it with copper wire. If you wish
to reuse the existing aluminum wire, have the connection at the
water heater made by a competent electrician. Contact a local
electrical contractor and/or the local electric utility.
4. Check all new water piping for leaks. Repair as needed.
Wiring
The water heater comes equipped with a 7 foot power cord
which can be used to connect to a 110/120 volt power
source if, (1) local codes allow, and (2) there is a three
prong receptacle available. This unit must have a grounded
outlet to operate.
OPTIONAL Field Installed Wiring
1. Provide a way to easily shut off the electric power when
working on the water heater. This could be with a cir-
cuit breaker or fuse block in the entrance box or a sepa-
rate disconnect switch.
You must provide all wiring, (1) to a receptacle or, (2)
between the water heater and junction box when the
power cord is not used.
2. Install and connect a circuit directly from the main fuse
or circuit breaker box. This circuit must be the right size
and have its own fuse or circuit breaker.
WARNING
This appliance must be grounded for safety and to insure
proper operation. Failure to do so could result in DEATH,
SERIOUS BODILY INJURY OR PROPERTY DAMAGE.
WIRE NUTS
7’ MAXIMUM
CORD LENGTH
(Factory Supplied)
CONDUIT
GREEN
GROUND SCREW
1
WARNING
3. A standard ⁄2″ conduit opening has been made in the
water heater junction box for the conduit connection.
4. Use wire nuts and connect the power supply wiring to
the wires inside the water heater’s junction box.
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.
12
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Installing the New Water Heater (cont’d)
5. The water heater must be electrically “grounded” by
the installer. The unit will not operate unless it is prop-
erly grounded. For complete grounding details and all
allowable exceptions, refer to local codes or in the
absence of local codes, with the National Electrical
Code, ANSI/NFPA 70 (current edition).
6. Replace the wiring junction cover using the screws
provided.
Wiring Diagram
CAUTION
isconnection when servicing con-
cause improper and dangerous
operation. Verify proper operation after servicing.
WARNING
Venting
The vent pipe from the water heater must be 3″ diameter
1
vent pipe and must slope upward ⁄8 inch per five linear feet.
WARNING
All vent gases must be completely vented to the outdoors of
the structure (dwelling).
To insure proper venting of this gas-fired water heater, the
correct vent pipe diameter must be utilized. Any additions of
other gas appliances on vent with this water heater will
adversely affect the operation of the water heater.
1
MIN. RISE
⁄8
″
PER FIVE FEET
WARNING
The vent outlet must connect to the water heater exhaust out-
let. The vent inlet piping must connect to the water heater air
inlet. Both the water heater connections are clearly marked.
Failure to read this instruction can result in DEATH, SERIOUS
BODILY INJURY, OR PROPERTY DAMAGE.
WARNING
WARNING
Obstructed or deteriorated vent systems may present seri-
ous health risk or asphyxiation.
Failure to have required clearances between water heater
and combustible material will result in a fire hazard.
13
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Installing the New Water Heater (cont’d)
Venting (cont’d)
1. The water heater requires its own (separate) venting
WARNING
system.
Be sure vent pipe is properly connected to prevent
escape of dangerous flue gases which could cause dead-
ly asphyxiation.
2. Only 3″ ABS Schedule 40 piping and fittings are accept-
able materials on the first five feet of the outlet vent system.
3. 3″ PCV, ABS, or CPVC Schedule 40 piping and fittings are
acceptable materials for the inlet vent system and for the
outlet vent system after the first five feet.
WARNING
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chem-
ical vapors. Spray can propellants, cleaning solvents,
refrigerator and air conditioner refrigerants, swimming
pool chemicals, calcium and sodium chloride, waxes,
bleach and process chemicals are typical compounds
which are potentially corrosive.
4. It cannot be connected to existing vent piping or chimney.
5. When venting through an outside wall, the vents must ter-
minate horizontally to the outdoors.
B. ALL 40 AND 50 GALLON 40,000 BTU/HR MODELS
1
3 ⁄2
'
In the carton is supplied:
1. Two 3″ inlet and outlet PVC Schedule 40 - 45° vent caps.
All other piping must be supplied by the supplier.
ONE 3″ SCHEDULE
40 PVC 45° INLET
STRAPPING
ELBOW SUPPLIED
TWO 3″ PVC SCHEDULE
40 90° STREET
ELBOW
REQUIRED*
SCHEDULE
40 PVC INLET AND
ONE 3″ SCHEDULE
OUTLET PIPE
40 PVC 45° OUTLET
REQUIRED
ELBOW SUPPLIED
1
Horizontal runs must be securely supported at 3 ⁄2 foot
intervals and vertical runs supported at 5 foot intervals.
VENTING THROUGH AN OUTSIDE WALL
A. ALL 75 GALLON MODELS AND 50 GALLON 65,000
BTU/HR MODELS
* If making an immediate horizontal run of vent off the
blower, two 3″ PVC or ABS schedule 40 street elbows
are required
In the carton is supplied:
1. Two 3″ inlet and outlet PVC Schedule 40 - 45° vent caps.
2. A 3″ ABS Schedule 40 - 90 street ell; used to connect the out-
let vent pipe to the water heater when the outlet vent pipe is
to be turned horizontally directly off the blower.
1. The water heater requires its own (separate) venting
system.
2. 3″ PVC, ABS, or CPVC Schedule 40 piping and fittings
are acceptable materials for the vent system on all 40
and 50 gallon models.
3. A 5‘ section of 3″ ABS Schedule 40 outlet vent pipe (more may
be required and must be supplied locally).
3. It cannot be connected to existing vent piping or
chimney.
ONE
3
″
SCHEDULE
3″ ABS SCHEDULE 40
90° STREET
40 PVC 45° INLET
ELBOW SUPPLIED
4. When venting through an outside wall, the vents must
terminate horizontally to the outdoors.
OUTLET ELBOW
SUPPLIED
5' SCHEDULE
40 ABS OUTLET
PIPE SUPPLIED
3″ PVC SCHEDULE
40 90° STREET
INLET ELBOW
REQUIRED
SCHEDULE
40 PVC INLET PIPE
REQUIRED
ONE
3″
SCHEDULE
40 PVC 45° OUTLET
ELBOW SUPPLIED
14
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Installing the New Water Heater (cont'd)
VENTING SYSTEM EXAMPLE INSTALLATIONS FOR
ALL MODELS
3 ELBOW
EXAMPLE
1
MIN. RISE
⁄8
″
PER FIVE FEET
The vent piping cannot under any circumstances be run
downhill.
CAULK
JOINT
1
MIN. RISE
⁄8
″
PER FIVE FEET
2.The total vertical and horizontal vent runs cannot exceed
the maximum length with the number of 90˚ elbows as
specified in the table below. If more elbows are required,
the venting distance must be reduced 5 feet for every 90°
elbow:
The vent piping can be installed as follows:
1
1.Horizontal runs require a minimum /8″ rise per five feet.
3″ DIA. VENTS
NUMBER OF 90˚ DEG.
ELBOWS*
MAX. LENGTH (FT.)
45
40
35
1
2
3
3 ELBOW
EXAMPLE
*NOTE: Two 45˚ elbows are equivalent to one 90° elbow.
One 90˚ elbow equals 5 feet of equivalent vent length.
1
MIN. RISE
⁄8
″
PER FIVE FEET
1 ELBOW
EXAMPLE
45′ MAX.
18″ MIN.
1
1
11 ⁄4″ MIN.
1
13 ⁄4″ MIN.
MIN. RISE
⁄8
″
PER FIVE FEET
1 ELBOW
EXAMPLE
38′
1
MIN. RISE
⁄8
″
3 ELBOW
EXAMPLE
PER FIVE FEET
7″
1
MIN. RISE
⁄
8
″
ONE ELBOW
PER FIVE FEET
3.Minimum vent length for all models is 18 inches.
15
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Installing the New Water Heater (cont'd)
VENT PIPE SEPARATION
Cementing PVC, ABS OR CPVC Pipe and Fittings
The inlet and outlet vent pipes must be separated by a min-
Read and observe all safety information printed on primer,
cleaner, and cement containers.
1
imum distance of 6 ⁄2 inches up to 24 inches maximum.
DANGER
1
6 ⁄2″ MIN.
24″ MAX.
Primer, cleaner, and cements are extremely flammable.
They are harmful or fatal if swallowed. The vapors are
harmful. They may irritate eyes and skin and can be
absorbed through the skin.
PRECAUTIONS
Always store primers, cleaner, and cements in cool, dry,
well ventilated places. Do not store them near heat,
sparks, or flames. Keep containers closed. Use them in
well ventilated areas. Wear impervious clothing while
handling. Do not smoke, eat, or drink while handling.
Wash thoroughly after handling and before eating. Wear
eye protection when handling. If swallowed, drink water,
do not induce vomiting, and call a physician or poison
control center immediately. If inhaled, get fresh air and
seek medical attention if ill feelings persist. In case of eye
and skin contact, immediately flush with plenty of water
for 15 minutes and seek medical attention if irritation
persists. KEEP OUT OF REACH OF CHILDREN.
CUTTING OPENINGS THROUGH AN OUTSIDE WALL
AND COLLAR INSTALLATION
After reading the manual and you have determined the
location of the opening in the wall, (using the drawing
1
below), cut one 3 ⁄2″ diameter hole for the inlet vent pip-
1
ing and one 3 ⁄2″ diameter hole for the outlet vent piping
through an exterior wall.
NOTE: When determining location of the openings in the
1
outside wall allow for the ⁄8″ rise per five feet that has
taken place in the horizontal run.
All primers, cleaners, and cements must meet all local
codes and applicable standards of the American Society
For Testing Materials Standards.
C
L OF FLUE
1
1
″
11
⁄
2
MIN.
Before using primers, cleaners, and cements, stir or shake,
making sure contents are liquid. Do not use if found to be
lumpy or jelly-like.
MIN. RISE
⁄8
″
PER FIVE FEET
1. Cut pipe ends squarely removing all burrs and dirt.
2. Dry fit pipe and fittings to be connected for proper fit.
3. Clean pipe and fitting with a primer/cleaner.
4. Apply a thin coat of cement to fitting, avoiding puddling
inside.
5. Apply a liberal coat of cement to pipe leaving no voids.
6. QUICKLY assemble parts while cement is fluid! If you
wait too long, re-coat pipes.
1
40 GAL.– 48 ⁄2″
1
50 GAL.– 57 ⁄2″
50 GAL.
(65,000 BTU) – 61″
75 GAL.– 63″
7. Push pipe completely into socket of fitting, turning as it
goes until it bottoms.
8. Hold pipe and fitting together for 30 seconds. Then care-
fully clean off excess with a cloth. Allow connections a
sufficient time to cure before disturbing.
9. Remember that vent pipes must be adequately and
securely supported.
The 3″ PVC, ABS or CPVC Schedule 40 vent pipe can be
run from the water heater through the wall or from the wall
to the water heater, whichever is most convenient. The vent
1
pipe must extend a minimum of 1 ⁄2″ through the exterior
1
APPROXIMATE SETTING TIME FOR 2 ⁄2″ TO 4″ PIPE
wall. Extending the vent cap as far as possible from the sur-
face of the exterior wall will help minimize discoloration of
the wall. Note that the inside flue mounting adaptors must
be slipped over the vent piping before locating the pipe
through the wall. Before securing the inside and outside
collars to the wall, use a silicone sealer between pipe and
opening to insure a water and air tight seal.
JOINTS
MOVEMENT
COMPLETE
SET
8 hrs.
15 hrs.
18 hrs.
OF JOINT
3
90°F to 150°F
50°F to 90°F
0°F to 50°F
⁄4
hr.
1 hr.
1
1 ⁄3 hr.
16
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Installing the New Water Heater (cont'd)
Venting (cont'd)
INSTALLATION SHOWING USE OF (OPTIONAL)
DELUXE HORIZONTAL VENT KIT:
INSTALLATION SHOWING USE OF PVC, ABS OR
CPVC PIPE FOR INLET AND OUTLET VENT PIPING:
Typical installation.
Inlet piping through any type wall.
AIR INTAKE
PIPE
EXTERIOR WALL
SILICONE
SEALER
VENT TO
OUTDOORS
INTAKE FOR
COMBUSTION AIR
1
1 ⁄2″ MIN. EXTENSION
THROUGH
EXTERIOR WALL
FLUE PRODUCTS
DISCHARGE PIPE
VENT CAP MUST
BE POSITIONED
DOWNWARD
SCREW
SCREW
SCREW
SCREW
SCREEN AT
OUTLET
FLUE MOUNTING ADAPTOR
FLUE MOUNTING
ADAPTOR
SILICONE SEALER
CONNECTING VENT TO BLOWER
1. If making an immediate horizontal run of vent off the
blower, one 3″ PVC inlet and one 3″ PVC (ABS for 75
Gal. Models and 50 Gal. 65,000 Btu/Hr Models) outlet
Schedule 40 street elbows are required. Place the elbow
in the required direction on the blower and using 3 sheet
metal screws, attach the elbow.
CAULK
JOINTS
2. If there is to be a vertical run of vent from the blower, the
3″ PVC inlet and the 3″ PVC (ABS for 75 Gal. Models
and 50 Gal. 65,000 Btu/Hr Models) outlet pipes must
be attached to the blower and venting hood, using 6
sheet metal screws.
If this concentric flue, through the wall type of venting sys-
tem is preferred, the vent kit can be ordered from the
Service Parts Dept. under kit #9002749. See also pages 34
to 37. Installation instructions are provided with the kit.
VENTING THROUGH A ROOF
CAULK
JOINTS
Two 3″ inlet and outlet PVC Schedule 40 45° vent caps are
supplied.
A 5’ section of 3″ ABS Schedule 40 outlet vent pipe (75 Gal.
Models and 50 Gal. 65,000 Btu/Hr Models only) is sup-
plied. (More may be required and must be supplied locally).
1. The water heater requires its own (separate) venting
system.
17
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Installing the New Water Heater (cont’d)
VENTING THROUGH A ROOF (CONT’D)
Gas Piping
2. Only 3″ ABS Schedule 40 piping and fittings are acceptable
materials on the first five feet of the outlet vent system of 75
Gal. Models and 50 Gal. 65,000 Btu/Hr Models only.
WARNING
3. 3″ PVC, ABS, or CPVC Schedule 40 piping and fittings are
acceptable materials for the inlet vent system and for the out-
let vent system (after the first five feet for 75 Gal. Models and
50 Gal. 65,000 Btu/Hr Models only).
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not
exceed 10.5 in. water column (2.6kPa)for natural gas or
13 in. water column (3.2 kPa) for propane (L.P.) gas. The
minimum inlet gas pressure listed on the rating plate is
for the purpose of input adjustment.
4. It cannot be connected to existing vent piping or chimney.
5. It must terminate vertically to the outdoors.
6. The total vertical and horizontal vent runs cannot exceed the
maximum length with a maximum number of 90˚ elbows as
specified in the table below. If more elbows are required, the
venting distance must be reduced 5 feet for every 90° elbow.
WARNING
If the gas control valve is subjected to pressure exceed-
1
ing /2 pound per square inch (3.5kPa), the damage to
the gas control valve could result in a fire or explosion
from leaking gas.
3″ DIA. VENTS
NUMBER OF 90˚ DEG.
ELBOWS*
MAX. LENGTH (FT.)
45
40
35
1
2
3
WARNING
If the main gas line shutoff serving all gas appliances is used,
also turn “OFF” the gas at each appliance. Leave all gas
appliances turned “OFF” until the water heater installation
is complete.
*NOTE: Two 45˚ elbows are equivalent to one 90˚ elbow.
One 90˚ elbow equals 5 feet of equivalent vent length.
A gas line of sufficient size must be run to the water heater.
Consult the current edition of National Fuel Gas Code ANSI
Z223.1, also referred to as NFPA 54 and the gas company
concerning pipe size.
There must be:
—A readily accessible manual shut off valve in the gas sup-
ply line serving the water heater, and
—A drip leg (sediment trap) ahead of the gas control valve
to help prevent dirt and foreign materials from entering
the gas control valve.
—A flexible gas connector or a ground joint union between
the shutoff valve and control valve to permit servicing of
the unit.
Be sure to check all the gas piping for leaks before lighting
the water heater. Use a soapy water solution, not a match
or open flame. Rinse off soapy solution and wipe dry.
When installed at elevations above 2,000 feet, input rat-
ings should be reduced at the rate of 4 percent for each
1,000 feet above sea level which requires replacement of
the burner orifice in accordance with the National Fuel Gas
Code ANSI Z223.1 / NFPA 54. Contact your local gas util-
ity for further information.
WARNING
TOTAL VERTICAL AND
HORIZONTAL RUNS - SEE
CHART ABOVE (ITEM 6).
Failure to replace the orifice could result in improper and
inefficient operation of the appliance, producing carbon
monoxide gas in excess of safe limits, which could result in
serious injury or death. Contact your gas supplier for any
specific changes which may be required in your area.
18
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Installing the New Water Heater (cont’d)
GAS PIPING WITH
FLEXIBLE CONNECTOR
GAS SUPPLY PIPING
WARNING
The appliance and its individual shutoff valve must be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
1
excess of /2 pound per square inch (3.5kPa).
The appliance must be isolated from the gas supply pip-
ing system by closing its individual manual shutoff valve
during any pressure testing of the gas supply piping sys-
MANUAL
SHUTOFF
VALVE
1
tem at test pressures equal to or less than /2 pound per
square inch (3.5kPa).
FLEXIBLE GAS CONNECTOR
LABELED AS COMPLYING
WITH ANSI STANDARDS
WARNING
GROUND JOINT
UNION (OPTIONAL)
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
WARNING
DRIP LEG
(SEDIMENT
TRAP)
GAS
CONTROL
VALVE
Use pipe joint compound or teflon tape marked as being resis-
tant to the action of petroleum [Propane (L.P.)] gases.
3″ MIN.
CAP
Connecting the gas piping to the gas control valve of the
water heater can be accomplished by either of the two
methods shown.
GAS PIPING WITH ALL BLACK IRON PIPE TO
GAS CONTROL
SEDIMENT TRAP
A sediment trap shall be installed as close to the inlet of the
water heater as practical at the time or water heater instal-
lation. The sediment trap shall be either a tee fitting with a
capped nipple in the bottom outlet or other device recog-
nized as an effective sediment trap. If a tee fitting is used, it
shall be installed in conformance with one of the methods
of installation shown.
GAS SUPPLY PIPING
MANUAL
SHUTOFF
VALVE
WARNING
Contaminants in the gas lines may cause improper oper-
ation of the gas control valve that may result in fire or
explosion. Before attaching the gas line be sure that all
gas pipe is clean on the inside. To trap any dirt or foreign
material in the gas supply line, a drip leg (sometimes
called a sediment trap) must be incorporated in the pip-
ing. The drip leg must be readily accessible. Install in
accordance with the “Gas Piping” section. Refer to the
current edition of the National Fuel Gas Code, ANSI
Z223.1, also referred to as NFPA 54.
GROUND JOINT
UNION
BLACK PIPE
DRIP LEG
GAS
(SEDIMENT
TRAP)
3″ MIN.
CONTROL
VALVE
CAP
19
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Installing the New Water Heater (cont’d)
Installation Checklist
BEFORE OPERATING THE WATER HEATER:
4. Is the water heater completely filled with water? See “Filling
the Water Heater” instructions in the “Installing the New
Water Heater” section.
1. Check the gas line for leaks.
5. Will a water leak damage anything? See the “Locating the
a. Use a soapy water solution. DO NOT test for gas leaks
New Water Heater” section.
using a match or open flame.
6. Is there proper clearance between the water heater and any-
thing that might catch fire? See the “Locating the New Water
Heater” section.
7. Do you have adequate ventilation so that the water heater
will operate properly? See “Combustion Air and Ventilation”
in the “Locating the New Water Heater” section.
b. Brush the soapy water solution on all gas pipes, joints
and fittings.
c. Check for bubbling soap. This means you have a leak.
Turn “OFF” gas and make the necessary repairs.
d. Recheck for leaks.
e. Rinse off soapy solution and wipe dry.
2. Is the new temperature-pressure relief valve properly
installed and piped to an adequate drain? See “Temperature-
Pressure Relief Valve” section.
3. Are the cold and hot water lines connected to the water
heater correctly? See “Water Piping” instructions in the
“Installing the New Water Heater” section.
8. Is the vent piping properly secured? See “Venting” instruc-
tions in the “Installing the New Water Heater” section.
9. Is there proper clearance between the vent pipe and any-
thing that might catch fire? See “Venting” instructions in the
“Installing the New Water Heater” section.
10. Is the vent pipe properly sloped and does the vent terminate
outdoors? See “Venting” instructions in the “Installing the
New Water Heater” section.
INTAKE FOR
COMBUSTION
AIR
11. Do you need to call your gas company to check the gas pipe
and its hookup?
Vacuum Relief
required by
some codes
(refer to local
codes)
EXHAUST
VENT TO
OUTDOORS
AIR INTAKE PIPE
COLD WATER INLET
FLUE PRODUCTS
DISCHARGE PIPE
SHUTOFF VALVE
HOT
WATER
OUTLET
TEMPERATURE-
PRESSURE RELIEF
VALVE
TEMPERED
WATER
OUTLET
DISCHARGE PIPE
(Do not cap or plug)
SUITABLE FOR WATER (POTABLE)
HEATING AND SPACE HEATING
PROVIDE A 6″ AIR
GAP BETWEEN THE
END OF THE
DISCHARGE PIPE
AND DRAIN
GAS
SUPPLY
SHUTOFF
VALVE
AUTOMATIC STORAGE WATER HEATER
FOR DIRECT VENT INSTALLATION
ELECTRICAL RATING: VOLTS 115/HZ60/AMPS 2
TEE
DRIP LEG
(Sediment trap)
PIPE CAP
MODEL RATING PLATE
20
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Operating
BLOWER MOTOR
This water heater is equipped with an electrically operated
venting system and electronic control. For the burner to
come on, the water heater thermostat must call for heat.
Then the system will begin sequencing, each section prov-
ing itself before gas is allowed to flow to the burner.
VENTING MANUAL
RESET SWITCH
BEFORE THE WATER HEATER WILL OPERATE:
VENTING HOOD
ON/OFF SWITCH
1. The control system must be connected to a grounded
110/120 volt power supply. The control system has an
overall rating of 2 amps. The water heater must be
securely and adequately grounded in accordance with
local codes and with the current edition of the National
Electrical Code ANSI/NFPA 70.
2. The ON/OFF toggle switch, located on the control box
above the thermostat must be in the “ON” position for
the electrical control system to operate allowing the gas
portion to operate (ignite burner).
AIR PRESSURE
SWITCH
3. The venting manual reset switch must be in the closed
position. See “Venting Manual Reset Switch” in the “For
Your Information” section.
4. There is a non-resettable hi-limit switch in the thermo-
stat, which must be good (closed) for the thermostat to
be operated. See “High Temperature Shut Off System”
in the “For Your Information” section.
ALL MODELS
OPERATION
When the thermostat calls for heat, gas is allowed to flow
to a (N/O) pressure switch closing it. An electrical circuit is
then made to the blower, turning it on. When the blower
has achieved sufficient venting, the air pressure switch will
close. A 120 volt circuit will be completed through the
venting manual reset switch and on to the 120 volt gas
valve. The 120 volt gas valve will open allowing gas to
flow to the burner. The hot surface ignitor will establish a
main burner flame.
120V GAS VALVE
BURNER
HOT SURFACE
IGNITOR
21
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Operating (cont’d)
3. The control module:
WARNING
BEFORE OPERATING [PROPANE (L.P.) GAS WATER
HEATERS]: Propane (L.P.) gas is heavier than air. Should
there be a leak in the system, the gas will settle near the
ground. Basements, crawl spaces, skirted areas under
manufactured (mobile) homes (even when ventilated),
closets and areas below ground level will serve as pock-
ets for the accumulation of this gas. Before attempting
to operate the water heater or turning a nearby electri-
cal light switch, be absolutely sure there is no accumu-
lated gas in the area. Search for odor of gas by sniffing
at ground level in the vicinity of the appliance. If odor
is detected, follow the steps indicated at “For Your
Safety” on the cover page of this manual, then leave the
premises.
a) Checks the pressure switch for an open circuit.
b) Energizes the blower.
c) Checks the pressure switch for a closed circuit to
prove draft.
d) Sends line voltage to the hot surface igniter with a
20-second warm up period.
e) Opens the gas valve and checks the sensing rod for
flame.
4. The burner heats the water to the desired thermostat
setting.
a) The resistance in the thermostat rises to the value
selected by the temperature control knob.
b) The control module closes the gas valve and 5
seconds later, removes power from the blower.
Operating instructions are located on front of the water
heater, above or to one side of the gas control valve. See
page 23.
5. Cycle is completed.
CONTROL SEQUENCE - HOT SURFACE DIRECT IGNITION
WARNING
AN ODORANT IS ADDED TO THE GAS USED BY
THIS WATER HEATER.
Pre-purge
5 sec.
20 sec.
4 sec.
1sec.
4 sec.
5 sec.
5 sec.
2
HSI Warm-up
Ignition Activation Period
Flame Recognition Period
Ignition Trial
FOR YOUR SAFETY
IF YOU SMELL GAS:
Interpurge
1. Do not try to light any appliance.
2. Do not touch any electrical switch; do not use any
phone in your building.
Post-purge
Retries
3. Immediately call you gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
4. If you cannot reach your gas supplier, call the fire
department.
Reset from Lockout
Flame Sensing (Nominal)
HSI Off/Run Mode
1 hr.
4.0 µ DC
CHECK FOR LEAKS
Be sure to check all your gas pipes for leaks before operat-
ing your water heater. Use a soapy water solution, not a
match or open flame. Check the factory gas fittings when
the main burner is turned “ON”.
WATER HEATING IGNITION SEQUENCE
(Make sure gas and electric power are connected properly)
1. The ignition control module is powered and monitors the
system, waiting for a call for heat from the thermostat.
2. The thermostat calls for heat by reading a resistance
value within a given range directly proportional to water
temperature.
22
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Operating (cont’d)
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss
of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. Do NOT try to light the burner by hand.
B. BEFORE OPERATING smell all around the
appliance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and will
settle on the floor.
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in the gas control but-
tons. Never use tools. If the control buttons will not
push in, don’t try to repair them, call a qualified ser-
vice technician. Force or attempted repair may
result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS:
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of
the control system and any gas control which has
been under water.
•
•
Do not try to light any appliance.
Do not touch any electric switch;
do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
•
OPERATING INSTRUCTIONS
5. This appliance is equipped with a device which auto-
matically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
VACATION
6. Wait five (5) minutes to
If you then smell gas,
clear out any gas.
STOP! Follow “B” in
A
B
C
VERY
HOT
WARM
the safety information above on this label. If you don’t
COOLER
HOTTER
smell gas, go to the next step.
7. Turn on all electrical power to the appliance.
8. Set the ON/OFF switch on the control box to the “ON”
--------------
----------------------- ---------------------- ------------------------------
------------------------------------------------------
position.
* -----------------------------------------------------------------------
* ----------------------------------------------------------
9. Set the thermostat to desired setting by first pressing
--------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
* ------------------------------------------------------------------------
the COOLER
and holding for 1 second. Then press the HOTTER
button
and HOTTER
buttons together
-----------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------
.
10. WATER TEMPERATURE ADJUSTMENT
is
1.
STOP! Read the safety information above
on this label.
approximately 120˚F.
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
2. Set the ON/OFF switch on the control box to the “ON”
position.
3. Set the thermostat to the lowest setting by first press-
ing the COOLER
together and holding for 1 second. Then press the
COOLER button
appears.
and HOTTER
buttons
11. If the appliance will not operate, follow the instruc-
tions “TO TURN OFF GAS TO APPLIANCE” and
call your technician or gas supplier.
until the WARM indicator light
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING
4. Set the ON/OFF switch on the control box to the
“OFF” position.
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat to the lowest setting by first pressing
2. Set the ON/OFF switch on the control box to the
“OFF” position.
3. Turn off all electric power to the appliance if service
is to be performed.
the COOLER
and holding for 1 second. Then press the COOLER
button until the WARM indicator light appears.
and HOTTER
buttons together
23
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Temperature Regulation
changing the temperature setting. To change the tempera-
ture setting follow these instructions:
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30°F high-
er or lower at the point of use such as, bathtubs, showers,
sink, etc.
1. “Wake Up” the temperature indicators by holding down
both “COOLER” and “HOTTER” temperature adjust-
ment buttons at the same time for one second (See
Figure below). One or two of the temperature indicators
will light up. These indicators will only remain on for
30 seconds if no further buttons are pressed. After 30
seconds the control will go back to “Sleep” mode.
Any water heaters intended purpose is to heat water. Hot
water is needed for cleaning, (bodies, dishes, clothing). Hot
water will present a scald hazard. Depending on the time
element, and the people involved (normal adults, children,
toddlers, elderly, infirm, etc.) scalding may occur at differ-
ent temperatures.
2. Release both of the temperature adjustment buttons.
WARNING
A. To decrease the temperature press and release the
“COOLER” button until the desired setting is reached.
HOTTER WATER CAN SCALD: Water heaters are intend-
ed to produce hot water. Water heated to a temperature
which will satisfy clothes washing, dish washing, and other
sanitizing needs can scald and permanently injure you
upon contact. Some people are more likely to be perma-
nently injured by hot water than others. These include the
elderly, children, the infirm, or physically/mentally hand-
icapped. If anyone using hot water in your home fits into
one of these groups or if there is a local code or state law
requiring a certain temperature water at the hot water tap,
then you must take special precautions. In addition to
using the lowest possible temperature setting that satisfies
your hot water needs, some type of tempering device, such
as a mixing valve, should be used at the hot water taps
used by these people or at the water heater. Mixing valves
are available at plumbing supply or hardware stores. A
qualified plumber should be consulted. Follow manufac-
turers instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
b. To increase the temperature press and release the
“HOTTER” button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower
or raise the temperature setting. The button must be pressed
and released for each temperature change desired.
TEMPERATURE INDICATORS
WARNING
Never allow small children to use a hot water tap, or to
draw their own bath water. Never leave a child or hand-
icapped person unattended in a bathtub or shower.
TEMPERATURE ADJUSTMENT BUTTONS
The thermostat of this water heater has been factory set at
its lowest position, to reduce the risk of scald injury. It is
adjustable and must be reset to the desired temperature set-
ting. The mark ( ▼ ) (on temperature setting of gas valve)
indicative of approximately 120°F is preferred starting
point. Some states have a requirement for a lower setting. If
you need hotter water, follow directions for temperature
adjustment, but beware of the warnings in this section.
Time to Produce
2nd & 3rd Degree
Burns on Adult Skin
Display
▼ A B C
Temperature Setting
C - Flashing = approx. 160°F
C = approx. 150°F
● ● ● ● ● ● About 1/2 seconds
● ● ● ● ● ● About 1-1/2 seconds
● ● ● ● ● ● Less than 5 seconds
● ● ● ● ● ● About 30 seconds
● ● ● ● ● ● More than 5 minutes
● ● ● ● ● ● - - - - - - - - - - - - - - - -
B = approx. 140°F
A = approx. 130°F
▼ = approx. 120°F
●
Pressing the “COOLER”
button decreases temperature
●
WARM = approx. 80°F
and pressing the “HOTTER”
perature.
button increases the tem-
NOTE: Water temperature range of 120°–140°F recom-
mended by most dishwasher manufacturers.
To avoid any unintentional changes in water temperature
settings, the control has a tamper resistant feature for
WARNING
Should overheating occur or the gas supply fail to shut off,
turn “OFF” the manual gas control valve to the appliance.
24
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For Your Information
Start Up Conditions
It is recommended that any devices installed which could
create a closed system have a by-pass and/or the system
have an expansion tank to relieve the pressure built by ther-
mal expansion in the water system. Expansion tanks are
available for ordering through local plumbing supply hous-
es. Contact the local water supplier and/or plumbing con-
tractor for assistance in controlling these situations.
CONDENSATION
Whenever the water heater is filled with cold water, a cer-
tain amount of condensation will form while the burner is
on. A water heater may appear to be leaking when in fact
the water is condensing. This usually happens when:
a. When a new water heater is filled with cold water for
the first time.
b. When gas burns and water vapor is produced in water
heaters, particularly high efficiency models where flue
temperatures are lower.
c. When you use large amounts of hot water in a short
time and the refill water is very cold.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
represent harmful or dangerous conditions.
Moisture from the products of combustion condenses on
the cooler tank surfaces and form drops of water which may
fall onto the burner or other hot surfaces and produce a
“sizzling” or “frying” noise.
Condensation causes sizzling and popping with the burner
area during heating and cooling periods and should be con-
sidered normal. See “Condensation” in this section.
Because of the suddenness and amount of water, conden-
sation water may be diagnosed as a “tank leak”. After the
water in the tank warms up (about 1-2 hours), the condi-
tion should disappear.
Operational Conditions
SMELLY WATER
Do not assume the water heater is leaking until there has
been enough time for the water in the tank to warm up.
In each water heater there is installed at least one anode
rod (see parts section) for corrosion protection of the tank.
Certain water conditions will cause a reaction between this
rod and the water. The most common complaint associated
with the anode rod is one of a “rotten egg smell”. This odor
is derived from hydrogen sulfide gas dissolved in the water.
The smell is the result of four factors which must all be pre-
sent for the odor to develop:
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the fami-
ly’s demands for hot water including dishwashers, washing
machines and shower heads.
Excessive condensation may be noticed during the winter
and early spring months when incoming water tempera-
tures are at their lowest.
a. a concentration of sulfate in the supply water.
b. little or no dissolved oxygen in the water.
c. a sulfate reducing bacteria within the water heater.
(This harmless bacteria is non-toxic to humans.)
d. an excess of active hydrogen in the tank. This is caused
by the corrosion protective action of the anode.
Good venting is essential for a gas fired water heater to
operate properly as well as to carry away products of com-
bustion and water vapor.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less
active material, and then chlorinating the water heater tank
and all hot water lines. Contact the local water heater sup-
plier for further information concerning an Anode
Replacement Kit #9000029 and this Chlorination
Treatment.
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke
and odor during the initial start-up. This is due to burning
off of oil from metal parts, and will disappear in a short
while.
THERMAL EXPANSION
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that continu-
ous chlorination and filtering conditioning equipment be
considered to eliminate the water problem.
Because of such events as high line pressure, frequent cut-
offs, the effects of water hammer among others, water sup-
ply systems may have installed devices such as pressure
reducing valves, check valves, back flow preventers, etc...to
control these types of problems. When these devices are
not equipped with an internal by-pass, and no other mea-
sures are taken, the devices cause the water system to be
closed. As water is heated, it expands (thermal expansion)
and closed systems do not allow for the expansion of heat-
ed water.
Do not remove the anode leaving the tank unprotected.
By doing so, all warranty on the water heater tank is
voided.
The water within the water heater tank expands as it is heat-
ed and increases the pressure of the water system. If the
relieving point of the water heater’s temperature-pressure
relief valve is reached, the valve will relieve the excess pres-
sure. The temperature-pressure relief valve is not intended
for the constant relief of thermal expansion. This is an
unacceptable condition and must be corrected.
25
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For Your Information (cont’d)
Operational Conditions (cont’d)
“AIR” IN HOT WATER FAUCETS
HIGH TEMPERATURE LIMIT SWITCH
(Single-Use Type Energy Cut Off)
The thermostat has a built-in limit switch which will actuate
in case of excessive water temperatures. The heater cannot
be relit until the gas control valve is replaced. It is important
that a serviceman be called to determine the reason for limit
operation and thus avoid repeated thermostat replacement.
Lower the temperature adjustment setting on new control.
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 pos-
sibility of injury under these conditions, 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
dishwasher or washing machine). If hydrogen gas is pre-
sent, 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
Should overheating occur or the gas supply fail to shut
off, turn “off” the manual gas control valve to the
appliance.
NOT ENOUGH OR NO HOT WATER
1. Check the manual gas shut off valve to be sure it is open.
VENTING MANUAL RESET SWITCH
2. The ON/OFF switch on the control box must be “ON”.
There is a venting manual reset switch located on the vent-
ing hood. If the switch is activated, it will not reset itself.
Before resetting this reset switch, check for flue blockage
and propriety of the venting system. To reset, press the red
button.
3. The temperature button adjustment may be set too low.
See the “Temperature Regulation” section.
4. The gas company can check the gas input to see if it is
correct. An underfired water heater will not heat water as
quickly.
5. Look for leaking or open hot water faucet’s. Make sure
all are closed.
VENTING MANUAL
RESET SWITCH
BLOWER MOTOR
6. The cold water inlet temperature may be colder during
the winter months. It will take longer to heat the water
and seem like less hot water.
7. If you cannot find what is wrong, call the local gas util-
ity and/or plumbing contractor.
WATER IS TOO HOT
1. The temperature adjustment setting may be set too high.
See the “Temperature Regulation” section.
NOTE: A period of time is necessary after an adjust-
ment has been made for the water temperature to
reach the new temperature setting.
VENTING HOOD
2. If lower temperature settings will not lower the water
temperature, call the local gas utility.
26
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Periodic Maintenance
Venting System Inspection
If proper flame characteristics are not evident, check for
accumulation of lint or other foreign material that restricts
or blocks the air openings in the heater or burner. Also
check Combustion Air and Ventilation requirements.
At least once a year a visual inspection should be made of
the venting system. You should look for:
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be
obstructed.
2. Damage or deterioration which could cause improper
venting or leakage of combustion products.
3. Rusted flakes around top of water heater.
WARNING
Be sure the vent piping is properly connected to prevent
escape of dangerous flue gasses which could cause
deadly asphyxiation.
WARNING
Soot build-up indicates a problem that requires correc-
tion before further use. Turn “OFF” gas to water heater
and leave “OFF” until repairs are made, because failure
to correct the cause of the sooting can result in a fire.
WARNING
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Burner Cleaning
WARNING
NOTE: Burner assembly must be handled carefully to
avoid damaging the hot surface ignitor.
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chemi-
cal vapors. Spray can propellants, cleaning solvents,
refrigerator and air conditioner refrigerants, swimming
pool chemicals, calcium and sodium chloride, waxes,
bleach and process chemicals are typical compounds
which are potentially corrosive.
In the event your burner needs cleaning, use the following
instructions:
If inspection of the burner shows that cleaning is required,
turn the ON/OFF rocker switch located on the control box
to “OFF” position and allow the burner to cool.
Loose deposits on or around the burner can be removed by
carefully using the hose of a vacuum cleaner inserted
through the access door of the water heater. If the burner
needs to be removed for additional cleaning, call the local
gas utility or qualified service agent to remove and clean
the burner with a soft brush. Clean main burner orifice with
a suitable soft material. Correct the problem that required
the burner to be cleaned.
WARNING
If after inspection of the vent system you found sooting
or deterioration, something is wrong. Call the local gas
utility to correct the problem and clean or replace the
flue and venting before resuming operation of the water
heater.
Burner Inspection
WARNING
Flood damage to a water heater may not be readily visi-
ble or immediately detectible. However, over a period
of time a flooded water heater will create dangerous
conditions which can cause DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE. Contact a qualified
service technician or contractor to replace a flooded
water heater. Do not attempt to repair the unit! It must
be replaced!
Check main burner every 12 months for proper flame char-
acteristics. This is done by removing outer and inner doors
on heater. The main burner should provide complete com-
bustion of gas; ignite rapidly; give reasonably quiet opera-
tion; cause no excessive flame lifting from burner ports.
Make sure that the flow of combustion and ventilation air is
not blocked.
27
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Periodic Maintenance (cont’d)
L.P. Gas Control Valve & Burner
Assembly Replacement Information
Anode Rod Inspection
The anode rod is used to protect the tank from corrosion.
Most hot water tanks are equipped with an anode rod. The
submerged rod sacrifices itself to protect the tank. Instead
of corroding the tank, water ions attack and eat away the
anode rod. This does not affect the water’s taste or color.
The rod must be maintained to keep the tank in operating
condition.
WARNING
PROPANE (L.P.) GAS CONTROL VALVE AND BURNER
ASSEMBLY REPLACEMENT INFORMATION.
For Propane (L.P.) Gas Models Only:
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode
rod indicates high water conductivity and should be
checked and/or replaced more often than an anode rod that
appears to be intact. Replacement of a depleted anode rod
can extend the life of your water heater. Inspection should
be conducted by a qualified technician, and at a minimum
should be checked annually after the warranty period.
Your water heater is equipped with a Propane (L.P.) gas
control valve and a main burner assembly with left hand
threads for the following fittings and their connections.
(1) The connection between the manifold and the gas
control valve (A to B) are left hand threads.
(2) The connection between the main burner orifice
and the manifold (C to D) are left hand threads.
For ordering these replacement parts, please refer to the
“Repair Parts” section of this manual.
Temperature-Pressure Relief
Valve Operation
The temperature-pressure relief valve must be manually
operated at least once a year.
TEMPERATURE-PRESSURE
RELIEF VALVE
A
DISCHARGE PIPE
B
WARNING
C
When checking the temperature-pressure relief valve
operation, make sure that (1) no one is in front of or
around the outlet of the temperature-pressure relief valve
discharge line, and (2) that the water manually discharged
will not cause any property damage because the water
may be extremely hot.
D
If after manually operating the valve, it fails to complete-
ly reset and continues to release water, immediately close
the cold water inlet to the water heater, follow the drain-
ing instructions, and replace the temperature-pressure
relief valve with a new one.
Housekeeping
Failure to install and maintain a new properly listed tem-
perature-pressure relief valve will release the manufacturer
from any claim which might result from excessive tempera-
ture or pressure.
Vacuum around base of water heater for dust, dirt, and lint
on a regular basis.
WARNING
WARNING
INSTALLED IN SUITABLE AREA: To insure sufficient
ventilation and combustion air supply, proper clear-
ances from the water heater must be maintained. See
“Locating the New Water Heater” section. Combustible
materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or
adjacent to the water heater which can cause a fire.
If the temperature-pressure relief valve on the appliance
weeps or discharges periodically, this may be due to
thermal expansion. Your water heater may have a check
valve installed in the water line or a water meter with a
check valve. Consult the water supplier and/or plumbing
contractor for further information. Do not plug the tem-
perature-pressure relief valve.
28
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Periodic Maintenance (cont’d)
Draining
The water heater should be drained if being shut down dur-
ing freezing temperatures. Also periodic draining and clean-
ing of sediment from the tank may be necessary.
1. Turn “OFF” gas supply to water heater.
2. CLOSE the cold water inlet valve to the water heater.
3. OPEN a nearby hot water faucet and leave open to
allow for draining.
4. Connect a hose to the drain valve and terminate to an
adequate drain.
5. OPEN the water heater drain valve to allow for tank
draining.
NOTE: If the water heater is going to be shut down and
drained for an extended period, the drain valve should
be left open with hose connected allowing water to ter-
minate to an adequate drain.
6. Close the drain valve.
7. Follow instructions in the “Filling The Water Heater”
section.
8. Follow the lighting instructions in the “Lighting” section
to restart the water heater.
Drain Valve Washer
Replacement
NOTE: For replacement, use a ⁄32″ x ⁄64″ x ⁄8″ thick washer
available at your nearest hardware store. For ordering
replacement washers, refer to the “Repair Parts” section.
17
13
1
1. Turn “OFF” gas supply to water heater.
2. Follow “Draining” instructions.
3. Turning counter clockwise, remove the hex cap below
the screw handle.
4. Remove the washer and put the new one in place.
5. Screw the handle and cap assembly back into the drain
valve and retighten using a wrench. DO NOT OVER
TIGHTEN.
6. Follow instructions in the “Filling The Water Heater”
section.
7. Check for leaks.
8. Follow the lighting instructions in the “Lighting” section
to restart the water heater.
HANDLE AND
CAP ASSEMBLY
WASHER
Service
If a condition persists or you are uncertain about the oper-
ation of the water heater, let a qualified person check it out.
Call the local utility and/or plumbing contractor
.
29
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Leakage Checkpoints
Use this guide to check a “Leaking” water heater. Many
suspected “Leakers” are not leaking tanks. Often the source
of the water can be found and corrected.
CAUTION
Read this manual first. Then before checking the water
heater make sure the gas supply has been turned “OFF”,
and never turn the gas “ON” before the tank is com-
pletely full of water.
If you are not thoroughly familiar with gas codes your water
heater, and safety practices, contact the gas utility to check
the water heater.
CAUTION
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
A
Water at the vent pipe is water vapor which has
A
condensed out of the combustion products. This is
caused by a problem in the vent. Contact the gas
utility.
* Condensation may be seen on pipes in humid
weather or pipe connections may be leaking.
B
C
B
* The primary anode rod fitting may be leaking.
C
B
Small amounts of water from temperature-pressure
D
relief valve may be due to thermal expansion or
high water pressure in your area.
E
D
* The temperature-pressure relief valve may be leak-
ing at the tank fitting.
E
Water from a drain valve may be due to the valve
opened slightly.
F
* The drain valve may be leaking at the tank fitting.
G
Combustion products contain water vapor which
H
can condense on the cooler surfaces of the tank.
Droplets form and drip into the fire or run on the
floor. This is common at the time of startup after
installation and when incoming water is cold.
Water in the water heater bottom or on the floor
I
may be from condensation, loose connections, or
the relief valve. DO NOT replace the water heater
until a full inspection of all possible water sources is
made and necessary corrective steps taken.
H
G
F
I
Leakage from other appliances, water lines, or
ground seepage should also be checked.
* To check where threaded portion enters tank, insert cotton swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions in the “Installing the New Water Heater” section.
30
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Troubleshooting
WARNING
WARNING
Label all wiring before disconnecting any wiring; to
ensure correct reconnection. Failure to follow this
instruction could cause improper and possible danger-
ous operation, resulting in DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE.
This troubleshooting guide has been supplied for use by
qualified service personnel who have a complete under-
standing of both electricity and gas.
THERMOSTAT AND GAS SUPPLY CHECK
Is gas being supplied to the
thermostat?
No
Yes
Turn “ON” gas supply.
Is thermostat calling for heat?
Run (hot) water from heater and
turn adjustment knob higher.
Check using a manometer at
thermostat pressure tap.
Yes
Is there a minimum gas pressure
4″ W.C. for natural gas or 10″
W.C. for propane (L.P.) gas?
Call gas company to increase
gas pressure.
No
Yes
GO TO SYSTEMS CHECK
SECTION, PAGE 32
31
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Troubleshooting (cont’d)
SYSTEMS CHECK
WARNING
Please check guidelines below. For your safety, water heater
service should be performed only by a qualified service
technician.
DO NOT BY-PASS ANY CONTROLS TO MAKE HEATER
OPERATE. OPERATE ONLY AS WIRED FROM FACTORY.
LED STATUS
A B C
● ● ● ● ● ●
PROBLEM
SOLUTION
An open earth ground circuit to the
ignition system.
1. Check that the earth ground connection is
properly connected.
2. Check that the ground conductor on the
water heater is properly connected.
▼
Wiring error or a high resistance to
earth ground.
1. Check for proper connection of line neutral
and hot wires.
2. Check that the water heater is securely
connected to earth ground.
A B C
● ● ● ● ● ●
▼
Pressure switch remained closed longer
than 5 seconds after the call for heat
began.
1. Pressure switch wiring is incorrect.
2. Replace pressure switch.
A B C
● ● ● ● ● ●
▼
Pressure switch remained opened longer
than 5 seconds after the combustion
blower was energized.
1. Pressure switch wiring is incorrect.
2. Pressure switch tubing not connected
correctly.
A B C
● ● ● ● ● ●
▼
3. Air intake or exhaust obstructed.
A B C
● ● ● ● ● ●
Error in the hot surface ignitor circuit.
System in lockout.
1. Check that all wiring is correct and secure.
2. Replace hot surface ignitor.
▼
1. Gas supply is off or too low to operate.
2. Hot surface ignitor not positioned correctly.
3. Low voltage to the water heater.
4. Electric polarity to unit is incorrect - test
and correct.
A B C
● ● ● ● ● ●
▼
Problem in the gas valve driver circuit.
Problem with the internal circuit.
Problem with the internal circuit.
1. Turn power to the water heater off for
10 seconds and then back on.
A B C
● ● ● ● ● ●
▼
2. Replace gas control valve.
1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
A B C
● ● ● ● ● ●
▼
1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
A B C
● ● ● ● ● ●
▼
A B C
● ● ● ● ● ●
Flame signal sensed out of proper
sequence.
1. Replace gas control valve.
▼
A B C
● ● ● ● ● ●
ECO activated.
1. Replace gas control valve.
▼
A B C
● ● ● ● ● ●
One of the temperature adjust buttons
stuck closed.
1. Press and release each of the buttons once.
2. Replace gas control valve.
▼
Water temperature sensor is either
open or short circuited.
1. Check that all wiring is correct and secure.
2. Replace gas control valve.
A B C
● ● ● ● ● ●
▼
32
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Troubleshooting (cont’d)
PROBLEM
CAUSE
Blower will not run.
SOLUTION
A) “ON/OFF” control switch turned off. Turn switch to the “ON” position.
B) Blower unplugged.
C) No power at outlet.
D) Thermostat defective.
E) Control harness defective.
F) High limit control circuit open.
G) Blower motor defective.
Thermostat problems.
A) Thermostat set too low.
B) Thermostat or ECO defective.
Others
A) Heater undersized.
B) Low gas pressure.
Plug blower back into 115 VAC. outlet.
Repair service to outlet.
Replace thermostat.
Replace control harness.
Replace ECO.
Replace Blower Assembly.
NOT ENOUGH
HOT WATER
Set temperature control higher.
Replace thermostat or ECO as required.
Reduce hot water use.
Contact dealer.
C) Incoming water is unusually cold.
D) Leaking hot water pipes or fixtures.
A) Defective air flow restrictor.
Allow more time for heater to reheat.
Have plumber check and repair leaks.
Take unit out of service immediately, call a
service representative.
B) Not enough dilution air to mix with
flue gases in inlet elbow.
Proper dilution air must be provided for comb-
ustion and dilution of flue temp. Refer to “INSTAL-
LING THE NEW WATER HEATER” section.
Supply air is too hot. Check for heat sources
around intake terminal and blockage of
dilution air leg.
VENT PIPE TOO HOT
(ABOVE 170˚F)
C) Dilution air too hot for mixing with
flue gases.
D) Wrong burner orifice.
A) Dirt in burner ports
Install correct orifice.
Turn off heater and gas, clean burner head.
B) Combustion air path restricted.
Check intake venting arrangements for
obstructions.
YELLOW FLAME
CONDENSATION
C) Not enough dilution air for proper
combustion.
A) Water on the floor under heater.
B) Water dripping from blower assembly. Provide drip “TEE” to catch condensation from
horizontal section of exhaust vent close to
Check Intake venting arrangement for
obstructions.
See “CONDENSATION” section.
blower assembly.
Improperly sealed, hot or cold supply
connections, relief valve, drain valve
Tighten threaded connections.
or thermostat threads.
WATER LEAKS
LEAKING T&P
Leakage from other appliances or water Inspect other appliances near water heater.
lines.
Condensation of flue products.
See “CONDENSATION” section.
Thermal expansion in closed water
Install thermal expansion tank (DO NOT plug
system.
T&P valve).
Improperly seated valve.
Check relief valve for proper operation
(DO NOT plug T&P valve).
HOT WATER ODORS
(Refer to CATHODIC
PROTECTION
High sulfate or mineral content in
water supply.
Bacteria in water supply.
Thermostat set too high.
Drain and flush heater thoroughly then refill.
Chlorinate water supply.
Refer to TEMPERATURE REGULATION.
See “CONDENSATION” section.
WATER TOO HOT
WATER HEATER SOUNDS Condensation dripping on burner.
SIZZLING-RUMBLING
Sediment at bottom of heater tank.
Clean sediment from tank. Refer to DRAINING
instruction in Maintenance section of manual.
SOOTING
Improper combustion.
Refer to COMBUSTION AIR AND VENTILATION
on pages 8 and 9.
HEATER LIGHTS BUT
GOES OUT IN 4-5
SECONDS
Outlet polarity is reversed.
Test polarity and correct.
33
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Repair Parts
35
1
Outlet Parts Only
75 Gallon Models
and 50 Gallon
65,000 Btu/Hr
Models
2
3
4
5
6
8
7
9
11
10
33
32
12
31
14
13
30
29
29
28
15
27
21
26
20
16
19
18
22
23
24
25
34
17
34
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Repair Parts (cont’d)
KEY PART
NO. DESCRIPTION
PART NUMBER
40 Gal.† 50 Gal.††
KEY PART
NO. DESCRIPTION
PART NUMBER
40 Gal.† 50 Gal.††
1. Vent Cap w/Screen
2. Adaptor, Flue Mounting 9002728 9002728
9001957 9001957
19. Burner Assembly (Nat.) 9002411 9002411
19. Burner Assembly (L.P.) 9002411 9002411
20. Inner Door
21. Drain Valve
22. Manifold (Natural)
22. Manifold (L.P.)
23. Right Access Door
w/Gasket
24. Left Access Door
w/Gasket
25A. Access Door Clips (2)
25B. Jacket/Access
Door Clips (8)
9000281 9000281
9000058 9000058
9003622 9003622
9003624 9003624
9000695 9000695
3. 5′ ABS Schedule 40
—
—
Vent Pipe
4. 90° ABS Schedule 40
Elbow
5. Vent/Blower Adapter
6. Blower
—
—
9002506 9002506
9002507 9002507
9002567 9002567
9000696 9000696
7. Flue Adaptor Gasket
(6″ x 10.102″)
9000694 9000694
9001305 9001305
8. Blower Gasket
9. Venting; Manual
Reset Switch
9002508 9002508
9002678 9002678
26. Pressure Switch (Air) Cover 9002569 9002569
27. Gas Thermostat (Nat.) 9003691 9003691
10. Vent Hood Assembly
11. Rubber Gasket – Wiring 9002519 9002519
9002509 9002509
27. Gas Thermostat (L.P.)
28. Power Cord
29. Mounting Bracket
30. On/Off Switch
31. Pressure Switch (Air)
32. Flue Baffle Assembly
33. Baffle Adaptor
Collar Assembly
9003692 9003692
9003095 9003095
9002512 9002512
9001773 9001773
9002568 9002643
9002510 9002632
12. T&P Valve
13. Dip Tube
14. Anode Rod
15. Wiring Harness
16. Drain Pan
17. Hot Surface Ignition
Assembly
18. Orifice (Natural)
Standard
18. Orifice (L.P.)
Standard
18. Orifice (Nat.)
High Altitude
18. Orifice (L.P.)
High Altitude
9000728 9000728
*
**
9000029 9000279
9003628 9003628
9002769 9002769
9003627 9003627
9002570
—
0230120 0230120
(#33)
(#33)
34. Water Heater Stand
35. Optional (Deluxe)
Horizontal Vent Kit
9001422 9001422
9002749 9002749
0230224 0230224
(#51) (#51)
0230141 0230141
(#36) (#36)
0230222 0230222
(#52) (#52)
* Straight
- 9003662
Diffuser Tip - 9003663
Turbo
- 9001986
- 9003664
**Straight
Diffuser Tip - 9003665
†- 40,000 Btuh Nat., 36,000 Btuh Propane (L.P.)
†† - 40,000 Btuh Nat., 38,000 Btuh Propane (L.P.)
Turbo
- 9003463
Now that you have purchased this Water Heater, should a need ever exist for repair parts or service, simply contact the com-
pany it was purchased from or the manufacturer listed on the model rating plate on the water heater.
Be sure to provide all pertinent facts when you call or visit.
Selling prices will be furnished on request or parts will be shipped at prevailing price and you will be billed accordingly.
The model number of your Gas Water Heater will be found on the model rating plate located above the gas control valve.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION:
MODEL NUMBER
SERIAL NUMBER
(TYPE GAS) NATURAL OR PROPANE (L.P.)
PART DESCRIPTION
PART NUMBER
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
35
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Repair Parts
35
1
Outlet Parts Only
75 Gallon Models
and 50 Gallon
65,000 Btu/Hr
Models
2
3
4
5
6
8
7
9
11
10
33
32
12
31
14
13
30
29
27
29
28
15
21
26
20
16
19
18
22
23
24
25
34
17
36
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Repair Parts (cont’d)
KEY PART
NO. DESCRIPTION
PART NUMBER
50 Gal.† 75 Gal.††
KEY PART
NO. DESCRIPTION
PART NUMBER
50 Gal.† 75 Gal.††
1. Vent Cap w/Screen
2. Adaptor, Flue Mounting 9002728 9002728
9001957 9001957
19. Burner Assembly (Nat.) 9003040 9003040
19. Burner Assembly (L.P.) 9003048 9003048
20. Inner Door
21. Drain Valve
22. Manifold (Natural)
22. Manifold (L.P.)
23. Right Access Door
w/Gasket
24. Left Access Door
w/Gasket
25A. Access Door Clips (2)
25B. Jacket/Access
Door Clips (8)
9000281 9000281
9000058 9000058
9003622 9003623
9003624 9003625
9000695 9000695
3. 5′ ABS Schedule 40
9002106 9002106
Vent Pipe
4. 90° ABS Schedule 40
Elbow
5. Vent/Blower Adapter
6. Blower
9002107 9002107
9003154 9002506
9003152 9002669
9002567 9002567
9000696 9000696
7. Flue Adaptor Gasket
(6″ x 10.102″)
9000694 9000694
9001305 9001305
8. Blower Gasket
9. Venting; Manual
Reset Switch
9002508 9002508
9002678 9002678
26. Pressure Switch (Air) Cover 9002569 9002569
27. Gas Thermostat (Nat.) 9003691 9003629
10. Vent Hood Assembly
11. Rubber Gasket – Wiring 9002519 9002519
9003220 9002670
27. Gas Thermostat (L.P.)
28. Power Cord
29. Mounting Bracket
30. On/Off Switch
31. Pressure Switch (Air)
32. Flue Baffle Assembly
33. Baffle Adaptor
Collar Assembly
9003692 9003630
9003095 9003095
9002512 9002512
9001773 9001773
9002511 9002568
9003217 9002653
12. T&P Valve
13. Dip Tube
14. Anode Rod
15. Wiring Harness
16. Drain Pan
17. Hot Surface Ignition
Assembly
18. Orifice (Natural)
Standard
9000728 9000728
*
**
9000029 9000279
9003628 9003628
9002769 9001608
9003627 9003626
†††
†††
0230209 0230279
(#27)
(#25)
34. Water Heater Stand
9001422
—
18. Orifice (L.P.)
Standard
18. Orifice (Nat.)
High Altitude
18. Orifice (L.P.)
High Altitude
0230260 0230260
(#43) (#43)
0230144 0230142
(#29) (#28)
0230261 0230261
(#44) (#44)
35. Optional (Deluxe)
Horizontal Vent Kit
9002749 9002749
††† Consists of the following parts:
Flue Adaptor
- 9001290
- 9001292
Adaptor Gasket
Adaptor Plate w/Gasket - 9001294
* Straight
Diffuser Tip
Turbo
- 9003666
- 9003486
- 9002067
- 9003667
- 9003668
- 9003501
†- 65,000 Btuh Nat., 60,000 Btuh Propane (L.P.)
†† - 70,000 Btuh Nat., 65,000 Btuh Propane (L.P.)
** Straight
Diffuser Tip
Turbo
Now that you have purchased this Water Heater, should a need ever exist for repair parts or service, simply contact the com-
pany it was purchased from or the manufacturer listed on the model rating plate on the water heater.
Be sure to provide all pertinent facts when you call or visit.
Selling prices will be furnished on request or parts will be shipped at prevailing price and you will be billed accordingly.
The model number of your Gas Water Heater will be found on the model rating plate located above the gas control valve.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION:
MODEL NUMBER
SERIAL NUMBER
(TYPE GAS) NATURAL OR PROPANE (L.P.)
PART DESCRIPTION
PART NUMBER
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
37
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Notes
38
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Notes
39
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