Ruud Water Heater AP14236 User Guide

!
Warning: This water heater is not  
Use & Care Manual  
suitable for use in manufactured (mobile) homes!  
With Installation Instructions for the Installer  
Residential Gas  
® Water Heaters  
Residential 40, 50, 60 Gallon  
The purpose of this manual is twofold: one, to provide the installer with the basic directions  
and recommendations for the proper installation and adjustment of the water heater; and two,  
for the owner–operator, to explain the features, operation, safety precautions, maintenance  
and troubleshooting of the water heater. This manual also includes a parts list.  
It is very important that all persons who are expected to install, operate or adjust this  
water heater read the instructions carefully so they may understand how to perform  
these operations. If you do not understand these instructions or any terms within it, seek  
professional assistance.  
Any questions regarding the operation, maintenance, service or warranty of this water heater  
should be directed to the seller from whom it was purchased. If additional information is  
required, refer to the section on “If you need service.”  
Do not destroy this manual. Please read carefully and keep in a safe place for future  
reference.  
V
ACATION  
A
B
C
VER  
HO
WARM  
V
ACATION  
A
B
C
VER  
HOT  
Y
WARM  
COOLER  
HOTTE
COOLER  
HOTTER  
Recognize this symbol as an indication of Important Safety Information!  
!
California Proposition 65 Warning: This product contains chemicals known to the  
State of California to cause cancer, birth defects or other reproductive harm.  
!
!
WARNING: If the information in these instructions is not followed exactly,  
a fire or explosion may result causing property damage, personal injury or death.  
!
FOR YOUR SAFETY!  
If you cannot reach your gas supplier, call  
the fire department.  
Do not store or use gasoline or other  
flammable vapors or liquids or other  
combustible materials in the vicinity of this or  
any other appliance. To do so may result in an  
explosion or fire.  
Do not return to your home until authorized  
by the gas supplier or fire department.  
Improper installation, adjustment, alteration,  
service or maintenance can cause property  
damage, personal injury, or death. Refer to  
this manual. Installation and service must be  
performed by a qualified installer, service  
agency or the gas supplier.  
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.  
S
I
G
N
D
Printed in USA  
AP14236 (05/07)  
R
T
I
E
I
®
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IMPORTANT SAFETY INFORMATION.  
READ ALL INSTRUCTIONS BEFORE USING.  
Be sure to read and understand the entire Use and Care Manual before attempting to install or operate this water  
heater. It may save you time and money. Pay particular attention to the Safety Instructions. Failure to follow these  
warnings could result in serious bodily injury or death. Should you have problems understanding the instructions in  
this manual, or have any questions, STOP, and get help from a qualified service technician, or the local gas utility.  
NOTICE: This water heater is equipped with a flammable vapor sensor that will automatically shut  
down the water heater in the presence of gasoline vapors and some other flammable vapors. If the  
flammable vapor sensor shuts down the water heater, contact a qualified service technician. Clear any  
hazardous materials and ventilate the area around the water heater. Do not turn off the appliance  
or adjust the ON/OFF switch in any way. Do not tamper with the flammable vapor sensor. Do not  
submerse the flammable vapor sensor in water. Do not allow the flammable vapor sensor to come into  
contact with any substances such as bleach or cleaners. See the “Gas Valve LED Error Code” Section  
of this manual for a list of error codes.  
DANGER!  
INSTALL THE BLOWER ASSEMBLY AND PROPERLY VENT  
THE WATER HEATER  
Failure to install the blower assembly and properly vent the water heater to the outdoors  
as outlined in the Venting Section of the Installation Instructions in this manual can result  
in unsafe operation of the water heater. To avoid the risk of fire, explosion, or asphyxiation  
from carbon monoxide, never operate this water heater unless it is properly vented and  
has an adequate air supply for proper operation. Be sure to inspect the vent system for  
proper installation at initial start-up; and at least annually thereafter. Refer to the Care and  
Cleaning section of this manual for more information regarding vent system inspection.  
WARNING!  
Gasoline, as well as other flammable materials and liquids (which include but are not  
limited to adhesives, solvents, paint thinners etc.), and the vapors they produce are  
extremely dangerous. DO NOT handle, use or store gasoline or other flammable or  
combustible materials anywhere near or in the vicinity of a water heater or any other  
appliance. Be sure to read and follow warning label pictured below and other labels on the  
water heater, as well as the warnings printed in this manual. Failure to do so can result in  
property damage, bodily injury or death.  
W A R N I N G  
!
FLAMMABLES  
Flammable Vapors  
FIRE AND EXPLOSION HAZARD  
Can result in serious injury or death.  
!
Do not store or use gasoline or other flammable vapors and liquids  
in the vicinity of this or any other appliance. Storage of or use of gasoline  
or other flammable vapors or liquids in the vicinity of this or any other  
appliance can result in serious injury or death.  
3
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IMPORTANT SAFETY INFORMATION.  
READ ALL INSTRUCTIONS BEFORE USING.  
!
DANGER!  
WATER TEMPERATURE SETTING  
Safety and energy conservation are factors to be considered when selecting the water  
temperature setting of a water heater’s gas control. Water temperatures above 125°F  
can cause severe burns or death from scalding. Be sure to read and follow the warnings  
outlined on the label pictured below. This label is also located on the water heater.  
Time/Temperature Relationship in Scalds  
Water Temperature  
Time To Produce a Serious Burn  
!
D A N G E R  
120°F  
More than 5 minutes  
11/2 to 2 minutes  
125°F  
130°F  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 11/2 seconds  
About 1 second  
135°F  
140°F  
145°F  
150°F  
155°F  
Table courtesy of Shriners Burn Institute  
The chart shown above may be used as a guide in  
determining the proper water temperature for your  
home.  
HOT  
DANGER: Households with small children, disabled,  
or elderly persons may require a 120°F or lower gas  
control (thermostat) setting to prevent contact with  
“HOT” water.  
!
Maximum water temperatures occur just after the  
burner has shut off. To find water temperature being  
delivered, turn on a hot water faucet and place  
a thermometer in the water stream and read the  
thermometer. (See page 24 and 25 for more details.)  
BURN  
Water temperature over 125°F can  
cause severe burns instantly or  
death from scalds.  
The temperature of the water in the heater can be  
regulated by pressing the temperature buttons on the  
front of the gas control (thermostat). To comply with  
safety regulations the gas control(thermostat) was  
set at its lowest setting before the water heater was  
shipped from the factory.  
Children, disabled and elderly are  
at highest risk of being scalded.  
The illustration below details the approximate water  
temperature for each mark on the Gas Control  
(Thermostat) Temperature Dial.  
See instruction manual before  
setting temperature at water  
heater.  
VACATION  
WARM  
A
B
C
Feel water before bathing or  
showering.  
VERY  
HOT  
!
DANGER: Hotter  
COOLER  
HOTTER  
water increases the  
potential for Hot Water  
SCALDS.  
Temperature limiting valves are  
available, see manual.  
WARNING  
Notice: Mixing valves are available for reducing point  
of use water temperature by mixing hot and cold water  
in branch water lines. Contact a licensed plumber or the  
local plumbing authority for further information.  
Display  
Temperature Setting  
Burns on Adult Skin  
▼ A B C  
WARM = approx. 70°F (21°C)  
▼ = approx. 120°F (49°C)  
A = approx. 130°F (54°C)  
B = approx. 140°F (60°C)  
C = approx. 150°F (66°C)  
--------------------  
More than 5 minutes  
About 30 seconds  
Less than 5 seconds  
About 1-1/2 seconds  
About 1/2 seconds  
● ○ ○ ○ ○ ○  
○ ○ ● ○ ○ ○  
○ ○ ○ ● ○ ○  
○ ○ ○ ○ ● ○  
○ ○ ○ ○ ○ ●  
○ ○ ○ ○ ○ ●  
4
C-Flashing = approx. 160°F (71°C)  
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DANGER!  
LIqUEFIED PETROLEUM (LP PROPANE OR BUTANE)  
AND NATURAL GAS MODELS  
LP and Natural gas have an odorant added to aid in detecting a gas leak. Some people  
may not physically be able to smell or recognize this odorant. If you are unsure or  
unfamiliar with the smell of LP or natural gas, ask the gas supplier. Other conditions,  
such as “odorant fade”, which causes the odorant to diminish in intensity, can also hide or  
camouflage a gas leak.  
Water heaters utilizing LP gas are  
!
DANGER: If a gas leak is present or  
different from natural gas models. A  
natural gas water heater will not function  
safely on LP gas and vice versa.  
suspected:  
Do not attempt to find the cause  
yourself.  
No attempt should ever be made to  
convert the water heater from natural  
gas to LP gas. To avoid possible  
Do not try to light any appliance.  
Do not touch any electrical switch.  
Do not use any phone in your building.  
equipment damage, personal injury or  
fire, do not connect the water heater to a  
fuel type not in accordance with the unit  
data plate. LP for LP units. Natural gas  
for natural gas units. These units are not  
certified for any other fuel type.  
Leave the house immediately and make  
sure your family and pets leave also.  
Leave the doors open for ventilation  
and contact the gas supplier, a qualified  
service agency or the fire department.  
LP appliances should not be installed  
below grade (for example, in a basement)  
if such installation is prohibited by  
federal, state and/or local laws, rules,  
regulations or customs.  
Stay away from the house (or building)  
until the service call has been made, the  
leak is corrected and a qualified agency  
has determined the area to be safe.  
LP gas must be used with great caution.  
It is heavier than air and will collect first  
in lower areas making it hard to detect at  
nose level.  
Before attempting to light the water  
heater, make sure to look and smell for  
gas leaks. Use a soapy solution to check  
all gas fittings and connections. Bubbling  
at a connection indicates a leak that must  
be corrected. When smelling to detect a  
gas leak, be sure to sniff near the floor  
also.  
Gas detectors are recommended in LP  
& natural gas applications and their  
installation should be in accordance  
with the detector manufacturer’s  
recommendations and/or local laws,  
rules, regulations or customs.  
It is recommended that more than one  
method, such as soapy solution, gas  
detectors, etc., be used to detect leaks in  
gas applications.  
5
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IMPORTANT SAFETY INFORMATION.  
READ ALL INSTRUCTIONS BEFORE USING.  
!
WARNING!  
For your safety, the information in this manual must be followed to minimize the risk of  
fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of  
life.  
FOR INSTALLATIONS IN THE STATE OF CALIFORNIA  
California Law requires that residential water heaters must be braced, anchored or  
strapped to resist falling or horizontal displacement due to earthquake motions. For  
residential water heaters up to 52-gallon capacity, a brochure with generic earthquake  
bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street,  
Suite 5100, Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater  
dealer.  
However, applicable local codes shall govern installation. For residential water heaters  
of a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable  
bracing procedures.  
SAFETY PRECAUTIONS  
Have the installer show you the location of the gas shut-off valve and how to shut it off  
if necessary. Turn off the manual shut-off valve if the water heater has been subjected to  
overheating, fire, flood, physical damage or if the gas supply fails to shut off.  
Read this manual entirely before installing  
Do not attempt to repair or replace any part  
of your water heater unless it is specifically  
recommended in this manual. All other  
servicing should be referred to a qualified  
technician.  
or operating the water heater.  
Use this appliance only for its intended  
purpose as described in this Use and Care  
Manual.  
Be sure your appliance is properly installed  
in accordance with local codes and the  
provided installation instructions.  
READ AND FOLLOW THIS SAFETY INFORMATION  
CAREFULLY.  
SAVE THESE INSTRUCTIONS  
6
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Installing the water heater.  
This water heater must be installed in accordance with these instructions, local codes, utility company  
requirements, and/or in the absence of local codes, use the latest edition of the American National  
Standard/National Fuel Gas Code. A copy can be purchased from either the American Gas Association,  
400 N. Capitol Street NW, Washington, DC 20001 as ANSI standard Z223.1 or National Fire Protection  
Association, 1 Batterymarch Park, Quincy, MA 02269 as booklet NFPA 54.  
Location  
Combustion Air Inlet  
The water heater should not be located  
in an area where leakage from the tank  
or connections will result in damage  
to the area adjacent to the heater or to  
lower floors of the structure.  
The water heater must be located so it is  
not subject to physical damage, for example,  
by moving vehicles, area flooding, etc.  
Openings  
Max.  
2.75”  
If local codes require the use of a stand  
kit to raise the water heater 18” above the  
floor, please contact the store where the  
water heater was purchased, or any water  
heater distributor. These kits must comply  
with local codes.  
When such areas cannot be avoided it is  
recommended that a suitable catch pan,  
adequately drained, must be installed  
under the water heater.  
Flammable  
Vapor  
Diameter of  
Sensor  
water heater  
plus 2” min.  
The water heater must be centered in  
the catch pan.  
The water heater should be installed  
so as to minimize the length of plastic  
vent pipe and the number of vent  
connection fittings required. (Refer to  
the “INSTALLATION” Section of this  
manual.)  
The catch pan must not restrict air  
flow to the combustion air inlet openings  
(perforation openings) located around the  
lower perimeter of the water heater.  
The auxiliary catch pan  
installation MUST conform  
to local codes.  
Notice: DO NOT allow  
the catch pan to obstuct  
the flammable vapor  
sensor.  
Long hot water lines should be insulated  
Catch pan kits are available from the store  
where the water heater was purchased, or  
any water heater distributor.  
to conserve water and energy.  
The water heater and water lines should  
be protected from exposure  
Make certain the floor underneath the  
water heater is strong enough to  
sufficiently support the weight of the  
water heater once it is filled with water.  
to freezing temperatures.  
Notice: DO NOT allow  
the flammable vapor  
sensor to become  
submerged in water.  
Make sure the catch pan  
is properly drained.  
Do not install the water heater in  
bathrooms, bedrooms, any occupied  
rooms normally kept closed, or in  
unprotected outdoor areas.  
A gas fired water heater or any other  
appliance should not be installed  
in a space where liquids which give off  
flammable vapors are to be used or stored.  
Such liquids include gasoline, LP gas  
(butane or propane), paint or adhesives  
and their thinners, solvents or removers.  
Minimum clearance from combustible  
construction:  
Front  
Sides  
Rear  
Top  
3”  
1”  
0”  
12”  
(7.6 cm) (2.5 cm)  
(0 cm)  
(30.5 cm)  
DO NOT block or obstruct any of the  
combustion air inlet openings located  
around the perimeter of the water  
heater. A minimum of 1” is required  
between these combustion air inlet  
openings and any obstruction.  
If the clearances stated on the  
Instruction/Warning Label, located on  
the front of the heater differ, install the  
water heater according to the clearances  
stated on the label.  
DO NOT obstruct or block the  
Flammable Vapor Sensor.  
If the water heater is installed in an  
alcove or closet, the entire floor must  
be covered by a wood or metal panel.  
A minimum of 24” clearance from the  
front and top should be available for  
adequate inspection and servicing.  
Because of natural air movement in a  
room or other enclosed space, flammable  
vapors can be carried some distance from  
where liquids which give off flammable  
vapors are to be used or stored. The open  
flame of the water heater’s pilot or main  
burner can ignite these vapors and create a  
shut down condition of the water heater  
which will not allow the water heater  
to ignite until examined by a Qualified  
Service Technician.  
!
WARNING: Combustible  
construction refers to  
adjacent walls and ceilings  
and should not be confused  
with combustible or  
The water heater may be installed on  
combustible floors, but not directly on  
carpeting. If the water heater must be  
installed on carpeting, place a metal or  
wood panel beneath the water heater,  
extending beyond its full width and  
flammable products and  
materials. Combustible  
and/or flammable products  
and materials should never  
be stored in the vicinity of  
this or any gas appliance.  
7
depth at least 3” in all directions.  
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Installing the water heater.  
Inspect Shipment  
Inspect the water heater for possible damage. Check the markings on the rating plate of  
the water heater to be certain the type of gas supplied corresponds to the water heater  
requirements.  
Combustion and Ventilation Air  
Ventilation (ambient) air temperature  
must be 100°F or less. Proper operation  
of the water heater requires air for  
combustion and ventilation. Provisions  
for combustion and ventilation air  
must comply with referenced codes and  
standards.  
The minimum net free area of each opening  
must not be less than one square inch  
per 1000 Btuh of the total input rating  
of all the appliances in the enclosure  
(but not less than 100 square inches), if  
each opening communicates with other  
unconfined areas inside the building.  
DO NOT block or obstruct any of the  
combustion air inlet openings located  
around the perimeter of the water  
heater. A minimum of 1” is required  
between these combustion air inlet  
openings and any obstruction.  
Buildings of unusually tight construction  
shall have the combustion and ventilation  
air supplied from outdoors, or a freely  
ventilated attic or crawl space.  
If air is supplied from outdoors, directly or  
through vertical ducts, there must be two  
openings located as specified above and  
each must have a minimum net free area  
of not less than one square inch per 4000  
Btuh of the total input rating of all the  
appliances in the enclosure.  
NOTICE: If the water heater is  
installed in an unconfined space within a  
building of conventional frame, masonry  
or metal construction, infiltration  
air is normally adequate for proper  
combustion and ventilation. If the  
water heater is installed in a confined  
space, provisions for combustion and  
ventilation air must be made.  
NOTICE: Do not install the  
water heater in attics where  
the temperature may exceed  
100°F. This water heater is  
equipped with a temperature  
sensing device that will  
shut off the water heater  
if the maximum allowable  
vent pipe temperature is  
exceeded.  
If horizontal ducts are used to  
communicate with the outdoors, each  
opening must have a minimum net free  
area of not less than one square inch per  
2000 Btuh of the total input rating of all  
the appliances in the enclosure. If ducts  
are used, the minimum dimensions of  
rectangular air ducts shall not be less than  
3”.  
DO NOT obstruct or block the  
Flammable Vapor Sensor.  
A confined space is one having a volume  
of less than 50 cubic feet per 1000 Btuh  
of the aggregate input of all appliances  
within that space.  
NOTICE: If the duct openings which  
supply combustion and ventilation air  
are to be covered with a protective  
screen or grill, the net free area  
(openings in the material) of the  
covering material must be used in  
determining the size of the openings.  
Protective screening for the openings  
MUST NOT be smaller than 1/4”mesh  
to prevent clogging by lint or other  
debris.  
The air must be supplied through two  
permanent openings of equal area. One  
is to be located within 12” above the floor  
and the other is to be located within 12”  
from the ceiling.  
Corrosive Atmospheres  
The air in beauty shops, dry cleaning  
should not be installed near establishments, photo processing  
will shorten the life of any gas burning  
appliance.  
NOTICE: The water heater  
an air supply containing  
halogenated hydrocarbons.  
labs, and storage areas for liquid and  
powdered bleaches or swimming pool  
chemicals often contain such halogenated  
hydrocarbons.  
Propellants from common spray cans  
or gas leaks from A/C and refrigeration  
equipment are highly corrosive after  
passing through a flame.  
An air supply containing halogenated  
hydrocarbons may be safe to breathe,  
but when it passes through a gas flame  
corrosive elements are released that  
The water heater warranty is voided when  
failure of the heater is due to operation in  
a corrosive atmosphere.  
8
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Thermal Expansion  
Determine if a check valve exists in the inlet water line. Check with your local water utility  
company. It may have been installed in the cold water line as a separate back flow preventer, or  
it may be part of a pressure reducing valve, water meter or water softener. A check valve located  
in the cold water inlet line can cause what is referred to as a “closed water system”. A cold water  
inlet line with no check valve or back flow prevention device is referred to as an “open” water  
system.  
As water is heated, it expands in volume and creates an increase in the pressure within the water  
system. This action is referred to as “thermal expansion”. In an “open” water system, expanding  
water which exceeds the capacity of the water heater flows back into the city main where the  
pressure is easily dissipated.  
A “closed water system”, however, prevents the expanding water from flowing back into the  
main supply line, and the result of “thermal expansion” can create a rapid and dangerous  
pressure increase in the water heater and system piping. This rapid pressure increase can quickly  
reach the safety setting of the relief valve, causing it to operate during each heating cycle. Thermal  
expansion, and the resulting rapid, and repeated expansion and contraction of components in the  
water heater and piping system can cause premature failure of the relief valve, and possibly the  
heater itself. Replacing the relief valve will not correct the problem!  
The suggested method of controlling thermal expansion is to install an expansion tank in the cold  
water line between the water heater and the check valve (see illustration below). The expansion  
tank is designed with an air cushion built in that compresses as the system pressure increases,  
thereby relieving the over pressure condition and eliminating the repeated operation of the relief  
valve. Other methods of controlling thermal expansion are also available. Contact your installing  
contractor, water supplier or plumbing inspector for additional information regarding this subject.  
IMPORTANT: Do not apply  
heat to the HOT or COLD  
water connections. If sweat  
connections are used, sweat  
tubing to adapter before  
fitting adapter to the cold  
water connections on heater.  
Any heat applied to the cold  
water supply fittings will  
permanently damage the  
dip tube and heat traps.  
Water Supply Connections  
Refer to the illustration below for suggested typical installation. The installation of unions or  
flexible copper connectors is recommended on the hot and cold water connections so that the  
water heater may be easily disconnected for servicing if necessary. The HOT and COLD water  
connections are clearly marked and are 3/4” NPT on all models. Install a shut-off valve in the cold  
water line near the water heater.  
Typical Installation  
1/4” per foot maximum slope up or  
down for horizontal venting.  
Vent connector  
Union  
Heat trap  
6” minimum  
Blower assembly  
Anode  
Hot water outlet to  
NOTICE: The National  
Fuel Gas Code (NFGC)  
mandates a manual  
fixtures  
Union  
Water Heater Jacket  
Temperature and  
pressure relief valve  
gas shut-off valve: See  
(NFGC) for complete  
instructions. Local codes  
or plumbing authority  
requirements may vary  
from the instructions or  
diagrams provided and  
take precedent over these  
instructions.  
Manual gas shut-off  
To gas supply  
Heat trap  
6” minimum  
Shut-off  
valve  
To cold water  
supply  
Ground joint union  
Shut-off valve  
Sediment trap  
Cap  
Thermal expansion  
tank (if required)  
Relief valve discharge  
line to suitable open  
drain.  
Drain  
valve  
Va cuum Relief Valve  
(Not Supplied)  
Thermostatic gas valve  
Jacket door  
Combustion Air  
Inlet Openings  
Flammable Vapor Sensor  
Auxiliary catch pan  
6” Air gap  
If required, install per local codes  
and valve manufacturer’s  
instructions.  
Drain Pan Pipe  
to suitable drain.  
9
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Installing the water heater.  
A new combination temperature and pressure relief valve, complying with the Standard for Relief Valves  
and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22, is supplied and must  
remain in the opening provided and marked for the purpose on the water heater. No valve of any type  
should be installed between the relief valve and the tank. Local codes shall govern the installation of  
relief valves.  
Relief Valve  
The pressure rating of the relief valve  
must not exceed 150 PSI, the maximum  
working pressure of the water heater as  
marked on the rating plate.  
The discharge line must be no smaller  
than the outlet of the valve and must  
pitch downward from the valve to allow  
complete drainage (by gravity) of the  
relief valve and discharge line.  
The Btuh rating of the relief valve must  
equal or exceed the Btuh input of the  
water heater as marked on its rating plate.  
The end of the discharge line should not  
be threaded or concealed and should be  
protected from freezing. No valve of  
any type, restriction, or reducer coupling  
should be installed in the discharge line.  
Position the outlet of the relief valve  
above a suitable open drain to eliminate  
potential water damage. Piping used  
should be of a type approved for hot water  
distribution.  
To Fill the Water Heater  
Make certain that the drain valve is  
closed, then open the shut-off valve in the  
cold water supply line.  
WARNING: The tank  
must be full of water before  
heater is turned on. The  
water heater warranty does  
not cover damage or failure  
resulting from operation  
with an empty or partially  
empty tank.  
Do not allow the flammable vapor sensor  
to become submerged in water.  
Open each hot water faucet slowly to  
allow the air to vent from the water  
heater and piping.  
A steady flow of water from the hot water  
faucet(s) indicates a full water heater.  
Condensation  
Condensation can form on the tank  
when it is first filled with water.  
Condensation might also occur with a  
heavy water draw and very cold inlet  
water temperatures.  
NOTICE: Additional information on this  
subject may be found at www.rheem.com,  
under Rheem Water Heating, "Support",  
scroll down to the Technical Service  
Section and to Bulletins 1400 Series  
Section and choose Bulletin #1402..  
Drops of water falling on the burner can  
produce a sizzling or pinging sound.  
This condition is not unusual, and will  
disappear after the water becomes heated.  
If, however, the condensation continues,  
examine the piping and fittings for  
possible leaks.  
10  
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WARNING: Do not attempt to convert this water heater for use with a different type of gas other than the type  
shown on the rating plate. Such conversion could result in hazardous operating conditions.  
Gas Supply  
The branch gas supply line to the water  
heater should be clean 1/2” black steel  
pipe or other approved gas piping  
material.  
the gas piping must be of the type resistant  
to the action of LP gas. Use compound  
sparingly on male threads only.  
A sediment trap should be installed at the  
bottom of the gas line.  
A ground joint union or ANSI design  
certified semi-rigid or flexible gas  
Do not use excessive force (over 31.5 ft  
lbs.) in tightening the pipe joint at the gas  
control (thermostat) inlet, particularly if  
teflon pipe compound is used, as the valve  
body may be damaged.  
appliance connector should be installed  
in the gas line close to the water heater.  
The National Fuel Gas Code (NFGC)  
mandates a manual gas shut-off valve: See  
(NFGC) for complete instructions.  
The inlet gas pressure to the water heater  
must not exceed 10.5” w.c. for natural gas,  
or 14” w.c. for LP gas. For purposes of  
input adjustment, the minimum inlet gas  
pressure (with main burner on) is shown  
on the water heater rating plate. If high or  
low gas pressures are present, contact your  
gas supplier for correction.  
If flexible connectors are used, the  
maximum length shall not exceed 36”  
and must meet the requirements in ANSI  
Z21.24-Connectors for Gas Appliances.  
If lever type gas shut-offs are used,  
they shall be T-Handle type.  
Compound used on the threaded joints of  
Leak Testing  
The water heater and its gas connections  
must be leak tested at normal operating  
pressures before it is placed in operation.  
WARNING: Never use  
an open flame to test for  
gas leaks, as property  
damage, personal injury, or  
death could result.  
The factory connections to the gas  
control (thermostat) should also be leak  
tested after the water heater is placed in  
operation.  
Turn on the manual gas shut-off  
valve near the water heater.  
Use a soapy water solution to test for  
leaks at all connections and fittings.  
Bubbles indicate a gas leak that must  
be corrected.  
Pressure Testing the Gas Supply System  
The water heater and its manual gas  
The water heater must be isolated from  
shut-off valve must be disconnected from the gas piping system by closing the  
the gas supply piping system during any  
pressure testing of that system at  
manual gas shut-off valve during any  
pressure testing of the gas supply piping  
pressures in excess of 3/8 psi (10.5” w.c.) at pressures equal to or less than  
for natural gas, or 1/2 psi (14” w.c.) for  
LP gas.  
3/8 psi (10.5” w.c.) for natural gas, or  
1/2 psi (14” w.c.) for LP gas.  
High Altitude  
Input rating of this water heater is  
WARNING: Failure to  
install a water heater  
suitable for the altitude at  
the location it is intended to  
serve, can result in improper  
operation of the appliance  
resulting in property  
damage and/or producing  
carbon monoxide gas, which  
could result in personal  
injury, or death.  
For installation between 2,000 and 7,700  
feet, refer to the Venting Information  
tables on page 13 and 14 for maximum  
vent lengths.  
based on sea level operation. At higher  
elevations the actual input rate may be  
lower than the value listed on the rating  
label due to the derating of natural gas and  
LP gas. This water heater can be installed  
at elevation up to 2,000 feet without any  
change or modification.  
Installations above 7,700 feet are not  
authorized.  
Contact the local gas supplier for more  
information.  
11  
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Installing the water heater.  
The water heater must be installed with the factory supplied blower assembly in place.  
Venting  
The water heater must be vented to the  
DANGER: Failure to  
install the blower assembly  
The support method used should isolate  
and properly vent the water  
heater to the outdoors as  
outlined in the Venting  
section of this manual will  
result in unsafe operation of  
the water heater causing  
bodily injury, explosion,  
fire or death.  
outdoors as described in these instructions. the vent pipe from floor joists or other  
DO NOT connect this water heater to  
an existing vent or chimney - it must  
be vented separately from all other  
appliances.  
structural members to help prevent the  
transmission of noise and vibration.  
Do not support, pin or otherwise secure  
the venting system in a way that restricts  
the normal thermal expansion and  
NOTICE: This unit can be vented using  
only the following recommended pipe  
material. Use only 2- or 3-inch diameter  
pipe.  
contraction of the chosen venting material.  
To avoid the risk of fire,  
explosion, or asphyxiation  
from carbon monoxide,  
NEVER operate the water  
heater unless it is properly  
vented and has adequate air  
supply for proper operation  
as outlined in the Venting  
section of this manual.  
If the water heater is being installed as a  
replacement for an existing power vented  
water heater, a thorough inspection of  
the existing venting system must be  
performed prior to any installation work.  
PVC (Schedule 40, ASTM D1785)  
CPVC (Schedule 40, ASTM F441)  
ABS (Schedule 40, ASTM D2661)  
Verify that the correct materials as  
detailed above have been used, and  
that the minimum or maximum vent  
length and terminal locations as  
detailed in this manual have been  
met.  
ABS (Schedule 40 DWV, Cellular Core,  
ASTM F891)  
The vent pipe must overlap  
a minimum of ½” on each  
connection. It is important  
that the vent pipe engages  
fully into any pipe fitting  
and be kept in that position  
until the adhesive has fully  
cured. DO NOT drill or  
punch holes in the plastic  
pipe or fittings.  
The fittings, other than the TERMINATION,  
should be equivalent to the following:  
Carefully inspect the entire venting  
system for any signs of cracks or  
fractures, particularly at the joints  
between elbows or other fittings and  
the straight length of vent pipe.  
PVC (Schedule 40 DWV, ASTM D2665)  
CPVC (Schedule 40, ASTM F438)  
ABS (Schedule 40 DWV, ASTM D2661)  
The unit may be vented horizontally  
through a wall or vertically through the  
roof.  
Check the system for signs of sagging  
or other stresses in the joints as a  
result of misalignment of any  
components in the system.  
NOTICE: This unit is  
equipped with a Flammable  
Vapor Sensor. Do not  
apply power until enough  
time has passed to allow the  
vapors from the primer and  
cement to dissipate.  
Vent pipe runs must be adequately  
supported along both vertical and  
horizontal lengths.  
If any of these conditions are found,  
they must be corrected in accordance  
with the venting instructions in this  
manual before completing the  
installation and putting the water  
heater into service.  
Maximum unsupported length is  
recommended to be no more than 6 feet.  
It is imperative that the first hanger  
be located on the horizontal length  
immediately adjacent to the first  
90-degree elbow from the vertical rise of  
vent pipe connected to the water heater.  
Additional installation infor-  
mation for The Commonwealth  
of Massachusetts is located on  
the back page of this manual.  
Blower Assembly Installation  
(if not factory installed)  
Rubber  
Coupling  
Sheet Metal  
Screws  
Blower  
Connect blower assembly with the electrical connector. Attach  
Blower Assembly to top pan using the six (6) screws provided  
(See diagram to the left). Install rubber coupling (supplied in  
the box with water heater) on blower housing and secure it.  
Assembly  
Flue  
Baffle  
Electrical  
Connector  
NOTICE: The Blower Assembly is model specific and only  
the blower assembly supplied should be used on this water  
heater.  
12  
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Maximum and Minimum Vent Lengths for Residential  
40 & 50 Gallon Power Vents ONLY  
Minimum vent length for 2”vent pipe is one (1) foot of vertical pipe, one (1)  
90°elbow, and three (3) feet of horizontal pipe.  
Maximum  
Altitude for  
2” & 3”  
Maximum Venting information for 2” Vents*  
Maximum Vent Pipe  
Length in Feet (ft)  
2,001’ and above.  
See Maximum Altitude  
chart on left.  
Models  
Number of  
90° elbows  
with Vent  
Number  
of 45°  
Elbows  
Maximum Vent Pipe  
Length in Feet (ft)  
0’ - 2,000’  
Vents  
42VP40SF,  
42VP40SPF,  
42VP50SF,  
42VP50SPF  
5,200’  
7,700’  
One (1)  
One (1)  
Two (2)  
Two (2)  
Three (3)  
None  
One (1)  
None  
44  
41  
38  
35  
32  
34  
31  
28  
25  
22  
42VP40F,  
42VP40PF,  
42VP50F,  
42VP50PF  
One (1)  
None  
* For the 2” vent, one 90° elbow is approximately equal to 6 feet of vent pipe.  
One 45° elbow is approximately equal to 3 feet of vent pipe.  
Minimum vent length for 3” vent pipe is one (1) foot of vertical pipe, one (1)  
90°elbow, and four (4) feet of horizontal pipe.  
Maximum Venting information for 3” Vents**  
NOTICE: The mixing of 2" and  
3" vent pipe is not recommended.  
If 3" pipe is used, a 2" to 3"  
reducer fitting is recommended at  
the rubber coupling.  
Number of 90° elbows  
with Vent  
Number of  
45° Elbows  
Maximum Vent Pipe  
Length in Feet (ft)  
0-Maximum Altitude: See chart on upper left.  
One (1)  
None  
One (1)  
None  
95  
92.5  
90  
One (1)  
Two (2)  
Two (2)  
Three (3)  
Three (3)  
Four (4)  
Four (4)  
Five (5)  
This water heater is supplied with  
a two-inch Schedule 40 PVC 45°  
vent terminal. When venting  
with 3" pipe, a Schedule 40 PVC  
45° vent terminal must be used.  
Screens for both 2" and 3" vent  
terminals have been included.  
One (1)  
None  
87.5  
85  
One (1)  
None  
82.5  
80  
One (1)  
None  
77.5  
75  
** For the 3” vent, one 90° elbow is approximately equal to 5 feet of vent  
pipe. One 45° elbow is approximately equal to 2.5 feet of vent pipe.  
13  
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Installing the water heater.  
Maximum and Minimum Vent Lengths for Residential  
60 Gallon Power Vents ONLY  
Minimum vent length for 3” vent pipe is one (1) foot of vertical pipe, one (1)  
90°elbow, and four (4) feet of horizontal pipe.  
Maximum Venting information for 3” Vents  
Maximum Vent Pipe  
Length in Feet (ft)  
2,001’ and above.  
See Maximum Altitude  
chart on left.  
Number of  
90° elbows  
with Vent  
Number  
of 45°  
Elbows  
Maximum Vent Pipe  
Length in Feet (ft)  
0’ - 2,000’  
Maximum  
Altitude for  
3” & 4”  
Models  
Vents  
One (1)  
One (1)  
Two (2)  
Two (2)  
Three (3)  
None  
One (1)  
None  
45  
42.5  
40  
35  
32.5  
30  
42VP60F  
42VP60PF  
7,700’  
One (1)  
None  
37.5  
35  
27.5  
25  
** For the 3” vent, one 90° elbow is approximately equal to 5 feet of vent  
pipe. One 45° elbow is approximately equal to 2.5 feet of vent pipe.  
Minimum vent length for 4” vent pipe is one (1) foot of vertical pipe, one (1)  
90°elbow, and four (4) feet of horizontal pipe.  
Maximum Venting information for 4” Vents**  
NOTICE: The mixing of 3" and 4"  
vent pipe is not recommended. If  
4" pipe is used, a 2" to 4" reducer  
fitting is recommended at the  
rubber coupling.  
Number of 90° elbows  
with Vent  
Number of  
45° Elbows  
Maximum Vent Pipe  
Length in Feet (ft)  
0-Maximum Altitude: See chart on upper left.  
One (1)  
None  
One (1)  
None  
95  
92.5  
90  
One (1)  
Two (2)  
Two (2)  
Three (3)  
Three (3)  
Four (4)  
Four (4)  
Five (5)  
This water heater is supplied with  
a 3" Schedule 40 PVC 90° vent  
terminal. When venting with 4"  
pipe, a Schedule 40 PVC 90° vent  
terminal must be used. Screens for  
both 3" and 4" vent terminals have  
been included.  
One (1)  
None  
87.5  
85  
One (1)  
None  
82.5  
80  
One (1)  
None  
77.5  
75  
** For the 4” vent, one 90° elbow is approximately equal to 5 feet of vent  
pipe. One 45° elbow is approximately equal to 2.5 feet of vent pipe.  
14  
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NOTICE: All pipe, fittings, solvent cement, primers and procedures must conform to American  
National Standards Institute and American Society for Testing and Materials (ANSI/ASTM) standards.  
Horizontal Vent Terminal Location  
The location of the vent terminal depends on the following  
minimum clearances and considerations (see illustration):  
Vent Terminal must be at least twelve (12) inches above  
Soffit vents  
grade level and above normal  
4'  
4'  
snow levels.  
Vent Terminal must be at least four (4) feet below, or four  
(4) feet horizontally from any door, operable window, soffit,  
under eave vent or gravity air inlet to the building or other  
appliances, or from gas or electric meters. Do not locate  
vent above walkways, doors, windows, air inlets, gas or  
electric meters or other equipment.  
Inside  
corner  
Electric  
meter  
4'  
4'  
Fresh  
air  
18"  
4'  
intake  
18"  
3' above  
Vent Terminal must be at least three (3) feet above any  
forced air inlet located within ten (10) feet. Any fresh or  
make-up air inlet such as for a dryer or furnace area is  
considered to be a forced air inlet.  
if within 10'  
12" (Above grade/snow level)  
window or vent  
Vent Terminal must be at least eighteen (18) inches from an  
inside corner formed by two exterior walls.  
Additional Considerations  
Caulk  
Do Not install vent terminal under any patio or deck.  
Rising moisture will  
collect under eaves  
To help prevent moisture from freezing on walls and under  
eaves, do not locate vent terminal on the side of a building  
with prevailing winter winds.  
If soffit vent is too  
close, block off and  
install new vent at  
another location  
6'  
When terminating the vent pipe through brick or masonry  
surfaces, a rust-resistant sheet metal backing plate  
behind the vent termination is recommended.  
(See illustration.)  
Inside  
corner  
Caulk  
6' (1.83 m)  
caulk  
6' caulk zone  
zone or to edge of  
window etc., starting  
within 6'  
Caulk  
Do Not locate vent terminal too close to shrubbery, as flue  
gasses may damage them.  
Caulk all cracks, seams and joints within six (6) feet of vent  
terminal.  
2 ft. sq. sheet metal plate on brick or  
2
b
masonry surface is recommended.  
4'  
All painted surfaces should be primed to lessen the chance of  
physical damage. Painted surfaces will require maintenance.  
WARNING Moisture in the flue gas will condense as it  
:
Insulate vent pipe exposed to cold conditions (attics, crawl  
spaces, etc.) with inflammable material to help prevent  
moisture from accumulating in vent pipe.  
leaves the vent terminal. In cold weather this condensate can  
freeze on the exterior wall, under the eaves and on  
surrounding objects. Some discoloration to the exterior of  
the building is to be expected. However, improper location  
or installation can result in severe damage to the structure  
or exterior finish of the building  
Do Not extend exposed vent pipe outside of building.  
15  
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NOTICE: All pipe, fittings, solvent cement, primers and procedures must conform to American  
National Standards Institute and American Society for Testing and Materials (ANSI/ASTM) standards.  
Horizontal Vent Installation  
Once the vent terminal location has been determined, make a  
2' x 2' Sheet  
hole through the exterior wall to accommodate the vent pipe.  
Vent pipe must exit exterior wall horizontally only.  
Metal Shieldon  
Brick or Masonry  
Walls  
Insert a small length of vent pipe through the wall and connect  
the coupling as shown to the left.  
*Vent Terminal  
with 1/2" Mesh  
Protective  
Vent Pipe  
Place the 1/2" mesh metal screen inside the terminal fitting  
and connect it as shown to the vent pipe on the exterior of the  
building.  
Screen Inside  
From  
Water Heater  
Complete the rest of the vent pipe installation to the water  
heater's vent connector fitting on the blower outlet.  
Pipe Coupling  
Outside of  
Building Wall  
If necessary support horizontal run as previously mentioned.  
* FOR THE 60 GALLON MODELS ONLY a 90° vent  
termination must be used and must be at least 2" from the wall.  
Vertical Vent Termination Location  
The location of the vent terminal depends on the following  
minimum clearances and considerations (see illustration):  
Insert 1/2" Mesh Protective  
Screen Inside Terminal Elbow  
Minimum twelve (12) inches above roof.  
Short Piece of Vent Pipe  
Minimum twelve (12) inches above anticipated snow level.  
Maximum twenty-four (24) inches above roof level without  
additional support for vent.  
Four (4) feet from any gable, dormer or other roof structure  
with building interior access (i.e., vent, window, etc.).  
Vent Pipe  
Through Roof  
Min. 12" Above Roof  
Ten (10) feet from any forced air inlet to the building. Any  
fresh or make-up air inlet such as a dryer or furnace area is  
considered to be a forced air inlet.  
Min. 12" Above  
Anticipated Snow  
Level.  
Elbow  
Vent Terminal  
Max. 24" Above Roof  
(Without Additional  
Support)  
Vertical Vent Installation  
Once the vent terminal location has been  
determined, make a hole through the roof  
and interior ceiling to accommodate the  
vent pipe.  
Determine the vent terminal height and cut  
vent pipe accordingly. Refer to the above  
section for proper vent terminal height.  
Connect vent elbow onto vertical pipe  
through roof.  
Complete the vent pipe installation to the  
water heater's vent connector fitting on the  
blower outlet.  
Connect short piece of vent pipe  
(approximately 3" long) to elbow, then  
insert 1/2" mesh metal screen into terminal  
elbow and join it to the short piece of vent  
pipe.  
Support vertical or horizontal lengths as  
previously mentioned.  
Install adequate flashing where the vent  
pipe passes through the roof.  
16  
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Installing the water heater.  
NOTICE: All pipe, fittings, solvent cement, primers and procedures must conform to American  
National Standards Institute and American Society for Testing and Materials (ANSI/ASTM) standards.  
Cementing Joints  
All joints in the vent piping must be  
properly sealed and the following  
materials are recommended:  
Wipe all excess cement from the joint  
with a rag. Allow 15 minutes before  
handling. Cure time will vary according  
to fit, temperature and humidity.  
WARNING: DANGER  
OF FIRE OR BODILY  
INJURY - Solvent cements  
and primers are highly  
flammable. Provide  
adequate ventilation and do  
not assemble near heat  
source or open flame. Do not  
smoke. Avoid skin or eye  
contact. Observe all cautions  
and warnings on material  
containers.  
PVC materials should use ASTM D2564  
grade cement.  
NOTICE: Stir the solvent cement  
frequently while using. Use a natural  
bristle brush or the dauber supplied  
with the can. The proper brush size is  
one inch.  
CPVC materials should use ASTM F493  
grade cement.  
ABS materials should use ASTM D2235  
grade cement.  
NOTICE: This unit is equipped with a  
Flammable Vapor Sensor. Do not apply  
power until enough time has passed to  
allow the vapors from the primer and  
cement to dissipate.  
Cleaner-Primer and Medium Body  
Solvent Cement:  
CAUTION:  
For proper installation:  
Cut pipe end square, remove jagged  
edges and burrs. Chamfer end of pipe,  
then clean fitting socket and pipe joint  
area of all dirt, grease or moisture.  
DO NOT use solvent cement  
that has become curdled,  
lumpy or thickened.  
After checking pipe and socket for  
proper fit, wipe socket and pipe with  
cleaner-primer. Apply a liberal coat of  
primer to inside surface of socket and  
outside of pipe. Do not allow primer to  
dry before applying cement.  
DO NOT thin solvent  
cement. Observe shelf  
precautions printed on the  
containers.  
For applications below 32°F  
use only low temperature  
type solvent cement.  
Apply a thin coat of cement evenly in  
the socket. quickly apply a heavy coat  
of cement to the pipe end and insert  
pipe into fitting with a slight twisting  
motion until it bottoms out.  
Appropriate solvent and  
cleaner must be used for the  
type of vent pipe used (PVC,  
CPVC or ABS).  
NOTICE: Cement must be fluid; if not,  
recoat.  
Hold the pipe fitting for 30 seconds to  
prevent the tapered socket from pushing  
the pipe out of the fitting.  
17  
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Wiring  
If local codes permit, the water heater may The maximum current draw is  
be connected to electric service with the  
power cord provided (DO NOT use an  
extension cord). A grounding receptacle is  
required.  
approximately 5.0 amps.  
The water heater must be electrically  
grounded in accordance with local  
codes, or, in the absence of local codes,  
in accordance with latest edition of the  
National Electric Code ANSI/NFPA No.  
70. Refer to the figures below for water  
If local codes do not permit the use of  
cord connections, a 120 V, 50/60 Hz  
power supply, with suitable disconnecting  
means, must be connected to the black and heater internal wiring.  
white leads in the heater control enclosure.  
NOTE: It is not recommended that this  
A knock-out hole is provided to permit use unit be installed on a GFCI circuit.  
of conduit or metal-clad cable connectors.  
CONNECTION DIAGRAM  
SCHEMATIC  
ON / OFF  
SWITCH  
BL  
INDUCER  
W
G
FLAME  
SENSOR  
IGNITER  
FV SENSOR  
PRESSURE  
SWITCH  
TEMPERATURE  
SWITCH  
ELECTRONIC  
CONTROL  
G
6 PIN CONNECTOR  
L2  
G
G
BK  
I
IGNITER AND  
FLAME PROBE  
FV  
BK  
W
R
R
Y
BL  
L1  
W
GAS  
VALVE  
ON / OFF  
SWITCH  
BK  
BK  
W
TEMPERATURE PRESSURE  
SWITCH  
SWITCH  
“H” “N”  
ELECTRONIC  
CONTROL  
W
Y
BK = BLACK  
BL = BLUE  
G
R
= GREEN  
= RED  
R
W
Y
= WHITE  
= YELLOW  
BL  
R
CAUTION! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and  
dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!  
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Installing the water heater.  
Insulation Blankets  
Insulation blankets, available to the  
general public, for external use on gas  
water heaters are not necessary. The  
purpose of an insulation blanket is to  
reduce the standby heat loss encountered  
with storage tank heaters. This water  
heater meets or exceeds the National  
Appliance Energy Conservation Act  
standards with respect to insulation and  
standby loss requirements making an  
insulation blanket unnecessary.  
CAUTION: If local codes require the  
application of an external insulation  
blanket to this water heater, pay careful  
attention to the following so as not to  
restrict the proper function and  
WARNING: If local  
codes require external  
application of insulation  
blanket kits the  
manufacturer’s instructions  
included with the kit must  
be carefully followed.  
operation of the water heater:  
Do not cover the operating or warning  
labels attached to the water heater or  
attempt to relocate them on the exterior  
of insulation blanket.  
Do not apply insulation to the top of the  
water heater. This will interfere with the  
safe operation of the blower assembly.  
The manufacturer’s warranty does not  
cover any damage or defect caused by  
installation, attachment or use of  
Do not cover the burner access door,  
jacket door, gas control (thermostat)/gas  
valve or pressure and temperature relief  
valve.  
any type of energy saving or other  
unapproved devices (other than those  
authorized by the manufacturer) into, onto  
or in conjunction with the water heater.  
The use of unauthorized energy saving  
devices may shorten the life of the water  
heater and may endanger life and property.  
Do not apply insulation to the bottom  
of the water heater or the area where  
the combustion air inlet openings and  
Flammable Vapor Sensor are located.  
This area must be unobstructed so as  
not to restrict combustion air flow to  
the burner or operation of the sensor.  
The manufacturer disclaims any  
responsibility for such loss or injury  
resulting from the use of such  
unauthorized devices.  
Inspect the insulation blanket frequently  
making certain it has not sagged  
and it is not restricting the air flow  
to the combustion air inlet openings  
(perforation holes) or the Flammable  
Vapor sensor located around the lower  
perimeter of the water heater jacket.  
This could result in an unsafe operating  
condition.  
Hot and Cold Pipe Insulation Installation  
NOTICE: If pipe  
Dilution Air Holes  
insulation is used, ensure  
that the thickness does  
not exceed ½”. Insulation  
thicker than ½” can  
interfere with the Blower  
Assembly Dilution Air  
Holes.  
Typical vertical piping arrangement  
Typical horizontal piping arrangement  
For increased energy efficiency, some  
water heaters have been supplied with  
two 24” sections of pipe insulation.  
Please install the insulation, according  
to the illustrations above, that best meets  
your requirements.  
19  
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Heat Trap  
For increased energy efficiency, some  
water heaters have been supplied with  
factory installed 3/4” NPT heat traps in  
the hot outlet line and cold water inlet  
line.  
These heat traps may require a minimum  
of one (1) 90° 3/4” NPT elbow and may  
require an additional 90° 3/4” NPT elbow  
or a 3/4” coupling depending on your  
installation needs. See Illustration of  
nipples and heat traps on page 33.  
During Installation of this water heater...........  
DO  
DON’T  
DO check inlet gas pressure to ensure  
DON’T block or restrict Combustion  
that it is within the range specified on the  
rating plate.  
Air Inlet Openings or the Flammable Vapor  
Sensor located around the lower portion of  
the water heater jacket.  
DO provide adequate air for combustion  
and ventilation as discussed in the Use and  
Care Manual and the National Fuel Gas  
Code.  
DON’T block or restrict the Blower  
Assembly Dilution Air holes (see diagram to  
the left).  
DO maintain proper clearances to  
DON’T remove the Burner Access  
combustibles as specified on the rating  
plate.  
Door unless absolutely necessary. This  
should only be done by a qualified service  
technician. A new burner access door gasket  
must be installed on any burner access door  
that has been removed.  
DO allow enough time for joint cement  
vapors to dissipate BEFORE applying  
power to the water heater.  
Blower Assembly Dilution Air Holes  
Location of Dilution Air Holes  
DO ensure that the venting system  
DON’T install this water heater where  
complies with the guidelines found in the  
Use and Care Manual and National Fuel Gas  
Code.  
standing water may occur. The base of the  
water heater is meant to be mounted on a dry  
surface.  
DO contact a qualified service technician  
DON’T allow cleaners, solvents, or other  
if the main burner will not stay lit. The burner  
chamber is designed to be sealed utilizing a  
gasket and tamper resistant screws.  
materials to come into contact with the  
Flammable Vapor Sensor.  
DON’T operate the water heater if the  
Burner Access  
Door Grommet  
V
A
CATION  
A
B
C
VER  
HOT  
Y
W
ARM  
COOLER  
HOTTER  
Sight Glass  
sight glass or burner access door grommet is  
damaged or broken (see to the left).  
Flammable  
Vapor Sensor  
20  
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Installation Checklist  
A. Water Heater Location  
Close to area of vent.  
Provisions made to protect area from water  
damage.  
Indoors and protected from freezing  
temperatures.  
Sufficient room to service heater.  
Proper clearance from combustible surfaces  
observed and water heater not installed on  
carpeted floor.  
Combustible materials, such as clothing,  
cleaning materials, rags, etc. clear of the  
base of the heater.  
Sufficient fresh air supply for proper  
operation of water heater.  
Clearances of 1” from combustion air inlet  
openings observed  
Air supply free of corrosive elements and  
flammable vapors.  
Flammable vapor sensor is not blocked.  
B. Water Supply  
Water heater completely filled with water.  
Air purged from water heater and piping.  
Water connections tight and free of leaks.  
C. Gas Supply  
connections and fittings for possible gas  
leak.  
Gas line equipped with shut-off valve, union  
and sediment trap.  
Approved pipe joint compound used.  
Soap and water solution used to check all  
Gas Company inspected installation (if  
required).  
D. Relief Valve  
Temperature and Pressure Relief Valve  
Discharge line protected from freezing.  
properly installed and discharge line run to  
open drain.  
E. Venting  
Heater vented separately from all other  
appliances.  
Vent pipe supported at required intervals.  
Appropriate minimum clearances observed.  
Flue baffle properly hung in top of heater’s  
flue.  
Precautions taken to prevent moisture damage  
around vent termination.  
Blower assembly properly installed.  
Vapors from vent pipe cement and primer  
have dissipated prior to applying electrical  
power.  
Proper materials and techniques used in vent  
assembly.  
Vent pipe properly secured to blower  
housing.  
F. Wiring  
Correct power supply (120 V).  
Electrical connections tight.  
Heater properly grounded and proper polarity  
observed.  
21  
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Supplemental instructions for gas water heaters installed  
in potable water/space heating applications.  
Local codes or plumbing authority requirements may vary from the instructions or diagrams provided  
in this manual and take precedent over these instructions.  
Hot water  
Combination Potable Water and Space Heating Application  
supply to  
house  
Tee fitting must be installed as shown.  
DANGER: If this water heater is  
This ensures that any air in the water lines  
will be purged through the domestic water  
faucets and showers.  
installed in an application intended to  
supply domestic hot water needs and  
hot water for space heating purposes,  
do not connect the heater to an existing  
heating unit or components of a heating  
system that have previously been used  
with a non drinking water system. Toxic  
chemicals such as those used for boiler  
treatment may be present and will  
contaminate the drinking water supply  
causing possible health risks. Never  
introduce toxic chemicals, such as those  
used for boiler treatment, into this  
system.  
Hot water  
supply to  
heating  
unit  
From HOT  
outlet on  
water heater  
DANGER: When this system  
requires water for space heating at  
elevated temperatures (above 125°F  
[52°C.]), a mixing or tempering valve  
must be installed in the hot water  
supply line to the house in order to  
reduce the scald hazard potential.  
Tee fitting for vertical hot  
water supply lines.  
From HOT  
Hot water  
supply to  
house  
outlet on  
water heater  
DANGER: Any piping or components  
used in the installation of this water  
heater in a combination potable and  
space heating application must be  
suitable for use with drinking water.  
Notice: 50' - 0" maximum distance from  
water heater to fan coil (developed length)  
is required for Massachusetts State.  
Hot water supply  
to heating unit  
Tee fitting for horizontal hot  
water supply lines.  
Typical Piping Diagram for Combination Potable/Space Heating Installation  
Pressure Gauge  
Nominal 3/4" size mixing or tempering valve  
(refer to warning above). Follow mixing or  
tempering valve manufacturer’s instructions for  
installation of the valve.  
3/4" Check Valve with 1/8" Hole  
3/4" Shut-Off Valve (Typ.)  
Minimum of 2'-0" developed length  
of 3/4" pipe.  
3/4" Tempered  
domestic hot water  
supply to house.  
3/4" cold water supply  
Air vent  
Spring loaded check valve in heating unit  
hot water supply line and cold water return  
line (not supplied with water heater)  
3/4" Shut-Off Valve (Typ.)  
NOTE: This check valve is incorporated  
in some heating units. Refer to the  
installation instructions supplied with  
specific heating unit to determine if it is  
required.  
Heat Trap  
6” Min.  
2 Gallon Thermal  
Expansion Tank (if  
required-not supplied  
with water heater)  
3/4" Shut-  
Off Valve  
(Typ.)  
Isolation valve in hot water supply line  
to heating unit (not supplied with water  
heater)  
Hot water  
to space heater  
Hot water coil  
See diagrams above for proper  
pipe application for vertical  
or horizontal supply lines.  
All bronze pump.  
Check valve  
internal in pump.  
Temperature and Pressure Relief  
Valve, tie to location approved by  
local code  
Air bleed valve.  
Water Sample Tap.  
Gas line to water heater  
3/4" HWS & HWR  
to Heating Coil.  
To HVAC Unit.  
Drain valve  
(not supplied with  
water heater)  
Temperature and pressure relief  
valve discharge line  
FAN  
T
ON  
OFF  
HEAT  
COOL  
Isolation valve in  
Gas Fired  
Water Heater  
Gas Control (Thermostat)  
cold water return line  
from heating unit (not  
supplied with water  
heater)  
Air Handler  
Gas Direct Vent discharge  
must comply with Local  
and State Codes  
Water Heater drain pan installed in  
accordance with the Local and State  
Code  
Water Heater to be in accordance with  
the Local and State Energy Code  
V a cuum Relief Valve  
(Not Supplied)  
Combustion Air Inlet  
Openings  
Electronically controlled pump timer.  
Activates every 6 hours for 60 seconds.  
Wire to bronze pump.  
All water piping shall be insulated in  
accordance with Local and State Energy  
Code.  
If required, install per local codes  
and valve manufacturer’s  
instructions.  
22  
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Lighting the water heater.  
Before operating this water heater, be sure to read and follow the instructions on the label pictured  
below and all other labels on the water heater, as well as the warnings printed in this manual. Failure  
to do so can result in unsafe operation of the water heater resulting in property damage, personal  
injury, or death. Should you have any problems reading or following the instructions in this manual,  
STOP, and get help from a qualified person.  
FOR YOUR SAFETY READ BEFORE OPERATING  
WARNING: If you do not follow these instructions and use the Use & Care Manual instructions  
exactly, a fire or explosion may result causing property damage, personal injury or loss of life.  
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.  
instructions.  
If you cannot reach your gas supplier, call  
the fire department.  
B. BEFORE PUTTING THIS APPLIANCE INTO  
SERVICE - 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.  
C.  
D.  
Use only your hand to push in the gas control  
buttons. Never use tools. If the control buttons  
will not push in, don’t try to repair them, call a  
qualified service technician. Force or attempted  
repair may result in fire or explosion.  
WHAT TO DO IF YOU SMELL GAS  
Do not use this appliance if any part has been  
under water. Immediately call a qualified in-  
staller or service agency to replace a flooded  
water heater. Do not attempt to repair the unit!  
It must be replaced!  
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 suppliers  
OPERATING INSTRUCTIONS  
Stop! Read the safety information above on  
this label.  
assembly to the “ON”position.  
1.  
2.  
9.  
Set thermostat to the desired temperature setting  
by pressing the COOLER and HOTTER  
Set the thermostat to the lowest setting by  
pressing the COOLER or HOTTER buttons  
buttons at the same time and holding them for (1)  
second. Depress the HOTTER button until the  
desired temperature is/are lit. The preferred start-  
ing point for temperature setting is indicated by  
on the thermostat.  
at the same time and holding them for (1)  
second. Depress the COOLER button until  
the WARM indicator light is lit.  
Toggle the “ON/OFF”switch located on the  
blower assembly to the “OFF”position.  
3.  
4.  
10.  
If the appliance will not operated, follow the  
instructions “TO TURN OFF GAS TO APPLIANCE”  
and call your service technician or gas supplier.  
Turn off all electric power to the appliance.  
5. This appliance is equipped with a Hot Surface  
Ignition System which automatically lights the  
burner. Do NOT open the inner door of this  
appliance and try to light the burner by hand!  
VACATION  
WARM  
A
B
C
VERY  
HOT  
COOLER  
HOTTER  
Wait five (5) minutes to clear out any gas. If you  
6.  
smell gas, STOP! Follow “B”in the safety inform-  
ation above on this label. If you do not smell  
gas, go to the next step.  
WARNING  
7. Turn on all electric power to the appliance.  
Toggle the “ON/OFF”switch located on the blower  
8.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to the lowest setting by first depressing the COOLER  
and HOTTER buttons at  
the same time and holding for 1 second. Depress the COOLER button until only the WARM indicator  
light appears.  
2.  
3.  
Toggle the“ON/OFF”switch located on the blower assembly to the“OFF”position.  
Turn off all electric power to the appliance if service is to be performed.  
AX4762  
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Operating the water heater.  
CAUTION: Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a  
long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE!! To dissipate such  
gas and to reduce risk of injury, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink  
before using any electrical appliance connected to the hot water system. If hydrogen is present, there will be an unusual sound  
such as air escaping through the pipe as the water begins to flow. Do not smoke or use an open flame near the faucet at the  
time it is open.  
Safety Precautions  
Do turn off manual gas shut-off valve if water heater  
has been subjected to over heating, fire, flood,  
physical damage or if the gas supply fails  
to shut off.  
Do Not store or use gasoline or other flammable  
vapors and liquids, such as adhesives or paint thinner,  
in vicinity of this or any other appliance.  
If such flammables must be used, open doors  
and windows for ventilation, and all gas burning  
appliances in the vicinity should be shut off including  
their pilot burners, to avoid vapors lighting.  
Do Not turn on water heater unless it is completely  
filled with water.  
Do Not turn on water heater if cold water supply  
shut-off valve is closed.  
NOTICE: Flammable vapors can be drawn by air  
currents from surrounding areas to the water heater.  
Do Not allow combustible materials such as  
newspaper, rags or mops to accumulate near  
water heater.  
If there is any difficulty in understanding or following  
the Operating Instructions or the Care and Cleaning  
section, it is recommended that a qualified person or  
serviceman perform the work.  
Operating Procedure  
This heater is equipped with a hot surface  
ignitor to light the main burner. There is  
no pilot light to be lit, but on initial start-  
up, it is recommended that the outer door  
be removed (leave inner door in place for  
the gas valve should open and the main  
burner ignite. After the main burner ignites,  
replace the outer door. If no main burner  
flame is established, the gas control will go  
through three trials for ignition before going  
safety) to determine if the hot surface ignitor into a lock-out. A warning light will alert  
and main burner are operating properly.  
the user of this lock-out condition. If this  
happens, refer to “Troubleshooting Guide.”  
Once filled with water, it is only necessary  
to plug the power cord in and make sure the  
“ON/OFF” switch located on the blower  
assembly is in the “ON” position to put the  
water heater into operation. Within seconds  
the hot surface ignitor should heat up, then  
TO SHUT OFF WATER HEATER – Turn  
switch on the blower assembly to the “OFF”  
position.  
Water Temperature Setting  
The temperature of the water in the water  
heater can be regulated by pressing the  
buttons on the front of the gas control  
(thermostat).  
Water temperatures above 125°F  
!
DANGER: Hotter water  
can cause severe burns or death from  
scalding. Be sure to read and follow the  
warnings outlined in this manual and on  
the label located on the water heater near  
the gas control thermostat.  
increases the Potential  
for Hot Water SCALDS.  
Households with small  
children, disabled, or elderly  
persons may require a 120°F  
or lower gas control  
(thermostat) setting to  
prevent contact with HOT  
water.  
Safety and energy conservation are factors  
to be considered when selecting the water  
temperature setting of the water heater’s  
gas control (thermostat(s)). The lower the  
Mixing valves are available for reducing  
point of use water temperature by mixing  
temperature setting, the greater the savings hot and cold water in branch water  
in energy and operating costs.  
lines. Contact a licensed plumber or  
the local plumbing authority for further  
information. (See page 4 for more details.)  
To comply with safety regulations, the gas  
control (thermostat) was set at its lowest  
setting before the water heater was shipped  
from the factory. The recommended  
starting point temperature is 120°F.  
The chart on the next page may be used  
as a guide in determining the proper water  
temperature for your home.  
24  
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Operating the water heater.  
Water Temperature Setting…  
Maximum water temperatures occur just  
after the burner has shut off. To determine  
the water temperature, turn on a hot water  
faucet and place a thermometer in the  
water stream.  
The hottest temperature water will be at  
the top of the tank, closest to the outlet  
pipe delivering hot water to the home.  
Stacking can cause this top layer of water  
to be hotter than the water toward the  
bottom of the tank near the gas control  
(thermostat). Therefore, always remember  
to test the water temperature with your  
hand before use and remember that hotter  
water increases the risk of scald injury.  
To avoid any unintentional changes in  
water temperature settings, the gas control  
(thermostat) has a tamper resistant feature  
for changing the temperature setting. To  
change the temperature setting follow  
these instructions.  
Also, always supervise young children or  
others who are incapacitated.  
1. "Wake Up" the temperature indicators  
by holding down both "COOLER" and  
"HOTTER" temperature adjustment  
buttons at the same time for one  
The gas control (thermostat) is constructed  
with a built in safety shut-off device  
designed to shut off the gas supply to the  
burner if the main burner is extinguished  
for any reason.  
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  
The gas control (thermostat) is also  
equipped with a single use gas shut off  
device that will shut off the gas supply  
control will go back to "sleep" mode.  
2. Release both of the temperature buttons. to the burner if the water heater exceeds  
normal operating temperatures. Refer to  
a. To decrease the temperature press  
and release the "COOLER" button  
until the desired setting is reached.  
the Before You Call For Service section of  
this manual, or contact your dealer.  
!
WARNING: Should overheating occur or  
the gas supply fail to shut off, turn off the  
manual gas control valve to the appliance.  
b. To increase the temperature press  
and release the "HOTTER" button  
until the desired setting is reached.  
If the water heater has been subjected to  
fire, flood or physical damage, turn off the  
manual gas control (shut-off) valve, and  
do not operate the water heater again until  
is has been checked by a qualified service  
technician.  
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.  
NOTICE: Replace any part of the gas  
control system which has been under water.  
A condition known as “stacking” or  
“layering” can occur when a  
series of short and frequent hot  
water draws are taken.  
VACATION  
WARM  
A
B
C
VERY  
HOT  
COOLER  
HOTTER  
WARNING  
Time/Temperature Relationship in Scalds  
Water Temperature  
Time To Produce a Serious Burn  
120°F  
More than 5 minutes  
11/2 to 2 minutes  
125°F  
Display  
Temperature Setting  
Burns on Adult Skin  
130°F  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 11/2 seconds  
About 1 second  
▼ A B C  
WARM = approx. 70°F (21°C)  
▼ = approx. 120°F (49°C)  
A = approx. 130°F (54°C)  
B = approx. 140°F (60°C)  
C = approx. 150°F (66°C)  
C-Flashing = approx. 160°F (71°C)  
--------------------  
More than 5 minutes  
About 30 seconds  
Less than 5 seconds  
About 1-1/2 seconds  
About 1/2 seconds  
135°F  
● ○ ○ ○ ○ ○  
○ ○ ● ○ ○ ○  
○ ○ ○ ● ○ ○  
○ ○ ○ ○ ● ○  
○ ○ ○ ○ ○ ●  
○ ○ ○ ○ ○ ●  
140°F  
145°F  
150°F  
155°F  
Table courtesy of Shriners Burn Institute  
25  
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Sequence of Operation…  
During initial start-up or a call for heat,  
the control will verify the vacuum switch  
is open.  
The blower motor will stay energized  
for an additional 30 seconds after the  
control verifies that the burner flame is  
extinguished in order to clear combustion  
gases from the water heater.  
Once the control verifies the blower  
vacuum switch is open, the control  
will energize the blower motor for the  
pre-purge sequence (approximately 5  
seconds).  
After the post-purge sequence, the control  
will de-energize the blower motor and go  
into a stand-by mode awaiting the next  
call for heat.  
The control will verify the blower vacuum  
switch has closed, ensuring that the  
blower is functioning properly and that the  
venting system is not blocked.  
This water heater is equipped with  
a flammable vapor sensor that is  
monitored continuously by the  
electronic control in all modes of  
operation.  
The control will then proceed through  
a sequence of self-diagnostics before  
initiating a trial for ignition.  
In the event that flammable vapors are  
detected, the control will automatically  
shut down the water heater and prevent  
the water heater from being started again.  
During the trial for ignition, the hot  
surface ignitor will warm up.  
Once the hot surface ignitor warms up, the  
main gas valve will open allowing gas to  
flow to the main burner.  
The following is a list of materials that  
will cause the Flammable Vapor Sensor  
to shut down the water heater.  
Once the main burner ignites, the control  
will verify that the burner flame is present  
through the flame sense circuit. The hot  
surface ignitor will then turn off.  
Vapors of Gasoline.  
Vapors of certain flammable paints,  
stains, and thinners.  
Vapors of vent pipe Cement &  
The main burner will remain lit  
throughout the heat cycle until the water  
temperature setting is reached.  
Solvents.  
Bleach (direct contact with  
flammable vapor sensor).  
Once the water temperature setting is  
reached, the control will close the main  
gas valve which will extinguish the main  
burner flames.  
Some other flammable materials and  
their vapors.  
If the flammable vapor sensor shuts  
down the water heater, then the electronic  
control will display the appropriate error  
code and you should then promptly  
contact a qualified service technician.  
Refer to the “Notice” on page 3 for  
additional information.  
26  
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Care and cleaning of the water heater.  
Draining the Water Heater  
Before turning off the cold water supply to  
the water heater, open a hot water faucet  
allowing sufficient cold water into the  
tank to prevent the risk of a scald injury  
while draining the water heater. Once the  
water in the tank is no longer hot, turn off  
the cold water supply to the water heater.  
Open a hot water faucet or lift the handle  
on the relief valve to admit air to the tank.  
!
CAUTION: Shut off gas to the water  
heater at the gas control (thermostat) gas  
cock or manual shut-off valve before  
draining water.  
!
DANGER: Before manually operating the  
temperature and pressure relief valve, make  
certain no one will be exposed to the hot  
water released by the valve. The water  
drained from the tank may be hot enough to  
present a scald hazard and should be  
directed to a suitable drain to prevent injury  
or damage.  
Attach a garden hose to the drain  
valve on the water heater and direct  
the stream of water to a drain. Open  
the valve.  
Routine Preventative Maintenance  
DANGER: Before  
manually operating the  
relief valve, make certain  
no one will be exposed to  
the danger of the hot water  
released by the valve. The  
water may be hot enough to  
create a scald hazard. The  
water should be released  
into a suitable drain to  
prevent injury or property  
damage.  
Properly maintained, your water heater  
will provide years of dependable trouble-  
free service.  
A water heater’s tank can act as a settling  
basin for solids suspended in the water.  
It is therefore not uncommon for hard  
water deposits to accumulate in the bottom  
of the tank. If allowed to accumulate,  
these solids can cover the gas control  
(thermostat) sensors, causing the sensors to  
operate erratically. Because accumulated  
solids can prevent the gas control  
It is recommended that a periodic  
inspection of the gas control (thermostat),  
burner, relief valve, internal flue-way and  
venting system should be made by service  
personnel qualified in gas appliance repair.  
(thermostat) sensors from accurately  
reading the water temperature, the water  
at the fixture can be hotter than the gas  
control (thermostat) setting. It is suggested  
that a few quarts of water be drained from  
the water heater’s tank every month to  
clean the tank of these deposits.  
It is suggested that a routine preventative  
maintenance program be established and  
followed by the user.  
!
DANGER: Hotter water  
increases the potential for  
Hot Water Scalds.  
Inspect plastic vent pipe. Make certain  
that all joints are secure and that vent  
pipe supports are all in place. Check  
the outdoor vent terminal to see that it is  
free of obstructions, and that there is no  
damage nearby casused by condensate.  
Rapid closing of faucets or solenoid valves  
in automatic water using appliances can  
cause a banging noise heard in a water  
pipe. Strategically located risers in the  
water pipe system or water hammer  
arresting devices can be used to minimize  
the problem.  
Inspect dilution air inlet and combustion  
air inlet openings. Make certain no  
blockage exists. Clean any lint, dirt or oil  
accumulation that may exist.  
At least once a year, lift and release the  
lever handle on the temperature pressure  
relief valve, located near the top of the  
water heater, to make certain the valve  
operates freely. Allow several gallons to  
flush through the discharge line to an open  
drain.  
The anode rod should be removed from the  
water heater’s tank annually for inspection  
and replaced when more than 6” of core  
wire is exposed at either end of the rod.  
Blower Assembly Dilution Air Holes  
Location of Dilution Air Holes  
Make sure the cold water supply is turned  
off before removing anode rod.  
DANGER: Failure to  
perform the recommended  
Routine Preventative  
Maintenance can harm the  
proper operation of this  
water heater, which can cause  
carbon monoxide dangers,  
excessive hot water  
This water heater incorporates a  
NOTICE: If the temperature and  
pressure relief valve on the water heater  
discharges periodically, this may be due  
to thermal expansion in a closed water  
system. Contact the water supplier or  
your plumbing contractor on how to  
correct this. DO NOT plug the relief  
valve outlet.  
combustion shut off device that shuts  
the operation of the water heater down if  
undesirable combustion conditions occur,  
such as the presence of flammable vapors  
or blockage of the combustion air inlet  
openings. Please contact a qualified  
Service Technician if this occurs.  
temperatures and other  
potentially hazardous  
conditions.  
27  
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!
DANGER: Combustible  
materials, such as clothing,  
cleaning materials, or  
Housekeeping  
Visually inspect the hot surface ignitor.  
When installed in a closet, DO NOT block  
or obstruct any of the combustion air inlet  
openings located around the perimeter  
of the water heater. A minimum of 1” is  
required between these combustion air inlet  
openings and any obstruction.  
To ensure sufficient ventilation and  
combustion air supply, proper clearances  
must be maintained.  
flammable liquids, etc., must  
not be placed against or next  
to the water heater.  
DO NOT obstruct or block the  
Flammable Vapor Sensor. The sensor  
does not require any maintenance or  
cleaning. DO NOT expose to cleaning  
agents.  
Venting System Inspection  
The water heater’s internal flue must be  
inspected annually to be certain it is clean  
by removing the blower assembly and flue  
baffle.  
Inspect dilution air holes. Make certain no  
blockage exists. Clean any lint, dirt or oil  
accumulation that may exist.  
Test for spillage at the dilution air holes  
after 5 minutes of burner operation. Place  
a blown out match or candle close to the  
dilution are holes. The smoke from the  
candle or match should be drawn into the  
dilution air holes. If the smoke is pushed  
away from the dilution air holes, the  
blower or vent system may be blocked.  
Contact qualified service personnel.  
When reinstalling the flue baffle make  
certain it is hung securely by its hanger at  
the top of the flue way.  
Reinstall the blower assembly.  
Inspect plastic vent pipe. Make certain  
that all joints are secure and that vent  
pipe supports are all in place. Check  
the outdoor vent terminal to see that it is  
free of obstructions, and that there is no  
damage nearby caused by condensate.  
Blower Assembly Dilution Air Holes  
Location of Dilution Air Holes  
Burner Inspection  
Visually inspect the hot surface ignitor  
and main burners annually.  
!
CAUTION: For your safety, cleaning of  
the burner must be performed only by  
qualified service personnel, as it involves the  
disconnection of gas piping and leak testing.  
The burner chamber is a sealed area. If the  
burner access door is removed, the burner  
access door gasket must be replaced.  
Through the sight glass, inspect the hot  
surface ignitor with the main burner off  
and inspect the main burner while firing.  
If any unusual burner operation is noted,  
the water heater should be shut off  
until qualified service assistance can be  
obtained.  
For cleaning, remove the burner from the  
water heater. A vacuum cleaner can be  
used on the burner and floor shield inside  
the water heater. The burner can also be  
cleaned by scrubbing with mild detergent.  
Proper burner flame pattern  
28  
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Care and cleaning of the water heater  
Vacation and Extended Shut-Down  
NOTICE: Refer to the  
Hydrogen Gas Caution in the  
Operating Instructions.  
If the water heater is to remain idle for an  
extended period of time, the power and  
water to the appliance should be turned off should be checked by qualified service  
After a long shut-down period, the  
water heater’s operation and controls  
to conserve energy and prevent a build-up  
of dangerous hydrogen gas.  
personnel. Make certain the water heater  
is completely filled again before placing it  
in operation.  
The water heater and piping should be  
drained if they might be subjected to  
freezing temperatures.  
Anode Rod  
NOTICE: Do not remove  
the anode rod from the water  
heater’s tank, except for  
inspection and/or replacement,  
as operation with the anode  
rod removed will greatly  
shorten the life of the glass  
lined tank and will exclude  
warranty coverage.  
This water heater is equipped with an  
anode rod designed to prolong the life  
of the glass lined tank. The anode rod is  
slowly consumed, thereby eliminating or  
minimizing corrosion of the glass lined  
tank.  
Water sometimes contains a high sulfate  
and/or mineral content and together with  
cathodic protection process can produce  
a hydrogen sulfide, or rotten egg odor in  
the heated water. Chlorination of the water  
supply should minimize the problem.  
29  
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Before You Call For Service…  
Troubleshooting Tips  
Save time and money! Review the charts on the following pages first and you may not need to call for service.  
This water heater incorporates a combustion shut off device that shuts the operation of the water heater  
down if undesirable combustion conditions occur, such as the presence of flammable vapors or blockage of  
the combustion air inlet openings. Please contact a qualified Service Technician if this occurs.  
Problem  
Possible Causes  
What To Do  
Condensation  
This usually happens when  
a new water heater is  
filled for the first time.  
This is normal. After the water in the tank warms  
up, the condensation will disappear. If, however, the  
condition persists, examine the piping and fittings  
for possible leaks.  
Moisture from the products  
of combustion condensing  
on the tank surface.  
This is normal and will disappear in time. Excessive  
condensation can cause main burner outage.  
An undersized water  
heater will cause  
condensation.  
Use a water heater size that meets the requirements  
of your needs.  
Yellow flame  
or soot  
Scale on top of the burner.  
Contact a qualified service technician to remove scale.  
Flue or Combustion air inlet  
openings are restricted.  
Remove obstruction or debris from flue or  
combustion air inlet openings on water heater jacket.  
Not enough combustion or  
ventilation air supplied to  
the water heater location.  
Proper operation of the water heater requires air for  
combustion and ventilation. See the Combustion and  
Ventilation Air information in the “Installing The  
Water Heater” section of this manual.  
Unable to light  
Air in gas line.  
Contact a qualified service technician to purge the air  
the main burner  
from the gas line.  
Gas Cock Knob not  
correctly positioned.  
Contact a qualified service technician to correctly position  
the gas cock knob.  
Blocked Exhaust  
Contact a qualified service technician to evaluate vent  
pipe for blockage.  
Pressure Switch  
Make sure the pressure switch hose is not "kinked".  
Wire Connection not fully  
secured.  
Contact a qualified service technician to confirm wire  
connections.  
Combustion Shut-off Device  
tripped,  
Combustion shut-off device should be inspected by a  
qualified service technician.  
Gas Control Problem  
Contact a qualified service technician.  
Main burner does not  
stay lit  
Gas Controls (Thermostat’s)  
single use gas shut-off device  
has opened.  
The gas control (thermostat) should be replaced by a  
qualified service technician.  
Combustion Shutoff Device  
Tripped.  
The combustion shutoff device should be inspected  
by a qualified service technician.  
CAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or other safety  
devices. Refer repairs to qualified service personnel.  
30  
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Before You Call For Service…  
Troubleshooting Tips  
Save time and money! Review the charts on the following pages first and you may not need to call for service.  
This water heater incorporates a combustion shut off device that shuts the operation of the water heater down  
if undesirable combustion conditions occur, such as the presence of flammable vapors or blockage of the  
combustion air inlet openings. Please contact a qualified Service Technician if this occurs.  
Problem  
Possible Causes  
What To Do  
Rumbling noise  
Scale and sediment  
Drain the water heater to remove scale and sediment from  
the tank. Refer to the top of page 26.  
Relief valve  
producing popping  
noise or draining  
Pressure build up  
caused by thermal  
expansion to a  
This is an unacceptable condition and must be  
corrected. Contact the water supplier or plumbing  
contractor on how to correct this. Do not plug the  
relief valve outlet.  
closed system.  
Not enough or  
no hot water  
Water usage may have  
exceeded the capacity  
of the water heater.  
Wait for the water heater to recover after an  
abnormal demand.  
Low gas pressure.  
Check gas supply pressure and manifold pressure.  
The gas control (thermostat)  
may be set too low.  
See the “Water Temperature Setting” of The Water  
Heater section of this manual.  
Leaking or open hot  
water faucets.  
Make sure all faucets are closed.  
Check valve error codes.  
“ON/OFF” switch turned off.  
Blower unplugged.  
Refer to gas valve error code table on page 30.  
Turn “ON”.  
Plug in. Verify power supply (120VAC).  
Contact a qualified service technician.  
Combustion Shutoff System  
tripped  
Water is too hot  
The gas control (thermostat)  
is set too high.  
See the “Water Temperature Setting” of The Water  
Heater section of this manual.  
Gas Control (Thermostat)  
Defective.  
Contact a qualified service technician to replace the  
gas control (thermostat).  
CAUTION: Make certain power to water heater is “OFF” before removing protective cover FOR ANY REASON.  
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and  
dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING.  
CAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or  
other safety devices. Refer repairs to qualified service personnel.  
31  
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Gas Valve LED Codes  
LED Status  
Problem  
Solution  
1. Check that the earth ground connection is properly  
connected.  
2. Check that the ground conductor on the water  
○ ○ ▼ A B C  
● ○ ○ ● ○ ○  
An open earth ground circuit to the  
ignition system.  
heater is properly connected.  
1. Check proper connection of line  
neutral and hot wires.  
2. Check that the water heater is securely connected  
○ ○ ▼ A B C  
● ○ ● ○ ● ○  
Wiring error or a high resistance to  
earth ground.  
to earth ground.  
1. Pressure switch wiring is incorrect.  
2. Replace pressure switch.  
Pressure switch remained closed  
longer  
○ ○ ▼ A B C  
● ○ ● ○ ○ ○  
than 5 seconds after the call for  
heat began.  
Pressure switch remained open lon-  
1. Pressure switch wiring is incorrect.  
2. Pressure switch tubing is not connected correctly.  
3. Air intake or exhaust obstructed.  
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.  
○ ○ ▼ A B C  
ger  
● ○ ● ○ ○ ●  
than 5 seconds after the combustion  
blower was energized.  
Error in the hot surface ignitor cir-  
cuit.  
○ ○ ▼ A B C  
● ○ ● ○ ● ●  
System in lockout.  
○ ○ ▼ A B C  
● ○ ○ ● ● ○  
3. Low voltage to the water heater.  
4. Electric polarity to unit is incorrect - test and cor-  
rect.  
5. Combustion shut-off device tripped, contact ser-  
vice agency.  
1. Turn power to the water heater off for 10 seconds  
and then back on.  
2. Replace gas control valve.  
○ ○ ▼ A B C  
Problem in the gas valve driver cir-  
cuit.  
● ○ ○ ○ ● ●  
1. Turn power to the water heater off for 10 seconds  
and then back on.  
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  
● ○ ● ● ● ○  
Problem with the internal circuit.  
Problem with the internal circuit.  
○ ○ ▼ A B C  
● ● ● ● ● ●  
1. Replace gas control valve.  
○ ○ ▼ A B C  
Flame signal sensed out of  
proper sequence.  
● ○ ○ ○ ● ○  
1. Replace gas control valve.  
○ ○ ▼ A B C  
ECO activated.  
● ○ ○ ● ● ●  
1. Press and release each of the buttons once.  
2. Replace gas control valve.  
1. Check that all wiring is correct and secure.  
○ ○ ▼ A B C  
One of the temperature adjust  
buttons stuck closed.  
● ○ ● ● ○ ○  
○ ○ ▼ A B C  
Water temperature sensor is either open  
or short circuited.  
● ○ ● ● ○ ●  
2. Replace gas control valve.  
1. Check for correct wiring to FV sensor.  
2. Check for open circuits to FV sensor.  
3. Replace FV sensor.  
○ ○ ▼ A B C  
● ○ ○ ● ○ ●  
Unit shuts down.  
1. FV sensor detected presence of flammable vapors.  
2. Contact a service agency.  
○ ○ ▼ A B C  
● ○ ○ ○ ○ ●  
Unit shuts down and in lockout.  
CAUTION: Make certain power to water heater is “OFF” before removing protective cover FOR ANY REASON.  
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and  
dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING.  
CAUTION: For your safety DO NOT attempt repair of gas piping, remote control, burners, vent connectors or other  
safety devices. Refer repairs to qualified service personnel.  
32  
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Replacement Parts.  
For 40 and 50 gallon models using natural or LP gas.  
Instructions For Placing a Parts Order  
All parts orders should include:  
Refer to page 36.  
The model and serial number of the  
water heater from the rating plate.  
CAUTION: For your safety, DO  
NOT attempt repair of gas piping,  
gas control (thermostat), burners,  
vent connectors or other safety devices.  
Refer repairs to qualified service  
personnel.  
Specify type of gas (natural or LP)  
as marked on the rating plate.  
Part description (as noted below) and  
number of parts desired.  
Rubber  
Coupling  
Use only original equipment  
replacement parts.  
Blower  
Assembly  
** Heat Trap Nipple  
Flue baffle and hanger  
*Burner Assembly Kit  
** Heat  
Trap  
Nipple  
Dip tube  
Dip tube gasket  
Anode rod  
Temperature and pressure  
relief valve  
The kit provides extra speed clips  
and tamper resistant screws.  
** May differ in actual appearance.  
Drain valve  
Gas Control (Thermostat)  
*Burner  
*Burner supply tube  
*Sight Glass  
Flammable Vapor Sensor  
Jacket Door  
*Burner Access Door Gasket  
*Burner orifice  
*Igniter  
*Burner Access Door Grommet  
*Burner Access Door  
33  
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Notes:  
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Notes:  
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IF YOU NEED SERVICE  
1. Should you have any questions about your new water heater, or if it requires adjustment, repair, or routine  
maintenance, it is suggested that you first contact your installer, plumbing contractor or previously agreed upon service  
agency. In the event the firm has moved, or is unavailable, refer to the telephone directory, commercial listings or local  
utility for qualified service assistance.  
2. Should your problem not be solved to your complete satisfaction, you should then contact the Manufacturer’s National  
Service Department at the following address:  
2600 Gunter Park Drive East  
Montgomery, Alabama 36109-1413  
Phone: 1-800-432-8373.  
When contacting the manufacturer, the following information will be requested:  
a. Model and serial number of the water heater as shown on the rating plate attached to the jacket of the heater.  
b. Address where the water heater is located and physical location.  
c. Name and address of installer and any service agency who performed service on the water heater.  
d. Date of original installation and dates any service work was performed.  
e. Details of the problems as you can best describe them.  
f. List of people, with dates, who have been contacted regarding your problem.  
Important Instructions for the Commonwealth of Massachusetts  
mounted to the exterior of the building at a minimum height of eight (8) feet  
above grade directly in line with the exhaust vent terminal for the horizon-  
tally vented gas fueled heating appliance or equipment. The sign shall read,  
in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY  
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".  
4. INSPECTION. The state or local gas inspector of the side wall horizon-  
tally vented gas fueled equipment shall not approve the installation unless,  
upon inspection, the inspector observes carbon monoxide detectors and  
signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1  
through 4.  
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR  
5.08(2)(a)1 through 4:  
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To  
Be Vented" in the most current edition of NFPA 54 as adopted by the Board;  
and  
The Commonwealth of Massachusetts requires compliance with regula-  
tion 5.08: Modifications to NFPA-54, Chapter 10 : 248 CMR 4.00  
and 5.00 for installation of through – the – wall vented gas appliances as  
follows:  
(1) Revise NFPA-54 section 10.5.4.2 by adding a second exception as fol-  
lows:  
Existing chimneys shall be permitted to have their use continued when a gas  
conversion burner is installed, and shall be equipped with a manually reset  
device that will automatically shut off the gas to the burner in the event of a  
sustained back-draft.  
(2) Revise 10.8.3 by adding the following additional requirements:  
(a) For all side wall horizontally vented gas fueled equipment installed in  
every dwelling, building or structure used in whole or in part for residential  
purposes, including those owned or operated by the Commonwealth and  
where the side wall exhaust vent termination is less than seven (7) feet above  
finished grade in the area of the venting, including but not limited to decks  
and porches, the following requirements shall be satisfied:  
2. Product Approved side wall horizontally vented gas fueled equipment in-  
stalled in a room or structure separate from the dwelling, building or structure  
used in whole or in part for residential purposes.  
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time  
of installation of the side wall horizontal vented gas fueled equipment, the  
installing plumber or gasfitter shall observe that a hard wired carbon monox-  
ide detector with an alarm and battery back-up is installed on the floor level  
where the gas equipment is to be installed. In addition, the installing plumber  
or gasfitter shall observe that a battery operated or hard wired carbon mon-  
oxide detector with an alarm is installed on each additional level of the dwell-  
ing, building or structure served by the side wall horizontal vented gas fueled  
equipment. It shall be the responsibility of the property owner to secure the  
services of qualified licensed professionals for the installation of hard wired  
carbon monoxide detectors  
a. In the event that the side wall horizontally vented gas fueled equipment is  
installed in a crawl space or an attic, the hard wired carbon monoxide detec-  
tor with alarm and battery back-up may be installed on the next adjacent floor  
level.  
b. In the event that the requirements of this subdivision can not be met at the  
time of completion of installation, the owner shall have a period of thirty (30)  
days to comply with the above requirements; provided, however, that during  
said thirty (30) day period, a battery operated carbon monoxide detector with  
an alarm shall be installed.  
(c) MANUFACTURER REqUIREMENTS - GAS EqUIPMENT VENTING  
SYSTEM PROVIDED. When the manufacturer of Product Approved side  
wall horizontally vented gas equipment provides a venting system design or  
venting system components with the equipment, the instructions provided  
by the manufacturer for installation of the equipment and the venting system  
shall include:  
1. Detailed instructions for the installation of the venting system design or  
the venting system components; and  
2. A complete parts list for the venting system design or venting system.  
(d) MANUFACTURER REqUIREMENTS - GAS EqUIPMENT VENTING  
SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved  
side wall horizontally vented gas fueled equipment does not provide the parts  
for venting the flue gases, but identifies "special venting systems", the fol-  
lowing requirements shall be satisfied by the manufacturer:  
1. The referenced "special venting system" instructions shall be included with  
the appliance or equipment installation instructions; and  
2. The "special venting systems" shall be Product Approved by the Board,  
and the instructions for that system shall include a parts list and detailed  
installation instructions.  
(e) A copy of all installation instructions for all Product Approved side wall  
horizontally vented gas fueled equipment, all venting instructions, all parts  
lists for venting instructions, and/or all venting design instructions shall  
remain with the appliance or equipment at the completion of the installation.  
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon  
monoxide detector as required in accordance with the above provisions shall  
comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.  
3. SIGNAGE. A metal or plastic identification plate shall be permanently  
36  
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