Bradford White Corp Water Heater DS140S User Manual

DIRECT VENT GAS WATER HEATER  
A Spanish language version of these instructions is available by contacting the  
company listed on the rating plate.  
La version espanola de estas instrucciones se puede obtener al escribirle a la  
fabrica cuyo nombre aparece en la placa de especificaciones.  
DS140S & DS150S  
INSTALLATION & OPERATING  
INSTRUCTION MANUAL  
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  
Do not store or use gasoline or other flammable,  
combustible, or corrosive vapors and liquids in the  
vicinity of this or any other appliance.  
WHAT TO DO IF YOU SMELL GAS  
·
·
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any  
phone in your building.  
·
·
Immediately call your gas supplier from a neighbor’s  
phone. Follow the gas supplier's instructions.  
If you cannot reach your gas supplier, call the fire  
department.  
Installation and service must be performed by a qualified  
installer, service agency or the gas supplier.  
For your family’s comfort, safety and convenience we  
recommend Bradford White water heaters to be installed and  
serviced by a plumbing professional.  
238-41099-00J REV
 
12/03  
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TABLE OF CONTENTS  
page  
GENERAL INFORMATION........................................................ 4  
INSTALLATION  
Locating The Water Heater...................................................... 6  
Minimum Clearances................................................................. 9  
Optional Direct Vent-Air Intake Terminal Guard.................... 9  
Venting..................................................................................... 12  
Horizontal and Vertical Vent-Air Intake Lengths ................... 14  
Vent-Air Intake System Installation.......................................... 17  
Water Connections.................................................................... 25  
Gas Connections....................................................................... 29  
GENERAL OPERATION ............................................................ 30  
Lighting and Shutdown Instructons....................................... 31  
Thermostat Adjustment............................................................. 32  
Burner Flame Checks ............................................................... 33  
MAINTENANCE........................................................................... 34  
PARTS LIST................................................................................. 37  
PARTS LIST DRAWINGS  
Direct Vent Water Heater.......................................................... 38  
Vent-Air Intake Kits.................................................................... 39  
INSTALLATIONS FOR POTABLE WATER AND SPACE  
HEATING....................................................................................... 40  
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GENERAL INFORMATION  
This gas-fired water heater’s design is certified by CSA International under the  
American National Standard Z21.10.1 - (as indicated on the rating plate) and  
CSA 4.1-M - (as indicated on the rating plate).  
This water heater must be installed in accordance with local codes or, in the  
absence of local codes, the National Fuel Gas Code, ANSI Z223.1-Latest  
Edition) and/or in Canada CAN/CGA B149 Installation Codes (Latest Editions).  
The warranty for this water heater is in effect only when the water heater is  
installed, adjusted, and operated in accordance with these Installatioand  
Operating Instructions. The manufacturer will not be held liable for any damage  
resulting from alteration and/or failure to comply with these instructions.  
This water heater is not design certified for installation in a mobile home. Such  
an installation may create a hazardous condition and will nullify the warranty.  
This water heater has been designed and certified for the purpose of heating  
potable water. The installation and use of this ater heater for any purpose  
other than the heating of potable water macause damage to the water heater  
and create a hazardous condition and nify the warranty.  
CAUTION  
Incorrect operation of this appliance may create a hazard to life  
and property and will nullify the warranty.  
Do not use this appliance if any part has been submerged in water. You should  
contact a qualified service technician to inspect the appliance and to replace  
any part of the control system including the combination gas control which has  
been submerged in water.  
DANGER  
Do not store or use gasoline or other flammable, combustible, or  
corrosive vapors and liquids in the vicinity of this or any other  
appliance.  
4
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General Information continued-  
IMPORTANT  
Before proceeding, please inspect the water heater and its components for  
possible damage. DO NOT install any damaged components. If damage is  
evident then please contact the supplier where the water heater was  
purchased or the manufacturer listed on the rating plate for replacement  
parts.  
Make sure that you check the rating plate and combination gas control on the  
water heater to be certain that the type of gas being supplied corresponds with  
the marking on the rating plate and combination gas control.  
A sacrificial anode is used to extend tank life. The removal of this anode, for  
any reason, will nullify the warranty. In areas where war is unusually active,  
an odor may occur at the hot water faucet due to a reaction between the  
sacrificial anode and the impurities in the water. If this should happen, an  
alternative anode may be purchased from the upplier that installed this water  
heater. This will minimize the odor while protecting the tank. Additionally, the  
water heater should be flushed with appropriate dissolvers to eliminate any  
bacteria.  
5
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INSTALLATION  
LOCATING THE WATER HEATER  
WARNING  
Water heaters are heat producing appliances. To avoid damage or injury, do  
not store materials against the water heater or vent-air intake system. Use  
proper care to avoid unnecessary contact (especially by children) with the  
water heater and vent-air intake components. UNDER NO CIRCUMSTANCES  
MUST FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT  
THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER  
HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY LOCATION FRM  
WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIR  
INTAKE SYSTEM.  
DO NOT install the water heater in any location where gasoline or  
flammable vapors are likely to be present.  
Water Heaters in residential garages shall be installed so that all  
burner(s) and burner ignition device(s) are located not less than 18  
inches (46 cm) above the floor and shabe located, or protected, to  
avoid physical damage. For other intallations refer to local codes. In  
the absence of local codes, the water heater shall be installed in  
compliance with the National Fuel Gas Code, ANSI Z223.1 - (Latest  
Edition) and/or in Canada, CN/CGA B149 Installation Codes (Latest  
Editions).  
The location of this water heater is of the utmost importance. Before installing  
this water heater, read the installation section of these instructions. After  
reading these installation and operating instructions, select a location for the  
water heater where the floor is level and is easily accessible to gas and water  
supply lines. DO NOT locate the water heater where water lines could  
be subjected to freezing temperatures. Make sure the cold water pipes  
are not located directly above the gas control so that condensate  
during humid weather does not drip on the controls.  
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Installation (Locating The Water Heater) continued-  
Water heater corrosion and component failure can be caused by the heating  
and breakdown of airborne chemical vapors. Examples of some typical  
compounds that are potentially corrosive are: spray can propellants, cleaning  
solvents, refrigerator and air conditioning refrigerants, swimming pool  
chemicals, calcium and sodium chloride, waxes and process chemicals.  
These materials are corrosive at very low concentration levels with little or no  
odor to reveal their presence. NOTE: DAMAGE TO THE WATER HEATER  
CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY  
THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF  
EXPOSURE HAS OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY  
CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HETER.  
WARNING  
Liquefied petroleum gases/propane gas are heavier than air  
and will remain at floor level if there is a leak. Basements,  
crawl spaces, closets and areas below ground level will  
serve as pockets for accumulation of leaking gas. Before  
lighting, smell all around the appliance area for gas. Be sure  
to smell next to the floor.  
IF YOU SMELL GAS:  
·
·
Do not try to light any appliance.  
Do not touch any electric switch; do not use any  
telephone in yor building.  
·
·
Immediately call your gas supplier from a neighbor’s  
telephone. Follow the gas supplier’s instructions.  
If you cannot reach your gas supplier, call the fire  
department.  
DO NOT OPERATE APPLIANCE UNTIL THE LEAKAGE IS  
CORRECTED!  
7
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Installation (Locating The Water Heater) continued-  
WARNING  
DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE  
NOT CERTAIN OF THE FOLLOWING:  
·
Liquefied petroleum gases/propane gas and natural gas have  
an odorant added by the gas supplier that aids in the detection  
of the gas.  
·
·
Most people recognize this odor as a “sulfur” or “rotten egg”  
smell.  
Other conditions, such as “odorant fade” can cause the orant  
to diminish in intensity, or ”fade”, and not be as readily  
detectable.  
·
·
If you have a diminished sense of smell, or are in any way unsure  
of the presence of gas, immediately contact your gas supplier  
from a neighbor’s telephone.  
Gas detectors are available. Contact your gas supplier, or  
plumbing professional, for more information.  
The water heater must be located close nough to the outside wall to keep the  
venting distance within the maximum distance described in the installation  
instructions. Note: The direct vent-air intake terminal must be installed on a  
vertical wall. Read the venting ction in this installation instruction manual  
before locating the water heater.  
This water heater must be located in an area where leakage of the tank or  
water line connections and the combination temperature and pressure relief  
valve will not result in damage to the area adjacent to the water heater or to  
lower floors of the structure. When such locations cannot be avoided, a  
suitable drain pan, adequately drained, be installed under the water heater.  
The pan must not restrict combustion airflow. The drain pan must be no  
greater than 1-½ inches (3.8 cm) deep and have a minimum length and width  
of at least four (4) inches (10.2 cm) measured from the jacket of the water  
heater. The drain pan, as described above, can be purchased from your  
plumbing professional. The drain pan must be piped to an adequate drain.  
The piping must be at least 3/4 inch (1.9 cm) in diameter and pitched for  
proper drainage.  
It is recommended that a minimum clearance of four (4) inches (10.2 cm) be  
provided on the side of the water heater for servicing and maintenance of the  
combination temperature and pressure relief valve.  
8
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Installation continued-  
MINIMUM CLEARANCES  
WARNING  
Failure to adhere to these installation and operating instructions  
may create a hazard to life and property and will nullify the  
warranty.  
This installation shall allow access to the front of the water heater and  
adequate clearance shall be provided for servicing and operating this  
water heater. The water heater may be installed on either a combuste or  
non-combustible floor. If the water heater is to be installed directly on  
carpeting, it shall be installed on top of a metal or wood panel extending  
beyond the full width and depth of the appliance by at least three (3) inches  
(7.6 cm) in any direction or, if the appliance is to be installed in an alcove or  
closet, the entire floor shall be covered by the panel. The minimum clearances  
to combustibles for this water heater is: zero (0) inch (0 cm) from the sides  
and rear, four (4) inches (10.2 cm) from the front of the jacket, zero (0) inch (0  
cm) from the plenum, zero (0) inch (0 cm) from the air intake elbow and  
telescopic tubes and twelve (12) inches (3.5 cm) from the direct vent-air  
intake terminal. (See Figure 1).  
OPTIONAL DIRECT VENT-AIR INTAKE TERMINAL GUARD  
WARNING  
The direct vent-air intake terminal is HOT while the water heater is  
in operation. Do not touch. Keep children, combustibles, gasoline  
and other liquids having flammable vapors away.  
It is recommended that a vent-air intake terminal guard be installed when the  
vent-air intake terminal is located where it can be touched accidentally, or  
accessed by children. (See Figure 2).  
A chain link or louvered fence may be used instead of the vent-air intake  
terminal guard. Maintain proper clearances as specified in this instruction  
manual to the vent-air intake terminal. (See Figure 3).  
9
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Installation (Minimum Clearances) continued-  
Figure 1  
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Installation continued-  
Figure 2  
Figure 3  
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Installation continued-  
VENTING  
This is a Direct Vent Gas Water Heater where all air for combustion is  
obtained from the outside atmosphere and all flue gases are discharged to the  
outside atmosphere.  
WARNING  
The vent-air intake system must be properly installed. Failure to  
properly install the vent-air intake system properly could rest in  
property damage, personal injury or death.  
DO NOT install any damaged vent-air intake system components.  
Contact the manufacturer of the water heater for replacement parts.  
Direct Vent-Air Intake Terminal (See Figure 4)  
·
·
·
·
Shall be installed with at least a 9 in. (22.9 cm) vent termination  
clearance from any air opening into a building.  
The bottom of the direct vent-air intake terminal shall be located at  
least 12 in. (30.5 cm) above gde.  
Installed at least 3 ft. (91.4 m) from any gas meter, gas valve or  
other gas regulating equipment.  
Must be installed in a lcation where it will not be blocked by snow.  
Note: Provide protection f the building materials from degradation by flue  
gases from the direct vent-air intake terminal.  
Exceptions for Installations in Canada  
The direct vent-air intake terminal shall not terminate:  
(a) directly above a paved sidewalk or paved driveway which is located  
between two single-family dwellings and serves both dwellings;  
(b) less than 7 ft. (2.1 m) above a paved sidewalk or a paved driveway  
located on public property;  
(c) within 6 ft. (1.8 m) of a mechanical air supply inlet to any building;  
(d) above a gas meter/regulator assembly within 3 ft. (91.4 cm) horizontally  
of the vertical centerline of the regulator;  
(e) within 6 ft. (1.8 m) of any gas service regulator vent outlet;  
(f) less than 12 in. (30.5 cm) above grade level;  
(g) within 12 in. (30.5 cm) of a window or door which can be opened in any  
building, any non-mechanical air supply inlet to any building or the  
combustion air inlet of any other appliance:  
12  
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Installation (Venting) continued-  
(h) underneath a verandah, porch or deck, unless:  
(i) the verandah, porch or deck is fully open on a minimum of two  
sides beneath the floor, and  
(ii) the distance between the top of the vent-air intake termination and  
the underside of the verandah, porch or deck is greater than 12 in.  
(30.5 cm).  
Figure 4  
13  
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Installation (Venting) continued-  
The co-axial vent-air intake tubes of this water heater can be installed in any  
360° configuration as long as the proper clearances for installation, plumbing,  
operation and servicing are maintained. (See Figure 5).  
Figure 5  
Note: Maintain proper clearances for installation, plumbing, operation  
and service.  
HORIZONTAL AND VERTICAL VENT-AIR INTAKE LENGTHS  
This Direct Vent Gas Water Heater comes with one (1) vent-air intake “Kit C”.  
Optional vent-air intake kits are available that can extend the horizontal length  
and/or vertical height of the vent-air intake system. Table A lists the various  
vertical and horizontal vent-air intake system configurations.  
14  
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Installation (Horizontal and Vertical Vent-Air Intake Lengths) continued-  
The water heater is shipped with the following standard vent and air intake  
system: 239-41097-00. The components of this vent and air intake systems is  
as follows:  
3” Vent Tube*  
5” Air Intake Tube*  
Vent Terminal  
Vent Terminal Hardware  
RTV Silicone Sealant  
3” Vent Elbow  
Inner Wall Term. Mounting Flange  
Outer Wall Term. Mounting Flange  
5” Vent Elbow  
*The vent and air intake telescopes from 13 3/4" to 23 11/16”.  
Table A  
Horizontal "X"  
13 1/4  
15  
22 1/4  
36  
58 5/16  
14 3/16 17 11/16 32 3/16  
55 7/8  
104 5/16  
order  
kit A  
order  
kit B  
no add'l  
kireq'd  
order  
kit C  
order  
kit D  
10  
14 3/4  
*order  
order  
order  
kit A  
order  
order  
15 11/16 kit A (2) kit A & B  
16 1/2 order *order  
19 3/16 kit A & B kit B (2)  
kit A & C kit A & D  
order order  
kit B & C kit B & D  
order  
kit B  
23 3/4  
33 11/16  
order  
kit A  
order  
kit B  
order  
kit C  
*order  
kit C (2)  
order  
kit D  
37 1/2  
order  
order  
*order  
*order  
order  
57 3/8 kit A & C kit C & B kit C (2) kit C (3) kit C & D  
59 136  
105 13/16 kit D & A kit D & B  
order  
order  
order  
kit D  
order  
kit D & C kit D (2)  
*order  
* (2) = Order two of the kits referenced.  
* (3) = Order three of the kits referenced.  
The bold text above show what kit(s) are needed in addition to the standard  
vent and air intake tubes. If the standard vent and air intake tubes are not  
used in the venting system (those that do not have bold text) they can be  
discarded or saved.  
15  
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Installation (Horizontal and Vertical Vent-Air Intake Lengths) continued-  
Figure 6  
16  
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Installation continued-  
VENT-AIR INTAKE SYSTEM INSTALLATION  
WARNING  
The vent-air intake system must be properly installed. Failure to  
properly install the vent-air intake system could result in property  
damage, personal injury or death.  
Do not install any damaged vent-air intake system components.  
Contact the manufacturer of the water heater for replacement parts.  
IMPORTANT  
When the following instructions specify, to seal a vent-air intake joint,  
use only Loctite Ultra Blue 587 RTV Silicone sealant. A tube of Loctite  
Ultra Blue 587 RTV Silicone sealant is supplied with every direct vent  
water heater and each optional vent-air intake kit. Make sure that all  
joints are completely sealed.  
When drilling pilot holes for the #8 sheet metal screws through the  
five (5) inch (12.7 cm) diameter comnents, be careful not to drill into  
the inner three (3) inch (7.6 cm) diameter components.  
Tools Required Fr Vent-Air Intake Installation  
The following minimum ools are required to properly install the vent-  
air intake system. Note: Wall construction will determine tool usage.  
Tape Measure  
Drill  
3/16 inch Diameter Drill Bit(s)  
1/8 inch Diameter Drill Bit(s)  
Masonry Drill Bit(s) (For Poured Concrete, Concrete Block and Brick Wall  
Construction)  
Reciprocating Saw w/appropriate Blade(s) (Dependent on Wall  
Construction)  
Chisel  
(For Poured Concrete, Concrete Block and Brick Wall Construction)  
Hammer (For Poured Concrete, Concrete Block and Brick Wall  
Construction)  
1/4 & 5/16 inch Nut Drivers (Preferred) or Slotted Head Screwdriver  
Phillips Head Screwdriver  
17  
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Installation (Vent-Air Intake System Installation) continued-  
1. Measure the vertical height “Y” required in your installation. (See Figure  
6). Reference the appropriate Table A to determine number of vent-air  
intake kits required in your installation.  
2. Measure the horizontal length “X” required in your installation (See Figure  
6). Reference Table A to determine number of vent-air intake kits required  
in your installation.  
3. Cut a 5-1/2 inch (14 cm) diameter minimum clearance hole in the wall at  
the point where the vent-air intake tubes will pass through the outside wall  
and connect with the direct vent-air intake terminal  
(See Figure 6).  
4. From outside the building, position the outer wall mount plate and direct  
vent-air intake terminal over the center of the opening. Mark the mounting  
screw hole locations. With a 3/16 inch diameter drill bit (not supplied), drill  
holes for the wall anchors (supplied). Install the wall anchors but DO NOT  
affix the outer wall mount plate and direct vent-air intake terminal to the  
wall at this time (See Figure 7). Note: Certain construction of walls may  
require the use of a different type of wll anchoring means than supplied.  
DO NOT modify the direct vent-air ike terminal or outer wall mount  
plate.  
Figure 7  
18  
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Installation (Vent-Air Intake System Installation) continued-  
IMPORTANT  
The following instructions detail the installation of the standard  
horizontal vent-air intake kit supplied with the water heater.  
5. Insert the straight end of the three (3) inch (7.6 cm) diameter elbow into  
the flue reducer until firmly seated and oriented in the correct direction.  
With a 1/8 inch diameter drill bit (not supplied), drill three (3) holes, 120o  
apart, through the flue reducer into the three (3) inch (7.6 cm) diameter  
elbow. Fasten with three (3) #8 sheet metal screws (supplied). sing the  
supplied special RTV silicone sealant, apply a sufficient amount to seal  
the joint (See Figure 8).  
Figure 8  
6. Place the straight end of the five (5) inch (12.7 cm) diameter elbow over the  
three (3) inch (7.6 cm) diameter elbow and plenum collar until seated on  
top of the plenum box. Make certain that the five (5) inch (12.7 cm)  
diameter elbow is oriented in the same direction as the three (3) inch (7.6  
cm) diameter elbow and both are oriented in the correct direction. Drill  
three (3) 1/8 inch diameter holes, 120o apart, through the five (5) inch (12.7  
cm) diameter elbow into the plenum collar. Fasten with three (3) #8 sheet  
metal screws (supplied) (See Figure 9).  
19  
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Installation (Vent-Air Intake System Installation) continued-  
Figure 9  
7. Extend the three (3) inch (7.6 cm) diameter telescopic tube to its  
maximum length and lide the backing plate over it. Place the large end of  
the three (3) inch (7.6 cm) diameter telescopic tube through the hole in the  
outside wall. Insert the smaller end of the three (3) inch diameter (7.6 cm)  
telescopic tube into the flared end of the three (3) inch (7.6 cm) diameter  
elbow, one (1) inch (2.5 cm) (or until seated). Drill three (3) 1/8 inch  
diametr holes, 120o apart, through the three (3) inch (7.6 cm) diameter  
elbow into the three (3) inch (7.6 cm) diameter telescopic tube. Fasten  
with three (3) #8 sheet metal screws (supplied). Adjust the overall length  
of the three (3) inch (7.6 cm) diameter telescopic tube so that 2-1/2 inches  
(6.4 cm) extends beyond the outside wall. Drill three (3) 1/8 inch diameter  
holes, 120o apart, through the three (3) inch (7.6 cm) diameter telescopic  
tubes where the small and large sections overlap. Fasten with three (3) #8  
sheet metal screws (supplied). Using the supplied special RTV silicone  
sealant, apply a sufficient amount to seal the joints (See Figure 10).  
20  
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Installation (Vent-Air Intake System Installation) continued-  
Figure 10  
8. Extend the five (5) inch (12.7 cm) dimeter telescopic tube to its maximum  
length. Place the large end of the five (5) inch (12.7 cm) diameter  
telescopic tube over the collar on the outer wall mount plate. Drill three (3)  
1/8 inch diameter holes, 12apart, through the five (5) inch (12.7 cm)  
diameter telescopic tube into the collar on the outer wall mount plate.  
Fasten with three (3) 8 sheet metal screws (supplied). Using the  
supplied special RTV silicone sealant, apply a sufficient amount to seal  
the joint (See Figure 11).  
Figure 11  
21  
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Installation (Vent-Air Intake System Installation) continued-  
9. From outside the building, slide the five (5) inch (12.7 cm) diameter  
telescopic tube through the opening in the wall until the outer wall mount  
plate is flush with the wall (See Figure 12).  
Figure 12  
10. Using the supplied special RTV silicone sealant, apply a bead one (1)  
inch (2.5 cm) from the end of the three (3) inch (7.6 cm) diameter tube  
that is part of the vent-air intake terminal. Slide the direct vent-air intake  
terminal into the three (3) inch (7.6 cm) diameter telescopic tube that  
extends through the wall and position it so it is flush with the outer wall  
mount plate. Make sure that the rain guard and the word “HOT” on the  
end of the direct vent-air intake terminal are oriented properly. Secure the  
direct vent-air intake terminal to the outer wall mount plate and wall with  
four (4) #10 x 1 inch screws (supplied) (See Figure 13). Note: Certain  
construction of walls may require the use of different type of anchoring  
means than supplied. DO NOT modify the direct vent-air intake terminal  
or outer wall mount plate.  
22  
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Installation (Vent-Air Intake System Installation) continued-  
Figure 13  
11. From inside the building, slide the backing plate over the five (5) inch  
(12.7 cm) diameter telescopic tube util it is flush with the wall. Adjust  
the length of the five (5) inch (12.7 m) diameter telescopic tube and  
insert the end into the flared end of the five (5) inch (12.7 cm) diameter  
elbow one (1) inch (2.5 cm) (or until seated). Drill three (3) 1/8 inch  
diameter holes, 120o apartrough the five (5) inch (12.7 cm) diameter  
elbow into the five (5) inch (12.7 cm) diameter telescopic tube and  
through the tubes wre the small and large sections overlap. Fasten  
with three (3) #8 sheet metal screws (supplied). Using the supplied  
special RTV silicone sealant, apply a sufficient amount to seal all joints  
(See Figure 14).  
Figure 14  
23  
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Installation (Vent-Air Intake System Installation) continued-  
12. Mark the mounting screw hole locations for the backing plate. Rotate the  
backing plate in order to gain access to the markings. With a 3/16 inch  
diameter drill bit (not supplied), drill holes for the supplied wall anchors.  
Install the wall anchors and secure the backing plate to the wall with  
four (4) #10 x 1 inch screws (supplied) (See Figure 15). Note: Certain  
construction of walls may require the use of a different type of anchoring  
means than supplied.  
Figure 15  
IMPORTANT  
When the installation is complete, visually inspect the air intake  
system to insure that all joints are completely sealed.  
24  
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Installation continued-  
WATER CONNECTIONS  
Note: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE  
MAIN WATER SUPPLY VALVE.  
After shutting off the main water supply, open a faucet to relieve the water line  
pressure to prevent any water from leaking out of the pipes while making the  
water connections to the water heater. After the pressure has been relieved,  
close the faucet. The COLD water inlet and HOT water outlet are identified on  
the top of the water heater. The fittings at the cold water inlet and hot water  
outlet are dielectric waterway fittings with 3/4” NPT male thread. Mae the  
proper plumbing connections between the water heater and the plumbing  
system to the house. Install a shut-off valve in the cold water supply line.  
CAUTION  
If sweat fittings are to be used, DO NOT apply heat to the nipples on top of  
the water heater. Sweat the tubing to the adapter before fitting the adapter  
to the water connections. It is imperative that heat is not applied to the  
nipples containing a plastic liner.  
25  
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WARNING  
For protection against excessive temperatures and pressure, install  
temperature and pressure protective equipment required by local codes,  
but not less than a combination temperature and pressure relief valve  
certified by a nationally recognized testing laboratory that maintains  
periodic inspection of production of listed equipment or materials as  
meeting the requirements of the Standard for Relief Valves and Automatic  
Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22 and the  
Standard CAN1-4.4 Temperature, Pressure, Temperature and Pressure  
Relief Valves and Vacuum Relief Valves. The combination temperature  
and pressure relief valve shall be marked with a maximum set pressure not  
to exceed the maximum working pressure of the water heater. The hourly  
BTU discharge capacity or the rated steam relief capacity of the  
combination temperature and pressure relief valve shall not be less than  
the input rating of the water heater.  
Install the combination temperature and pressure relief valve into the  
opening provided and marked for this purpose on the water heater.  
Note: Some models may already be equipped or supplied with a  
combination temperature and pressure relief valve. Verify that the  
combination temperature and pressure relief valve complies with local  
codes. If the combination temperature ad pressure relief valve does not  
comply with local codes, replace it witone that does. Follow the  
installation instructions above on this page.  
Install a discharge line which rminates six (6) inches (15 cm) above the  
floor, or any distance below the structural floor, to the outlet of the  
combination temperature and pressure relief valve. DO NOT allow water  
from the discharge line to contact any live electrical part. The discharge  
line is to be installed to allow for complete drainage of both the  
combination temperature and pressure relief valve and the discharge line.  
The water from the discharge line must be directed to a suitable drain or  
area that will not be damaged by water (Refer to page 6 “LOCATING THE  
WATER HEATER.” The discharge opening must not be subjected to  
blockage or freezing. DO NOT thread, plug or cap the discharge line.  
It is recommended that a minimum clearance of four (4) inches (10.2 cm)  
be provided on the side of the water heater for servicing and maintenance  
of the combination temperature and pressure relief valve.  
Do not place a shutoff valve between the combination temperature and  
pressure relief valve and the water heater, or on discharge pipes between  
such valves or the atmosphere.  
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Installation (Water Connections) continued-  
WARNING  
FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4”  
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE  
MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM  
EXCESSIVE TEMPERATURES AND PRESSURES.  
If this water heater is installed in a closed water supply system, such as the  
one having a back-flow preventer in the cold water supply, provisions shall be  
made to control thermal expansion. DO NOT operate  
this water heater in a closed system without provisions for controlling thermal  
expansion. Your water supplier or local plumbing inspector should be  
contacted on how to control this situation  
After installation of the water lines, open the main water supply valve and fill  
the water heater. While the water heater is filling, open several hot water  
faucets to allow air to escape from the water system. When a steady stream  
of water flows through the faucets, close them and check all water connections  
for possible leaks. NEVER OPERATE THE WATER HEATER WITHOUT  
FIRST BEING CERTAIN IT IS FILLED WITH WATER.  
WARNING  
Hydrogen gas can be produced in an operating water heater that  
has not had water drawn from the tank for a long period of time  
(generally two weeks or more). Hydrogen gas is extremely  
flammable. To prevent the possibility of injury under these  
conditions, we recommend the hot water faucet to be open for  
several minutes at the kitchen sink before you use any electrical  
appliance which is connected to the hot water system. If hydrogen  
is present, there will be an unusual sound such as air escaping  
through the pipes as hot water begins to flow. Do not smoke or  
have open flame near the faucet at the time it is open.  
This water heater can deliver scalding temperature water at any faucet in the  
system. Be careful whenever using hot water to avoid scalding injury. Certain  
appliances such as dishwashers and automatic clothing washers may require  
increased temperature water. By setting the thermostat on this water heater  
to obtain the increased temperature water required by these appliances, you  
may create the potential for scald injury. To protect against injury, you should  
install an ASSE approved mixing valve in the water system. This valve will  
reduce point of discharge temperature by mixing cold  
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Installation (Water Connections) continued-  
and hot water in branch supply lines. Such valves are available from the  
manufacturer of this water heater or a local plumbing supplier. Please consult  
with a plumbing professional.  
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GAS CONNECTIONS  
The gas supply lines must meet all requirements of the National Fuel Gas  
Code, ANSI Z223.1 - (Latest Edition) and/or in Canada, CAN/CGA B149  
Installation Codes - (Latest Editions).  
The minimum permissible gas supply pressure for the purpose of input  
adjustment is one (1.0) inch (.25kPa) water column above the operating  
manifold pressure. See the rating plate and combination gas control for the  
manifold pressure and gas type. The maximum permissible gas supply  
pressure is fourteen (14.0) inches (3.5kPa) water column for natural gas and  
liquefied petroleum gases/propane gas.  
1. Connect this water heater only to the type of gas (natural or propane  
gas) as shown on the rating plate. Use clean 1/2 inch black iron  
pipe. (Dirt and scale from the pipe can enter the combination control and  
cause it to malfunction). The inlet gas line must hae a drip leg (sediment  
trap) installed as close as possible to the water heater’s combination gas  
control having a minimum length of three (3) inches (7.6 cm). A ground  
joint union must be installed in the gas supply line feeding the water heater  
to permit servicing of the water heater. Compounds used on the threaded  
joints of the gas piping must be resistant to the action of liquefied  
petroleum gases/propane gas.  
2. This water heater and its gas connection must be leak tested before  
placing the water heater in operation. Check for gas leaks with a  
soap and water solution and a brush or a commercial leak detector  
fluid. NEVER USE A MATCH OR OPEN FLAME FOR TESTING!  
CAUTION  
The water heater and its individual shutoff valve must be disconnected from  
the gas supply piping system during any pressure testing of the system at  
test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be  
isolated from the gas supply piping system by closing its manual shutoff  
valve during any pressure testing of the gas supply system at test  
pressures equal to or less than 1/2 psi (3.5 kPa). The supply line must be  
capped when not connected to the water heater.  
29  
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GENERAL OPERATION  
WARNING  
Water heaters are heat producing appliances. To avoid damage or injury,  
do not store materials against the water heater or vent-air intake system.  
Use proper care to avoid unnecessary contact (especially by children) with  
the water heater and vent-air intake system. UNDER NO  
CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS  
GASOLINE OR PAINT THINNER BE USED OR STORED IN THE  
VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM OR  
IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER  
HEATER OR VENT-AIR INTAKE SYSTEM.  
TO FILL THE WATER HEATER  
1. Close the water heater drain valve by turning the kob clockwise.  
2. Open the cold water supply shut-off valve.  
3. Open several hot water faucets to allow air to escape from the system.  
4. When a steady stream of water flows from the faucets, the water heater is  
filled. Close the faucets and check for water leaks at the water heater  
drain valve, combination temperature and pressure relief valve and the hot  
and cold water connections.  
TO DRAIN THE WATER HEATER  
Should it become necessary to completely drain the water heater, make sure  
you follow the steps below:  
1. Rotate the thermostat dial clockwise to the “PILOT LIGHTING” position.  
2. Rotate and partially depress gas control knob clockwise to the “OFF”  
position.  
3. Shut off the gas supply to the water heater.  
4. Close the cold water supply shut-off valve.  
5. Open te drain valve on the water heater by turning the knob counter-  
clockwise. The drain valve has threads on the end that will allow the  
connection of a standard hose coupling.  
6. Open a hot water faucet to allow air to enter the system.  
To refill the water heater, refer to “To Fill the Water Heater.”  
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General Operation continued-  
THERMOSTAT ADJUSTMENT  
The thermostat dial is set to its lowest temperature setting when shipped from  
the factory. Remember that lower temperature settings are more energy  
efficient. Adjust the temperature by turning the thermostat dial. It is  
suggested that the starting point setting not be greater than the “ ” mark on  
the thermostat dial (approximately 120°F [49°C]) as indicated below. Rotate  
the thermostat dial clockwise  
Rotate the thermostat dial counterclockwise  
to increase the temperature setting.  
to decrease the  
temperature setting. Adjust the dial until the minimum acceptable temperature  
is achieved (See figure below for approximate temperature settings).  
Figure 16  
DANGER  
Hotter water increases the risk of scald injury. Scalding may occur within  
five (5) seconds at a temperature setting of 135°F (57° C). To protect  
against hot water injury, install an ASSE approved mixing valve in the  
water system. This valve will reduce point of discharge temperature by  
mixing cold and hot water in branch water lines. A licensed plumbing  
professional or local plumbing authority should be consulted.  
Note: This water heater is equipped with an energy cut out device to  
prevent overheating. Should overheating occur or the gas supply fail to  
shut off, turn off the manual gas control valve to the appliance and call a  
qualified service technician.  
Note: Whenever the water heater is filled with cold water, condensate will  
form on the cool tank surface and drops of water will fall on the hot burner  
and combustion chamber surfaces producing a “sizzling” noise.  
Condensation is normal and does not indicate a leak. It will disappear  
when the tank becomes heated.  
32  
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General Operation continued-  
BURNER FLAME CHECKS  
At the time of installation and at periodic intervals (not more than six (6)  
months), a visual check of the pilot and main burner flames should be  
conducted. The flames should be similar to those pictured below. The main  
burner should light smoothly from the pilot. (See Figure 17).  
Figure 17  
33  
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MAINTENANCE  
WARNING  
Water heaters are heat producing appliances. To avoid damage or injury,  
do not store materials against the water heater or vent-air intake system.  
Use proper care to avoid unnecessary contact (especially by children) with  
the water heater and vent-air intake system. UNDER NO  
CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS  
GASOLINE OR PAINT THINNER BE USED OR STORED IN THE  
VICINITY OF THIS WATER HEATER, VENT-AIR INTAKE SYSTEM OR  
IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER  
HEATER OR VENT-AIR INTAKE SYSTEM.  
IMPORTANT  
The water heater should be inspected at a minimum annually by a  
qualified service technician for damaged components and/or joints  
not sealed. DO NOT operate this water heater if any part is found  
damaged or if any joint is found not seaed.  
The following maintenance should be permed by a qualified service  
technician at the minimum periodic intervals suggested below. In some  
installations the maintenance interval may be more frequent depending on  
upon the amount of use and the perating conditions of the water heater.  
Regular inspection and maintenance of the water heater and vent-air intake  
system will help to insure afe and reliable operation.  
1. Annually check the operation of the thermostat.  
2. The flow of combustion and ventilation air MUST NOT be restricted.  
Annually inspect the direct vent-air intake terminal to insure it is not  
blocked or damaged. Clear the direct vent-air intake terminal openings of  
any dirt, dust, or other restrictions. WARNING! Certain areas of the  
direct vent-air intake terminal are HOT.  
3. Annually inspect the vent-air intake system to insure that all components  
are securely fastened and all joints and seams are properly sealed.  
4. At all times keep the water heater area clear and free from combustible  
materials, gasoline and other flammable vapors and liquids.  
5. Bi-annually conduct a visual check of the main and pilot burner flames to  
determine that they are burning properly. See information on page 33  
“BURNER FLAME CHECKS.”  
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Maintenance continued-  
6. Annually remove the inner door and main burner assembly to clean orifices  
and related parts of any dirt or other foreign material. Inspect the burner  
ports for obstructions or debris and clean with a wire brush as needed.  
Wire brush and/or vacuum clean the combustion chamber as needed to  
remove scale deposits and debris. Inspect the inner door gasket for wear  
and tear and replace if necessary. NOTE: It is imperative for proper  
operation of the water heater that the inner door be properly sealed.  
7. At least once a year, check the combination temperature and pressure  
relief valve to insure that the valve has not become encrusted with lime.  
Lift the lever at the lever at the top of the valve several times unthe valve  
seats properly without leaking and operates freely.  
WARNING  
When lifting lever of the combination temperatue and pressure  
relief valve, hot water will be released under pressure. Be careful  
that any released water does not result in bodily injury or property  
damage.  
8. Monthly, drain off a gallon of water to remove silt and sediment by using  
the water heater’s drain valve.  
WARNING! THIS WATER MAY BE HOT.  
9. If the combination temperature and pressure relief valve on the appliance  
discharges periodically, this may be due to thermal expansion in a closed  
water supply system. Contact the water supplier or local plumbing  
inspector on how to correct this situation. Do not plug the combination  
temperature and pressure relief valve outlet.  
10. A comination sacrificial anode rod/hot water outlet nipple has been  
installed to extend tank life. The anode rod should be inspected  
periodically (every two years) and replaced when necessary to prolong  
tank life. Contact the plumbing professional who installed the water heater  
or the manufacturer listed on the rating plate for anode replacement  
information. The use of a water softener may increase the speed of anode  
consumption. More frequent inspection of the anode is needed when  
using softened (or phosphate treated) water.  
Maintenance (continued)-  
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CAUTION  
FOR YOUR SAFETY. DO NOT ATTEMPT REPAIR OF COMBINATION  
GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A  
QUALIFIED SERVICE TECHNICIAN.  
Contact your supplier or plumbing professional for replacement parts or contact  
the company at the address given on the rating plate of the water heater.  
Provide the part name, model and serial numbers of the water heater when  
ordering parts.  
READ THE WARRANTY FOR A FULL EXPLANATION OF THE LENGTH OF  
TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.  
Manufactured under one or more of the following U.S. Patents:  
4,416,222; 4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983;  
4,861,968; 4,867,106; 4,904,428; 5,000,893; 5,023,031; 5,052,346;  
5,081,696; 5,092,519; 5,115,767; 5,199,385; 5,277,171; 5,341,770;  
5,372,185; 5,485,879; 5,574,822; 5,596,9525,660,165; 5,682,666;  
5,943,984. Other U.S. and Foreign pateapplications pending. Current  
Canadian Patents: 1,272,914; 1,280,3; 1,289,832; 2,045,862;  
2,107,012; 2,108,186; 2,112,515.  
Complete the following information and retain for future reference:  
Model No:  
Serial No :  
Installation Date:  
Service Phone No.  
Days:  
Nights:  
Address:  
Supplier:  
Supplier’s Phone No:  
PART NAME & DESCRIPTION  
36  
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1.  
2.  
3.  
4.  
Direct Vent-Air Intake Terminal  
Outer Wall Mount Plate  
Backing Plate  
Five (5) inch (12.7 cm)  
Diameter Telescopic Air Intake  
Tube  
21.  
22.  
23.  
24.  
Piezo Ignitor Assembly  
Drain Valve  
Outer Door  
Jacket  
5.  
Three (3) inch (7.6 cm)  
Diameter Telescopic Vent  
Tube  
25.  
Inner Door Assembly  
6.  
7.  
Five (5) inch (12.7 cm)  
Diameter Elbow  
Three (3) inch (7.6 cm)  
Diameter Elbow  
26.  
27.  
Air Intake Boot  
Air Intake Boot Gasket  
8.  
9.  
10.  
11.  
12.  
Plenum  
Plenum Gasket  
Flue Reducer  
Jacket Top  
28.  
29.  
30.  
Pilot Assembly w/Electrode  
Gas Feed Line (Burner)  
Main Burner Orifice  
31A. 42 Pot Steel Burner  
31B. 65 Port Cast Iron Burner  
(Certain Models)  
Insulation  
13.  
14.  
Glass Lined Tank  
Flue Baffle Assembly  
32.  
Radiation Shield  
3A. Direct Vent-Air Intake Kit A  
(Optional)  
15.  
16.  
17.  
18.  
19.  
20.  
Dip Tube & Nipple  
33B. Direct Vent-Air Intake Kit B  
(Optional)  
33C. Direct Vent-Air Intake Kit C  
(Supplied & Optional)  
33D. Direct Vent-Air Intake Kit D  
(Optional)  
33E. Direct Vent-Air Intake Kit E  
(Optional)  
Anode Rod & Nipple  
Temperature-Presure Relief  
Valve (Certain Models)  
Air Intake Tube  
Combustion Chamber  
Assmbly  
Combination Gas Control  
w/E.C.O.  
34.  
Loctite Ultra Blue 587 RTV  
Silicone Sealant  
35.  
Direct Vent-Air Intake Terminal  
Guard (Optional)  
Note: Provide the part name, model and serial numbers of the water heater when  
ordering parts.  
THIS MANUAL SHOULD BE KEPT WITH THE WATER HEATER  
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DIRECT VENT WATER HEATER  
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VENT-AIR INTAKE KITS  
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THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:  
GAS WATER HEATERS  
SUITABLE FOR WATER (POTABLE) HEATING AND SPACE  
HEATING  
1. All piping components connected to this water heater for space heating  
applications must be suitable for use with potable water. In  
Massachusetts, space heating piping must not exceed 50 feet.  
2. Toxic chemicals, such as those used for boiler treatment, must not  
be introduced into potable water used for space heating;  
3. This water heater must not be connected to an existing heating system  
or component(s) previously used with a non-potable water heating  
appliance;  
4. When the system requires water for space heating t temperatures higher  
than required for other means, such as an ASSE approved mixing valve  
must be installed to temper the water for those uses in order to reduce the  
scald hazard potential.  
Please refer to the illustration for suggested piping arrangements.  
40  
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