1

Instruction Manual

PRINTED IN THE U.S.A 0408 197836-000

Keep thIs Manual In the pocKet on heater for future reference whenever MaIntenance adjustMent or servIce Is requIred.

power vent/power dIrect vent Gas Models wIth hot surface IGnItIon

all technIcal and warrantY questIons: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.

resIdentIal Gas water heaters

• for Your safety •AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

www.statewaterheaters.com

2

safe InstallatIon, use and servIceYour safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

all safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury.

the california safe drinking water and toxic enforcement act requires the Governor of california to publish a list of substances known to the state of california to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

this product contains a chemical known to the state of california to cause cancer, birth defects, or other reproductive harm. this appliance can cause low level exposure to some of the substances listed, including formaldehyde, carbon monoxide and soot.

IMportant defInItIons

• Qualified Installer or Service Agency: Installation and service of this water heater requires ability equivalent to that ofaQualifiedAgency(asdefinedbyANSIbelow)inthefieldinvolved.Installationskillssuchasplumbing,airsupply,venting,gassupply,electricalsupplyarerequiredinadditiontoelectricaltestingskillswhenperformingservice.

• ANSI Z223.1 2006 Sec. 3.3.83: “QualifiedAgency”-“Anyindividual,firm,corporationorcompanythateitherinpersonorthrougharepresentativeisengagedinandisresponsiblefor(a)theinstallation,testingorreplacementofgaspipingor(b)theconnection,installation,testing,repairorservicingofappliancesandequipment;thatisexperiencedinsuchwork;thatisfamiliarwithallprecautionsrequired;andthathascompliedwithalltherequirementsoftheauthorityhavingjurisdiction.”.

• Gas Supplier: TheNaturalGasorPropaneUtilityorservicewhosuppliesgas forutilizationby thegasburning applianceswithinthisapplication.Thegassuppliertypicallyhasresponsibilityfortheinspectionandcodeapprovalof gaspipinguptoandincludingtheNaturalGasmeterorPropanestoragetankofabuilding.

3

General safetY

4

General safetY

5

thank Youforpurchasingthiswaterheater.Properlyinstalledandmaintained,itshouldgiveyouyearsoftroublefreeservice.

Abbreviations Found In This Instruction Manual:• CSA-CanadianStandardsAssociation• ANSI-AmericanNationalStandardsInstitute• NFPA-NationalFireProtectionAssociation• ASME-AmericanSocietyofMechanicalEngineers•GAMA-GasApplianceManufacturer’sAssociation• UL-UnderwritersLaboratoriesInc.

This gas-firedwater heater is design certified byUnderwritersLaboratories Inc. under American National Standard/CSA Standard forGasWaterHeatersANSIZ21.10.3•CSA4.3(currentedition).

preparInG for the InstallatIon

1. Read the “GeneralSafety”section,page3and4of thismanualfirstand then theentiremanualcarefully. If youdon’t follow thesafety rules, thewaterheaterwill notoperateproperly. It couldcause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

Thismanualcontainsinstructionsfortheinstallation,operation,andmaintenanceofthegas-firedwaterheater.Italsocontainswarnings throughout themanual that youmust read and beawareof.Allwarningsandall instructionsareessential to theproperoperationofthewaterheaterandyoursafety.Sincewecannotputeverythingonthefirstfewpages,read the entIre Manual Before atteMptInG to Install or operate the water heater.

2. The installation must conform with these instructions and the local codeauthorityhaving jurisdiction. In theabsenceof localcodes,theinstallationmustcomplywiththecurrenteditionsoftheNational Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National Electrical Code, NFPA 70 or CAN/CSA-B149.1, the Natural Gas and PropaneInstallationCodeandCSAC22.1,theCanadianElectricalCode. All documents are available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131. NFPA documents are also available from the National Fire Protection Association,1BatterymarchPark,Quincy,MA02269.

3. Thewaterheaterwheninstalledmustbegroundedinaccordancewith the local codes, or in the absence of local codes: the National ElectricalCode(NFPA70)ortheCanadianElectricalCode(C22.1).

4.Ifafter reading thismanualyouhaveanyquestionsordonotunderstandanyportionoftheinstructions,callthelocalgasutilityorthemanufacturerwhosenameappearsontheratingplate.

5.Carefullyplan theplacewhereyouaregoing toput thewaterheater.Correctcombustion,ventaction,andventpipeinstallationare very important in preventing death frompossible carbonmonoxidepoisoningandfires,seeFigures1and2.

Examinethelocationtoensurethewaterheatercomplieswiththe“FactstoConsiderAboutLocation”sectioninthismanual.

6. For California installation this water heater must be braced, anchored, or strapped to avoid falling ormoving during anearthquake.Seeinstructionsforcorrectinstallationprocedures.InstructionsmaybeobtainedfromCaliforniaOfficeoftheStateArchitect, 400 P Street, Sacramento, CA 95814.

7. Massachusetts Code requires this water heater to be installed in accordancewithMassachusetts248-CMR2.00:StatePlumbingCodeand248-CMR5.00,Seepage8.

8.ComplieswithSCAQMDrule#1146anddistrictshavingequivalentNOxrequirements.

IntroductIon

taBle of contentsSAFE INSTALLATION, USE AND SERVICE............................2GENERAL SAFETY..................................................................3TABLE OF CONTENTS ............................................................5INTRODUCTION ......................................................................5 PreparingfortheInstallation .............................................5 Get to Know Your Water Heater ........................................6INSTALLATION CONSIDERATIONS .......................................7 RoughInDimensions........................................................7 Commonwealth of Massachusetts ....................................8 WaterPiping-MixingValveUsage ...................................9 Facts to Consider About Location ...................................10 InsulationBlankets ..........................................................11 Combustion Air and Ventilation .......................................11 AppliancesinUnconfinedSpaces ...........................11 AppliancesinConfinedSpaces ..............................11INSTALLING THE WATER HEATER ..................................... 13 ChemicalVaporCorrosion ..............................................13 WaterPiping ...................................................................13 Temperature-PressureReliefValve ................................14 GasPiping ......................................................................15 SedimentTraps ...............................................................16 FillingtheWaterHeater ..................................................16 Venting ............................................................................16 VentPipeTermination ............................................... 16-17 PlanningtheVentSystem ...............................................19 Condensate.....................................................................19 Installation of Vent System..............................................20 Vent Terminal Installation, Sidewall .................................20 SequenceofInstallations,Figure18A ............................20 DirectVenting..................................................................20 Direct Vent Terminal Installation ......................................20

Installation Sequence......................................................21 Vertical Vent Terminal Installation ...................................21 Installation of Vent System, Sidewall ..............................22 Installation of Vertical Vent System .................................22 VentPipePreparation .....................................................26 Controls and Switches ....................................................28 PowerVentWiringSchematic.........................................29LIGHTING & OPERATING LABEL .........................................30TEMPERATURE REGULATION ............................................31USING THE ELECTRONIC CONTROLLER ..........................32FOR YOUR INFORMATION ...................................................36 StartUpConditions Smoke/Odor ............................................................36 ThermalExpansion .................................................36 StrangeSounds ......................................................36 OperationalConditions ...................................................36 Smelly Water ...........................................................36 “Air”inHotWaterFaucets .......................................36PERIODIC MAINTENANCE ...................................................37 VentingSystemInspection..............................................37 BurnerOperationandInspection ....................................37 BurnerCleaning ..............................................................37 Housekeeping .................................................................37 AnodeRodInspection.....................................................38 Temperature-PressureReliefValveOperation ...............38 Draining...........................................................................38 Service ............................................................................39LEAKAGE CHECKPOINTS ....................................................39TROUBLESHOOTING ...........................................................40NOTES ............................................................................. 41-42WARRANTY ...........................................................................43

6

* CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** see “planning the vent system,” “Installation of vent system” and “condensate” for more information.

FIGURE 1.

vacuuM relIef valve

*Install perlocal codes

M display enclosure ** n exhaust elbow assembly ** o condensate tubing p off/on switch q display label r hot water outlet *S Electrical Outlet (120VAC) t Gas supply u Main Manual Gas shutoff valve v union w Inlet water shutoff valve X cold water Inlet

Get to Know Your water heater - Gas Models

a control assembly B Blocked Inlet switch c Blocked outlet switch d fan prover switch e Blower assembly f Burner assembly G flame sensor h hot surface Igniter I junction Box j Gas valve assembly K display Board l top plastic enclosure

Y Inlet dip tube Z T/P Relief Valve aa rating plate BB labels cc drain valve ** dd vent terminal ee drain pan ff anode GG Insulation hh upper temperature probe II access door

replaceMent parts and delIMInG productsReplacementpartsandrecommendeddelimermaybeorderedthroughauthorizedservicersordistributors.Whenorderingparts,providecompletemodelandserialnumbers(seeratingplate),quantityandnameofpartdesired.Standardhardwareitemsmaybepurchasedlocally.

caution: Thisaccesspanelcoversa 2”NPTplug thatwas requiredduring themanufacturing of thiswaterheater.This2”NPTflangeisnot a cleanout fitting,removingthe2”NPTplugandusingthisfittingasacleanout could void your warranty.

access panel

7

rough-In-dimensions

Model Units A B C D E F

100Inches 68.50 49.25 22.00 15.75 3.00 8.00

cm 174 125.09 55.88 40.00 7.62 20.32

Top/Side Inlet and Outlet: 3/4” NPTGas Inlet: 1/2” NPT

capacity, Gas and electrical characteristics

ModelApproximateCapacity Manifold Pressure Electrical Characteristics

U.S. Gals. Liters GasType “WC kPA Volts/Hz Amperes

100 50 189 Nat./LP 0” 0” 120/60 <5

All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.

recovery capacities - u.s. Gallons/hr. and liters/hr. at temperature rise Indicated

Model

Input RecoveryCapacities

Rating(Btu/hr)

Rating(kW)

Temp.Rise

F 30 40 50 60 70 80 90 100 110 120 130 140

C 17 22 28 33 39 44 50 56 61 67 72 78

100 100,000 29.3GPH 387 291 233 194 166 145 129 116 106 97 90 83

LPH 1465 1102 882 734 628 549 488 439 401 367 341 314

Recovery capacity based on 96% thermal efficiency

InstallatIon consIderatIonsrouGh In dIMensIons

FIGURE 1A.

8

Forallsidewallterminated,horizontallyventedpowervent,directvent,andpowerdirectventgasfueledwaterheatersinstalledineverydwelling,buildingorstructureusedinwholeorinpartforresidentialpurposes,includingthoseownedoroperatedbytheCommonwealthandwherethesidewallexhaustventterminationislessthanseven(7)feetabovefinishedgrade in theareaof theventing, includingbutnot limitedtodecksandporches, thefollowingrequirementsshall be satisfied:

InstallatIon of carBon MonoXIde detectorsAtthetimeofinstallationofthesidewallhorizontalventedgasfueledequipment,theinstallingplumberorgasfittershallobservethatahardwiredcarbonmonoxidedetectorwithanalarmandbatteryback-upisinstalledonthefloorlevelwherethegasequipmentistobeinstalled.Inaddition,theinstallingplumberorgasfittershallobservethatabatteryoperatedorhardwiredcarbonmonoxidedetectorwithanalarmisinstalledoneachadditionallevelofthedwelling,buildingorstructureservedbythesidewallhorizontalventedgasfueledequipment.Itshallbetheresponsibilityofthepropertyownertosecuretheservicesofqualifiedlicensedprofessionalsfortheinstallationofhardwiredcarbonmonoxidedetectors.

Intheeventthatthesidewallhorizontallyventedgasfueledequipmentisinstalledinacrawlspaceoranattic,thehardwiredcarbonmonoxidedetectorwithalarmandbatteryback-upmaybeinstalledonthenextadjacentfloorlevel.

Intheeventthattherequirementsofthissubdivisioncannotbemetatthetimeofcompletionofinstallation,theownershallhaveaperiodofthirty(30)daystocomplywiththeaboverequirementsprovidedthatduringsaidthirty(30)dayperiod,abatteryoperatedcarbonmonoxidedetectorwithanalarmshallbeinstalled.

approved carBon MonoXIde detectors EachcarbonmonoxidedetectorasrequiredinaccordancewiththeaboveprovisionsshallcomplywithNFPA720andbeANSI/UL2034listedandCSAcertified.

sIGnaGe Ametalorplasticidentificationplateshallbepermanentlymountedtotheexteriorofthebuildingataminimumheightofeight(8)feetabovegradedirectlyinlinewiththeexhaustventterminalforthehorizontallyventedgasfueledheatingapplianceorequipment.Thesignshall read, inprintsizeno lessthanone-half(1/2) inch insize,“Gas vent dIrectlY Below. Keep clear of all oBstructIons.”

InspectIon Thestateorlocalgasinspectorofthesidewallhorizontallyventedgasfueledequipmentshallnotapprovetheinstallationunless,uponinspection,theinspectorobservescarbonmonoxidedetectorsandsignageinstalledinaccordancewiththeprovisionsof248CMR5.08(2)(a)1through4.

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

1.TheequipmentlistedinChapter10entitled“EquipmentNotRequiredToBeVented”inthemostcurrenteditionofNFPA 54asadoptedbytheBoard;and

2.ProductApprovedsidewallhorizontallyventedgasfueledequipmentinstalledinaroomorstructureseparatefromthe dwelling,building,orstructureusedinwholeorinpartforresidentialpurposes.

Manufacturer requIreMents - Gas equIpMent ventInG sYsteM provIded When the manufacturer of Product Approvedsidewallhorizontallyventedgasequipmentprovidesaventingsystemdesignorventingsystemcomponentswiththeequipment,theinstructionsprovidedbythemanufacturerforinstallationoftheequipmentandtheventingsystemshallinclude:

1.Detailedinstructionsfortheinstallationoftheventingsystemdesignortheventingsystemcomponents;and

2.Acompletepartslistfortheventingsystemdesignorventingsystem.

Manufacturer requIreMents - Gas equIpMent ventInG sYsteM not provIded When the manufacturer ofaProductApprovedsidewallhorizontallyventedgasfueledequipmentdoesnotprovidethepartsforventingthefluegases,butidentifies“specialventingsystems,”thefollowingrequirementsshallbesatisfiedbythemanufacturer:

1.Thereferenced“specialventingsystem”instructionsshallbeincludedwiththeapplianceorequipmentinstallationinstructions;and

2.The“specialventingsystems”shallbeProductApprovedbytheBoard,andtheinstructionsforthatsystemshallinclude apartslistanddetailedinstallationinstructions.

AcopyofallinstallationinstructionsforallProductApprovedsidewallhorizontallyventedgasfueledequipment,allventinginstructions,allpartslistsforventinginstructions,and/orallventingdesigninstructionsshallremainwiththeapplianceor equipmentatthecompletionoftheinstallation.

InstallatIon requIreMents for the coMMonwealth of Massachusetts

9

FIGURE 2.

water pIpInG - MIXInG valve usaGe

This appliance has been design certified as complying withAmerican National Standard/CSA Standard for water heaters and is considered suitable for:

Water (Potable) Heating and Space Heating: All models are consideredsuitableforwater(potable)heatingandspaceheating.

HOTTER WATER CAN SCALD: Waterheatersareintendedtoproducehotwater.Waterheatedto a temperature which will satisfy space heating, clotheswashing, dish washing, and other sanitizing needs can scaldandpermanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,andthephysicallyordevelopmentallydisabled.Ifanyoneusinghotwaterfromthisheaterfitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthelowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasaMixingValve,shallbeusedatthehotwatertapsusedby these people or at the water heater, see Figure 2.Mixingvalves are available at plumbing supply or hardware stores.Consult aQualified Installer or ServiceAgency. Followmixingvalvemanufacturer’s instructions for installation of the valves.Beforechangingthefactorysettingonthethermostat,readthe“TemperatureRegulation”sectioninthismanual.

* the side recirculation loop connections may not be used as the primary water inlet and outlet connections. for your convenience, plugs are installed in these fittings at the factory. Remove these plugs if needed for your specific installation. Otherwise (as with all connections) check for leaks while filling the tank with water and after completing the installation.

10

facts to consIder aBout the locatIon

Carefully choose an indoor location for the new water heater, because theplacementisaveryimportantconsiderationforthesafetyoftheoccupantsinthebuildingandforthemosteconomicaluseoftheappliance.this water heater is not for use in manufactured (mobile) homes or outdoor installation.

Whetherreplacinganoldwaterheaterorputtingthewaterheaterinanewlocation,thefollowingcriticalpointsmustbeobserved:

1.Selectalocationindoorsascloseaspracticaltotheventterminalorlocationtowhichthewaterheaterventpipingisgoingtobeconnected,andascentralizedwiththewaterpipingsystemaspossible.

2.Selectedlocationmustprovideadequateclearancesforservicing

andproperoperationofthewaterheater.

Installationofthewaterheatermustbeaccomplishedinsuchamannerthatifthetankoranyconnectionsshouldleak,theflowwillnotcausedamagetothestructure.Forthisreason,itisnotadvisabletoinstallthewaterheaterinanatticorupperfloor.Whensuchlocationscannotbeavoided,asuitabledrainpanshouldbeinstalledunderthewaterheater.Drainpansareavailableatyourlocalhardwarestore.Suchadrainpanmusthaveaclearanceofatleast1.0”(2.5cm)greaterthananypointonthewaterheater’souterjacketandmustbepipedtoanadequatedrain.Thepanmustnotrestrictcombustionairflow.Forexample,ifacircularpanisused,itmustbeaminimumof27”(69cm)indiameter.SeeFigure1.

Waterheaterlifedependsuponwaterquality,waterpressureandthe environment in which the water heater is installed. Water heaters aresometimesinstalled in locationswhereleakagemayresult inpropertydamage,evenwiththeuseofadrainpanpipedtoadrain.However,unanticipateddamagecanbereducedorpreventedbyaleakdetectororwatershut-offdeviceusedinconjunctionwithapipeddrainpan.Thesedevicesareavailablefromsomeplumbingsupplywholesalersandretailers,anddetectandreacttoleakagein various ways:

• Sensorsmountedinthedrainpanthattriggeranalarmorturnofftheincomingwatertothewaterheaterwhenleakageisdetected.

• Sensorsmountedinthedrainpanthatturnoffthewatersupplytotheentirebuildingwhenwaterisdetectedinthedrainpan.

•Watersupplyshut-offdevices thatactivatebasedon thewaterpressuredifferentialbetweenthecoldwaterandhotwaterpipesconnected to the water heater.

• Devicesthatwillturnoffthegassupplytoagaswaterheaterwhileatthesametimeshuttingoffitswatersupply.

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VAPORS) ARE LIKELY TO BE PRESENT OR STORED(GARAGES,STORAGEANDUTILITYAREAS,ETC.):Flammableliquids(suchasgasoline,solvents,propane(LPorbutane,etc.)andothersubstances(suchasadhesives,etc.)emitflammablevaporswhichcanbeignitedbyagaswaterheater’shotsurfaceigniterormainburner.Theresultingflashbackandfirecancausedeathorserious burns to anyone in the area.

Also,thewaterheatermustbelocatedand/orprotectedsoitisnotsubjecttophysicaldamagebyamovingvehicle.

This water heatermust not be installed directly on carpeting.Carpetingmustbeprotectedbymetalorwoodpanelbeneaththeapplianceextendingbeyondthefullwidthanddepthoftheappliancebyatleast3”(7.6cm)inanydirection,oriftheapplianceisinstalled

11

inanalcoveorcloset,theentirefloormustbecoveredbythepanel.Failuretoheedthiswarningmayresultinafirehazard.

Minimum clearances between the water heater and combustible constructionare0inchatthesidesandrear,5.5”(14.0cm)fromthefrontand12”(30.5cm)fromthetop.(Standardclearance.)Ifclearancesstated on the heater differ from standard clearances, install water heateraccordingtoclearancesstatedontheheater.

Adequateclearance24”(61.0cm)forservicingthisapplianceshouldbeconsideredbeforeinstallation,suchaschangingtheanodes,etc.

Aminimumclearanceof5.5”(14.0cm)mustbeallowedforaccesstoreplaceablepartssuchasthethermostats,drainvalveandreliefvalve.

When installing theheater, considerationmust begiven to properlocation.Locationselectedshouldbeasclosetothewallaspracticableandascentralizedwiththewaterpipingsystemaspossible.

FIGURE 4.

InsulatIon BlanKetsInsulationblanketsareavailabletothegeneralpublicforexternaluseongaswaterheatersbutarenotnecessarywiththeseproducts.Thepurposeofan insulationblanket is to reduce thestandbyheat lossencounteredwithstorage tankheaters.YourwaterheatermeetsorexceedstheEnergyPolicyActstandardswithrespecttoinsulationandstandbylossrequirements,makinganinsulationblanketunnecessary.

Shouldyouchoosetoapplyaninsulationblankettothisheater,youshould follow these instructions (For identification of componentsmentionedbelow,seeFigure1).Failuretofollowtheseinstructionscan restrict theairflowrequired forpropercombustion,potentiallyresultinginfire,asphyxiation,seriouspersonalinjuryordeath.

• Do notapplyinsulationtothetopofthewaterheater,asthiswill interferewithsafeoperationoftheblowerassembly.

• Do notcovertheouterdoor,thermostatortemperature&pressure relief valve.

• Do notallow insulation tocomewithin2” (5.1cm)of thefloor to preventblockageofcombustionairflowtotheburner.

• Do not cover the instructionmanual. Keep iton thesideof the water heater or nearby for future reference.

• Doobtainnewwarningandinstructionlabelsfromthemanufacturer

forplacementontheblanketdirectlyovertheexistinglabels.• Do inspect the insulation blanket frequently tomake certain it doesnotsag,therebyobstructingcombustionairflow.

coMBustIon aIr and ventIlatIon

Agaswaterheatercannotoperateproperlywithoutthecorrectamountofairforcombustion.Donotinstallinaconfinedareasuchasacloset,unless you provide air as shown in the “Facts toConsiderAboutLocation”section.Neverobstructtheflowofventilationair.Ifyouhaveanydoubtsorquestionsatall,callyourgassupplier.Failuretoprovidetheproperamountofcombustionaircanresultinafireorexplosionandcausedeath,seriousbodilyinjury,orpropertydamage.

FIGURE 5.

Ifthiswaterheaterwillbeusedinbeautyshops,barbershops,cleaningestablishments,orself-servicelaundrieswithdrycleaningequipment,itisimperativethatthewaterheater(s)beinstalleddirectventsothatallairforcombustionandventilationistakenfromoutdoors.

Propellants of aerosol sprays and volatile compounds, (cleaners,chlorinebasedchemicals,refrigerants,etc.)inadditiontobeinghighlyflammableinmanycases,willalsoreacttoformcorrosivehydrochloricacidwhenexposedtothecombustionproductsofthewaterheater.Theresultscanbehazardous,andalsocauseproductfailure.

applIances In unconfIned spaces

unconfIned space is spacewhose volume is not less than 50cubicfeetper1,000Btuperhour(4.8cubicmetersperkW)oftheaggregateinputratingofallappliancesinstalledinthatspace.Roomscommunicatingdirectlywiththespace inwhichtheappliancesareinstalled,throughopeningsnotfurnishedwithdoors,areconsideredapartoftheunconfinedspace.In unconfined spaces in buildings, infiltrationmaybeadequate toprovide air for combustion, ventilation and dilution of flue gases.However, in buildings of tight construction (for example,weatherstripping,heavilyinsulated,caulked,vaporbarrier,etc.),additionalairmayneedtobeprovidedusingthemethodsdescribedin“AppliancesinConfinedSpace”thatfollows.”

applIances In confIned spacesconfIned spaceisaspacewhosevolumeislessthan50cubicfeetper1,000Btuperhour(4.8cmperkW)oftheaggregateinputratingofallappliancesinstalledinthatspace.Whendrawingcombustionairfrominsideaconventionallyconstructedbuildingtoaconfinedspace,suchaspaceshallbeprovidedwithtwopermanentopenings.ONEWITHIN12INCHES(30cm)OF THE ENCLOSURETOPANDONEWITHIN 12 INCHES (30cm)OFTHEENCLOSUREBOTTOM.Eachopeningshallhave

12

afreeareaofonesquareinchper1000Btu/hr(22cm2/kW)ofthetotalinputofallappliancesintheenclosure,butnotlessthan100squareinches(645cm2).

Iftheconfinedspaceiswithinabuildingoftightconstruction,airforcombustion and ventilation must be obtained from outdoors. When directlycommunicatingwiththeoutdoorsorcommunicatingthroughverticalducts,twopermanentopenings,locatedintheabovemanner,shallbeprovided.Eachopeningshallhaveafreeareaofnot lessthanonesquareinchper4000Btu/hr(5.5cm2/kW)oftotalinputofallappliancesintheenclosure.Ifhorizontalductsareused,eachopeningshallhaveafreeareaofnotlessthanonesquareinchper2000Btu/hr(11cm2/kW)ofthetotalinputofallappliancesintheenclosure.

a. all aIr froM InsIde BuIldInGs: (SeeFigure5and6)

Theconfinedspaceshallbeprovidedwith twopermanentopeningscommunicatingdirectlywithanadditional room(s)ofsufficientvolumeso that thecombinedvolumeofall spacesmeets thecriteria foranunconfinedspace.Thetotalinputofallgasutilizationequipmentinstalledinthecombinedspaceshallbeconsideredinmakingthisdetermination.Eachopeningshall haveaminimum freeareaofonesquare inchper1,000Btuperhour(22cm2/kW)of the total input ratingofallgasutilizationequipmentintheconfinedspace,butnotlessthan100squareinches (645cm2).Oneopeningshall commencewithin12 inches (30cm)ofthetopandonecommencingwithin12inches(30cm)ofthebottom of the enclosures.

FIGURE 6.

B. all aIr froM outdoors:(SeeFigures7,8and9)

Theconfinedspaceshallbeprovidedwithtwopermanentopenings,one commencingwithin 12 inches (30 cm) of the top and onecommencingwithin12inches(30cm)fromthebottomoftheenclosure.Theopeningsshallcommunicatedirectly,orbyducts,withtheoutdoorsorspaces(crawlorattic)thatfreelycommunicatewiththeoutdoors.

1. Whendirectlycommunicatingwiththeoutdoors,eachopeningshallhaveaminimumfreeareaof1squareinchper4,000Btuperhour(5.5cm2/kW)oftotalinputratingofallequipmentintheenclosure,seeFigure7.

FIGURE 7.2.Whencommunicatingwiththeoutdoorsthroughverticalducts,each

openingshallhaveaminimumfreeareaof1squareinchper4,000Btuperhour(5.5cm2/kW)oftotalinputratingofallequipmentintheenclosure,seeFigure8.

3. Whencommunicatingwiththeoutdoorsthroughhorizontalducts,eachopeningshallhaveaminimumfreeareaof1squareinchper2,000

Btuperhour(11cm2/kW))oftotalinputratingofallequipmentintheenclosure,seeFigure9.

FIGURE 8.4. When ducts are used, they shall be of the same cross-sectional area

asthefreeareaoftheopeningstowhichtheyconnect.Theminimumshortsidedimensionofrectangularairductsshallnotbelessthan3inches(7.6cm),seeFigure9.

FIGURE 9.

5. Alternatively a single permanent openingmaybeusedwhencommunicatingdirectlywiththeoutdoors,orwithspacesthatfreelycommunicatewiththeoutdoors.Theopeningshallhaveaminimumfreeareaof1squareinchper3,000BTUperhour(8.3cm2/kW)oftotalinputratingofallequipmentinenclosure.SeeFigure9A.

FIGURE 9.

6.LouversandGrilles:Incalculatingfreearea,considerationshallbegivento theblockingeffectoflouvers,grillesorscreensprotectingopenings.Screensusedshallnotbesmallerthan1/4inch(6.4mm)mesh.Ifthefreeareathroughadesignoflouverorgrilleisknown,itshouldbeusedincalculatingthesizeopeningrequiredtoprovidethefreeareaspecified.Ifthedesignandfreeareaisnotknown,itmaybeassumedthatwoodlouverswillbe20-25percentfreeareaandmetallouversandgrilleswillhave60-75percentfreearea.Louversandgrillesshallbefixedintheopenpositionorinterlockedwiththeequipmentsothattheyareopenedautomaticallyduringequipmentoperation.

7.SpecialConditionsCreatedbyMechanicalExhaustingorFireplaces:operationofexhaust fans,ventilationsystems,clothesdryersorfireplacesmaycreateconditionsrequiringspecialattentiontoavoidunsatisfactoryoperationofinstalledgasutilizationequipment.

13

closed water sYsteMs

Water supply systemsmay,becauseof code requirementsor suchconditionsashighlinepressure,amongothers,haveinstalleddevicessuchaspressurereducingvalves,checkvalves,andbackflowpreventers.Devices such as these cause the water system to be a closed system.

therMal eXpansIon

Aswaterisheated,itexpands(thermalexpansion).Inaclosedsystemthevolumeofwaterwillgrowwhenitisheated.Asthevolumeofwatergrowstherewillbeacorrespondingincreaseinwaterpressureduetothermalexpansion.Thermalexpansioncancauseprematuretankfailure(leakage).Thistypeoffailureisnotcoveredunderthelimitedwarranty.Thermalexpansioncanalsocauseintermittenttemperature-pressurereliefvalveoperation:waterdischargedfromthevalveduetoexcessivepressurebuildup.Thisconditionisnotcoveredunderthelimitedwarranty.Thetemperature-pressurereliefvalveisnotintendedfortheconstantreliefofthermalexpansion.

A properly sized thermal expansion tank should be installedon all closed systems to control the harmful effects of thermal expansion..

FIGURE 10.

note: to protect against untimely corrosion of hot and cold water fittings, it is strongly recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe, see Figure 2 also.

cheMIcal vapor corrosIon

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.

Spray can propellants, cleaning solvents, refrigerator and airconditioning refrigerants, swimming pool chemicals, calcium andsodiumchloride(watersoftenersalt),waxes,andprocesschemicalsaretypicalcompoundswhicharepotentiallycorrosive.

Donotstoreproductsofthissortneartheheater.Also,airwhichisbrought in contactwith theheater should not contain anyof thesechemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure ofwaterheaterisduetoacorrosiveatmosphere.(Seelimitedwarrantyforcompletetermsandconditions).

water pIpInG

HOTTER WATER CAN SCALD: Waterheatersareintendedtoproducehotwater.Waterheatedtoatemperaturewhichwillsatisfyspaceheating,clotheswashing,dishwashing,cleaningandothersanitizingneedscanscaldandpermanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,thephysicallyordevelopmentallydisabled.Ifanyoneusinghotwaterfitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthelowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasa*mixingvalve,shallbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater,seeFigure2.Valvesforreducingpointofusetemperaturebymixingcoldandhotwaterarealsoavailable: ConsultaQualified InstallerorServiceAgency.Follow manufacturer’sinstructions for installationof thevalves.Beforechanging the factorysettingon the thermostat, readthe“TemperatureRegulation”section inthis manual.

Thiswaterheatershallnotbeconnectedtoanyheatingsystemsorcomponent(s)usedwithanon-potablewaterheatingappliance.

All piping components connected to this unit for space heatingapplicationsshallbesuitableforusewithpotablewater.

Toxicchemicals,suchasthoseusedforboilertreatmentshallnotbeintroduced into this system.

Whenthesystemrequireswaterforspaceheatingattemperatureshigherthanrequiredfordomesticwaterpurposes,atemperingvalvemustbeinstalled.PleaserefertoFigure2forsuggestedpipingarrangement.

InstallInG the new water heater

14

Figures2and10showthetypicalattachmentofthewaterpipingtothewaterheater.Thewaterheater isequippedwith3/4 inchNPTwater connections.

note: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water heater connections. do not solder the water lines directly to the water heater connections. It will harm the dip tube and damage the tank.

T & P Valve and Pipe Insulation (if supplied)

Remove insulation forT&P valve and pipe connections fromcarton.

FIGURE 11.

Fit pipe insulation over the incoming cold water line and thehotwater line.Makesurethat the insulation isagainst thetopcoveroftheheater.FitT&Pvalveinsulationovervalve.Makesure that the insulation does not interfere with the lever of the T & P valve.

Secureallinsulationusingtape.

teMperature-pressure relIef valve

This heater is provided with a properly certified combination temperature-pressurereliefvalvebythemanufacturer.

Thevalve iscertifiedbyanationally recognized testing laboratorythatmaintainsperiodicinspectionofproductionoflistedequipmentofmaterialsasmeetingtherequirementsforReliefValvesforHotWaterSupplySystems,ANSIZ21.22•CSA4.4,andthecoderequirementsof ASME.

Ifreplaced,thevalvemustmeettherequirementsoflocalcodes,butnot less thanacombination temperatureandpressure reliefvalvecertifiedasindicatedintheaboveparagraph.

The valvemust bemarkedwith amaximum set pressure not toexceedthemarkedhydrostaticworkingpressureofthewaterheater (150psi=1,035kPa)andadischargecapacitynotlessthanthewater heater Btu/hr input rate as shown on the water heater’smodelratingplate.

Forsafeoperationofthewaterheater,thereliefvalvemustnotberemovedfromitsdesignatedopeningnorplugged.

Thetemperature-pressurereliefvalvemustbeinstalleddirectlyintothefittingofthewaterheaterdesignedforthereliefvalve.Positionthevalvedownwardandprovidetubingsothatanydischargewillexitonlywithin6inches(15.2cm)above,oratanydistancebelowthe structural floor. Be certain that no contact is made with any liveelectricalpart.Thedischargeopeningmustnotbeblockedorreducedinsizeunderanycircumstances.Excessivelength,over30feet(9.14m),oruseofmorethanfourelbowscancauserestriction and reduce thedischarge capacity of the valve, seeFigures10.

Novalveorotherobstruction istobeplacedbetweenthereliefvalveandthetank.Donotconnecttubingdirectlytodischargedrainunlessa6”(15.2cm)airgapisprovided.Topreventbodilyinjury, hazard to life, orpropertydamage, the relief valvemustbeallowedtodischargewaterinquantitiesshouldcircumstancesdemand.Ifthedischargepipeisnotconnectedtoadrainorothersuitablemeans,thewaterflowmaycausepropertydamage.

TheDischargePipe:

•Shallnotbesmallerinsizethantheoutletpipesizeofthevalve,or haveanyreducingcouplingsorotherrestrictions.

•Shallnotbepluggedorblocked.

•Shallbeofmateriallistedforhotwaterdistribution.

•Shallbeinstalledsoastoallowcompletedrainageofboththe temperature-pressurereliefvalve,andthedischargepipe.

•Shallterminateatanadequatedrain.

•Shallnothaveanyvalvebetweenthereliefvalveandtank.

15

The temperature-pressure relief valve must be manuallyoperatedatleastonceayear,seeFigure28.Cautionshouldbetakentoensurethat(1)nooneisinfrontoforaroundtheoutletofthetemperature-pressurereliefvalvedischargeline,and(2)thewatermanuallydischargedwillnotcauseanybodilyinjuryorpropertydamagebecausethewatermaybeextremelyhot.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetand continues to release water, immediately close the cold water inlet to thewater heater, follow the draining instructions, andreplacethetemperature-pressurereliefvalvewithanewone.

Gas pIpInG

Makesuregassuppliedissametypelistedonmodelratingplate.Theinletgaspressuremustnotexceed14inchwatercolumn(3.5kPa)fornaturalandpropanegas(L.P.).Theminimuminletgaspressureshownonratingplateisthatwhichwillpermitfiringatratedinput.

All gaspipingmust complywith local codesandordinancesorwith the NationalFuelGasCode (ANSIZ223.1/NFPA-54)or theNaturalGasandPropaneInstallationCode(CAN/CSAB149.1)whicheverapplies.Copperorbrasstubingandfittings(excepttinlinedcoppertubing)shallnotbeused.

Ifthegascontrolvalveissubjectedtopressuresexceeding1/2psi(3.5kPa),thedamagetothegascontrolvalvecouldresultinafireorexplosionfromleakinggas.

IfthemaingaslineShut-offservingallgasappliancesisused,alsoturn“off”thegasateachappliance.Leaveallgasappliancesshut“off”untilthewaterheaterinstallationiscomplete.

A gas line of sufficient size must be run to the water heater.Consult the current edition of National Fuel Gas Code (ANSIZ223.1/NFPA54)ortheNaturalGasandPropaneInstallationCode (CAN/CSAB149.1)andyourgassupplierconcerningpipesize.

There must be:

•Areadilyaccessiblemanualshutoffvalve in thegassupplylineservingthewaterheater,and

•Adripleg(sedimenttrap)aheadofthegascontrolvalvetohelppreventdirtandforeignmaterialsfromenteringthegascontrolvalve.

•Aflexiblegasconnectororagroundjointunionbetweentheshut off valve and control valve to permit servicing of theunit.

Besuretocheckallthegaspipingforleaksbeforelightingthewaterheater.Useasoapywatersolution,notamatchoropenflame.Rinseoffsoapysolutionandwipedry.

hIGh altItude InstallatIons

Ratedinputsaresuitableupto10,100feet(3,079m)elevation.Consultthefactoryforinstallationataltitudesover10,100feet(3,079m).

WARNING: THIS HIGH EFFICIENCY WATER HEATER IS CERTIFIED FOR USE WITHOUT MODIFICATION FOR AN ALTITUDE OF 10,100 FEET(3,079METERS).INSTALLATIONSABOVETHESEALTITUDESMAY REQUIRE REPLACEMENT OF BURNER ORIFICE. CALL THE TECHNICALCENTERAT(800)365-0024FOR REQUIREMENTS.

Somegasutility companiesderate their gas for altitude,makingitunnecessarytoinstallhighaltitudeorifices.CallthelocalgasorutilitycompanytoverifyBTUcontent.

Duetotheinputrationreductionathighaltitudes,theoutputratingoftheapplianceisalsoreducedandshouldbecompensatedforinthesizingoftheequipmentforapplications.

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

Theapplianceanditsgasconnectionmustbeleaktestedbeforeplacingtheapplianceinoperation.

TheapplianceanditsindividualShut-offvalveshallbedisconnectedfromthegassupplypipingsystemduringanypressuretestingofthatsystemattestpressuresinexcessof1/2poundpersquareinch(3.5kPa). ItshallbeisolatedfromthegassupplypipingsystembyclosingitsindividualmanualShut-offvalveduringanypressuretestingofthegassupplypipingsystemattestpressuresequaltoorlessthan1/2poundpersquareinch(3.5kPa).

IMportant: MaKe sure the Gas lIne Is pIped In wIth hard pIpe. avoId fleX lIne constructIon for Gas due to possIBle Gas flow proBleMs.

16

sedIMent traps

Asedimenttrapshallbeinstalledasclosetothegasinletofthewaterheateraspracticalatthetimeofwaterheaterinstallation.Thesedimenttrapshallbeeitherateefittingwithacappednippleinthebottomoutletorotherdevicerecognizedasaneffectivesedimenttrap.

Contaminantsinthegaslinesmaycauseimproperoperationofthegascontrolvalvethatmayresultinfireorexplosion.Beforeattachingthegaslinebesurethatallgaspipeiscleanontheinside.Totrapanydirtorforeignmaterialinthegassupplyline,adripleg(sometimescalledasedimenttrap)mustbeincorporatedinthepiping.Thedriplegmustbereadilyaccessible.Installinaccordancewiththe“GasPiping” section.Refer to the current editionof theNationalFuelGasCode(ANSIZ223.1/NFPA54)ortheNaturalGasandPropaneInstallationCode(CAN/CSAB149.1).

fIllInG the water heater

Neverusethiswaterheaterunlessitiscompletelyfullofwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gastothewaterheater.

Tofillthewaterheaterwithwater:1. Closethewaterheaterdrainvalvebyturningthehandletotheright

(clockwise).Thedrainvalveisonthelowerfrontofthewaterheater.2. Open the cold water supply valve to the water heater.

note: the cold water supply valve must be left open when the water heater is in use.

3. Toinsurecompletefillingofthetank,allowairtoexitbyopeningthenearesthotwaterfaucet.Allowwatertorununtilaconstantflowisobtained.Thiswillletairoutofthewaterheaterandthepiping.

4. Checkallwaterpipingandconnectionsforleaks.Repairasneeded.

ventInG

vent pIpe terMInatIon

Thefirststepistodeterminewheretheventpipewillterminate.SeeFigures19,20,and21.TheventmayterminatethroughasidewallasshowninFigure19orthroughtheroofasshowninFigures20and21.

The vent systemmust terminate so that proper clearancesare maintained as ci ted in local codes or the current edition of theNational FuelGasCode, (ANSI Z223.1, 12.9.1through 12.9.4) or the Natural Gas and Propane InstallationCode(CAN/CSA-B149.1).

InstructionsonproperinstallationthroughasidewallareprovidedinFigures15A,15B,15C,and15D.

Plan the vent system layout so that proper clearances aremaintainedfromplumbingandwiring.

Vent pipes servingpower ventedappliancesare classifiedbybuildingcodesas“ventconnectors”.Requiredclearancesfromcombustiblematerials must be provided in accordance withinformation in this manual under FACTS TO CONSIDER ABOUT LOCATION and INSTALLING THE WATER HEATER, and with the National Fuel Gas Code and local codes.

17

FIGURE 15B.

u.s. power vent

canadIan power vent

warnInGVENT HOOD(S) MAY BE

eXtreMelY hot durInG operatIon.

warnInGVENT HOOD(S) MAY BE

eXtreMelY hot durInG operatIon.

FIGURE 15A.

cautIonto prevent eXhaustInG products froM cIrculatInG to the aIr IntaKe In wIndY/cold areas, the MaXIMuM practIcal dIstance Between these two

terMInals Is recoMMended.

18FIGURE 15D.

u.s. dIrect vent

canadIan dIrect vent

warnInGVENT HOOD(S) MAY BE

eXtreMelY hot durInG operatIon.

warnInGVENT HOOD(S) MAY BE

eXtreMelY hot durInG operatIon.

FIGURE 15C.

cautIonto prevent eXhaustInG products froM cIrculatInG to the aIr IntaKe In wIndY/cold areas, the MaXIMuM practIcal dIstance Between these two

terMInals Is recoMMended.

19

plannInG the vent sYsteM

Plan the routeof theventsystemfromtheexhaustelbow to theplannedlocationoftheventterminal.1. Layouttotalventsystemtouseaminimumofventpipeandelbows.2. Thiswaterheateriscapableofventingfluegasesequivalentto

25’(7.6m)of2”pipe,65’(19.8m)of3”pipe,or128’(39.0m)of4”pipeaslistedinTable1.

TABLE 1 Number of 2” Maximum 3” Maximum 4” Maximum 90° Elbows Pipe - ft. (m) Pipe - ft. (m) Pipe - ft. (m) 1 20(6.1) 60(18.3) 120(36.6) 2 15(4.6) 55(16.8) 112(34.1) 3 10(3.0) 50(15.2) 104(31.7) 4 -- 45(13.7) 96(29.3) 5 -- 40(12.2) 88(26.8) 6 -- 35(10.7) 80(24.3)

Theminimumventlengthsforeachofthepipesizesisone90°plus2’(61cm)ofstraightpipeandtheappropriatetermination. note:Theequivalentfeet(m)ofpipelistedaboveareexclusive

of the termination. That is, the termination, with an installed screen, is assumed to be in the system and the remainder of the systemmustnotexceedthelengthsdiscussedabove.

3. Theexhaustelbowassemblyisdesignedtoacceptonlystraightsectionsof2”pipe.Tostart,aminimumof2”(5.1cm)of2”pipemustbe insertedandglued to theexhaustelbowassembly ifutilizing3”or4”ventpipe.Usethesamemethodwiththeblowerinletifadirectventconfigurationisutilized.

If using 2” inch vent pipe: Aminimumof2”(5.1cm)diameterventpipemustbeattached

totheexhaustelbowassembly.Thetotalsystemcannotexceedthe lengthsdiscussedabove,whereeachelbow isequal to5equivalentfeet(1.5m)ofstraightpipe.

If using 3” or 4” inch vent pipe: Twoinches(5.1cm)of2”pipemustbeattachedtotheexhaust

elbowassemblybeforeaddingareducertoacquirethedesiredpipediameter.Anappropriatelysized45degreeelbow(suppliedlocally-aschedule40DWV)ventterminalmustbeobtainedwithanequivalentscreen(suppliedinventkit).Thetotalsystemcannotexceedtheequivalentpipelengthsdiscussedabovewhereeachelbowisequalto5feet(1.5m)ofstraightpipe(3”ventpipe)or8feet(2.4m)ofstraightpipe(4”ventpipe).

u.s. InstallatIons: note: ThisunitcanbeventedwithPVCpipematerials(CellularCore

ASTM-F891;DWVASTM-D2665orCSAB181.2;Schedule40,80,120ASTM-D1785orCSAB137.3;orSDRSeriesASTM-D2241orCSAB137.3),CPVCpipematerials(CPVC41ASTM-D2846orCSAB137.6;Schedule40,80ASTM-F441orCSAB137.6;orSDRSeriesASTM-F442),ABSpipematerials(Schedule40DWVASTM-D2661orCSAB181.1orSchedule40DWVCellularCoreASTM-F628).Thefittings,otherthanthe TERMINATION should be equivalent to PVC-DWVfittingsmeetingASTMD-2665(UseCPVCfittings,ASTMF-438forCPVCpipeandABSfittings,ASTMD-2661/3311forABSpipe).IfCPVCorABSpipeandfittingsareused,thenpropercementmustbeusedforalljoints,includingjoiningthepipetoTermination(PVCMaterial).IflocalcodesdonotallowtheuseofthePVCterminationwhenamaterialotherthanPVCisusedforventing,thenanequivalentfittingofthatmaterialmaybesubstitutedifthescreeninthePVCterminalisremovedandinsertedintothenewfitting.

canadian Installation of this water heater must comply with can/CSA B149.1 - Natural Gas and Propane Installation Code which requires the vent system components be certified to ULC S636.

ThiswaterheaterhasbeendesigncertifiedtobeventedwithPVCpipecertifiedandmarkedascomplyingwithULCS636.Thiswaterheaterissuppliedwitha2inch22.5degreeterminationelbowthatisaspecialfittingthatmustbeusedwiththeappliance.Anyoutletpiping,fittingsandglueusedtoventthisappliancethatisnotsuppliedbythemanufacturermustcomplywiththeULCS636requirements.

PVCMaterialsshoulduseASTMD-2564GradeCement;CPVCMaterials should use ASTM F-493 Grade Cement and ABS Materials should use ASTM D-2235 Grade Cement.

Ifthewaterheaterisbeinginstalledasareplacementforanexistingpowerventedheaterinpre-existingventing,athoroughinspection

ofexistingventingsystemmustbeperformedpriortoanyinstallationwork.Verifythatcorrectmaterialasdetailedabovehasbeenused,andthattheminimumormaximumventlengthsandterminallocationasdetailedinthismanualhavebeenmet.Carefullyinspecttheentireventingsystemforanysignsofcracksorfractures,particularlyatjointsbetweenelbowsandotherfittingsandstraightrunsofventpipe.Checksystemforsignsofsaggingorotherstressesinjointsasaresultofmisalignmentofanycomponentsinthesystem.Ifanyofthese conditions are found, they must be corrected in accordance with theventinginstructionsinthismanualbeforecompletinginstallationandputtingthewaterheaterintoservice.

note: a. Forwater heaters in locationswith high ambienttemperatures(above100°F) it isrecommendedthatCPVCorABSpipeandfittingsbeused.B.A22.5degreeelbow(2”ventpipe)ora45degreeelbow(3”and4”ventpipe)withaninstalledscreen VENT TERMINAL must be used in all cases.

4. There will be some installations where condensate will be formed inthehorizontalrunsoftheventsystem. This condensate will runintothecondensateelbow.Thewaterheaterisshippedwitha condensate hose that attaches to the condensate elbow. No otherteeorfittingisrequired.

condensateThiswaterheaterisacondensingunitandrequiresadraintobelocatedincloseproximitytoallowthecondensatetodrainsafely.Thecondensatedrainsfromtheunitattheexhaustteelocatedatthebottomoftheunit (seefigure16).Condensatefromthiswaterheaterismildlyacidic.Please note that some local codes require that condensate is treated byusingapHneutralizingfilterpriortodisposal.Caution must be used to ensure that the drain is free and clear of debris andwillnotallowbackflowthroughthecondensatehose.Considerationmustbegiven toavoid freezingof thecondensate lineswhichcould result inexcessivebuildupof condensate inside thewaterheater.Waterproofheat tapemayberequired toprevent freezingof thecondensate lines. Please ensure that the outlet of the condensate drain does notcreateaslipperyconditionwhichcouldleadtopersonalinjury.

condensatIon warnInG: thIs water heater Is a condensInG unIt and requIres a draIn to Be located In close proXIMItY to allow condensate to draIn safelY. the condensate draIns froM unIt at the eXhaust elBow located at BottoM of unIt. note: It Is IMportant that the condensate hose not Be elevated aBove the eXhaust elBow, see FIGURE 16. CONDENSATE BUILD-UP WILL BLOCK THE EXHAUST outlet, whIch wIll cause IMproper operatIon.

FIGURE 16.

20

InstallatIon of vent sYsteM

Beforebeginninginstallationofpipingsystemthoroughlyreadthe section of this manual VENT PIPE PREPARATION.

If you are installing your system so that it vents through roof,please refer to section titled INSTALLATIONOFVERTICALVENT SYSTEM.

vent terMInal InstallatIon, sIdewall

1. Installtheventterminalbyusingthecoverplateasatemplatetomarktheholefortheventpipetopassthroughthewall.BEWARE OF CONCEALED WIRING AND PIPING INSIDE THE WALL.

2. If theVent Terminal is being installed on the outside of afinishedwall, itmaybeeasier tomarkboth the insideandoutsidewall. Aligntheholesbydrillingaholethroughthecenterofthetemplatefromtheinsidethroughtotheoutside.Thetemplatecannowbepositionedontheoutsidewallusingthedrilledholeasacenteringpointforthetemplate.

3. A)MASONRYSIDEWALLS Chiselanopeningapproximatelyonehalfinch(1.3cm)larger

thanthemarkedcircle. B)WOODENSIDEWALLS Drillapilotholeapproximatelyonequarterinch(0.64cm)outside

ofthemarkedcircle.Thispilotholeisusedasastartingpointfor a saws-all or sabre sawblade.Cut around themarkedcirclestayingapproximatelyonequarterinch(0.64cm)outsideof the line. (Thiswill allow the vent to easily slide throughthe opening. The resulting gap will be covered up by theVentTerminalcoverplate.)Repeatthissteponinsidewallifnecessary.

SEQUENCE OF INSTALLATIONS, FIGURE 18A

CutalengthofPVCpipeabout3.5inches(8.9cm)longerthanthewall thicknessat theopening. Glue the vent terminal to thissectionofpipe.Slidethewallplateoverthepipetostopagainsttheventterminal.Placeabeadofcaulking(notsupplied)aroundthe gap between the pipe and cover plate. Apply enough tofillsomeofthegapbetweenthepipeandwall.Placesomeofthecaulkingonthebackoftheplatetoholditagainstthewallafterinstallation.Iftheventpipeisinstalleduptothewall,withacouplingon theendagainst thewallopening, thepipewiththe vent terminal canbeprepared for gluing before insertingthrough the wall. Slide the pipe through the wall and insertintothecouplingontheothersideofthewall,makingsurethatthevent terminalendsuppointed in thecorrectposition,seeFigure18A.

VENT TERMINATION - FIGURE 18A.

dIrect ventInG

Theairintakeprovidedontheunitcontainsameshscreentopreventlargeparticlesfromenteringtheunit.

FIGURE 18B.

WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH SCREEN MUST BE REMOVED. THE INLET VENT PIPE MAYTHENBEGLUEDTOTHEAIRINTAKE(SeeFigure18B)PROVIDED ON THE UNIT. THE SCREEN REMOVED FROM THE INTAKENEEDSTOBEINSERTEDINTOTHE2”-22.5DEGREEVENT TERMINAL SUPPLIED IN THE VENT TERMINAL KIT.

dIrect vent terMInal InstallatIon IMportantTHIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT TERMINAL AND AN EXHAUST VENT TERMINAL. THE INTAKE VENTTERMINALISA2”22.5°PVCELBOW(-)WITHAMESHWIRESCREENANDTHEEXHAUSTVENTTERMINALISA2”22.5°PVCELBOW WITH A MESH WIRE SCREEN.

NOTE: TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO TERMINALS IS RECOMMENDED.

FIGURE 18C.

WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.

1.Theintakeairterminalandtheexhaustventterminalmustterminateonthesameexteriorwallandmustbeseparatedbyaminimumof24”(61cm)onverticalcenterline(seeFigure18C).Incolderclimatesincreasing the 24” (61cm)minimumwill reducepossibility of frostoverfromsidewindsblowingexhaustvaporstotheairintakeofthedirect vent.

2.Thehorizontalcenterlineoftheintakeairterminalmaynotbelocatedlowerthanthehorizontalcenterlineoftheexhaustventterminal(seeFigure18C).

21

InstallatIon sequenceForinstallationsintheCityofLosAngeles,CaliforniaCategoryIVPVCPipesuchasthatmanufacturedbyBrownlinePipeCompany,mustbeusedasventpipematerial.

cautIonvent terMInals supplIed wIth heater Must Be used.

NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ THE VENT PIPE MANUFACTURER’SINSTALLATION INSTRUCTIONS.

1. After the points of termination have been determined, use the cover plates as templates to mark the holes for theventpipes tobe inserted through thewall.BEWAREOFCONCEALED WIRING AND PIPING INSIDE OF WALL. If the ventterminalsarebeinginstalledontheoutsideofafinishedwall, itmay be easier tomark both the inside and outsidewall.Aligntheholesbydrillingaholethroughthecenterofthetemplatefromtheinsidethroughtotheoutside.Thetemplatecannowbepositionedontheoutsidewallusingthedrilledholesasacenteringpointforthetemplate.

A.) MASONRYSIDEWALLSChisel an opening approximately 1/2”(1.3cm)largerthanthemarkedcircle.

B.) WOODENSIDEWALLSDrillapilotholeapproximately one quarter inch outside of themarked circle. This pilot hole is usedasa starting point for a saws-all or sabresawblade.Cutaroundthemarkedcirclestaying approximately one quarter inch outside of the line. (Thiswill allow the vent pipe to easily slide through theopening.The resultinggapwill be coveredby the vent terminal cover plates.) Repeat this step on the inside wall if necessary.2. Cutalengthof3”PVCpipeabout3.5”(8.9cm)longerthanthe wallthicknessattheopening.3. Gluetheintakeventterminaltothesectionofthepipe.4. Slidethewallplateoverpipetostopagainstintakeventterminal.5. Placeabeadofcaulking(notsupplied)aroundthegapbetween the pipe and the wall. Place some of the caulking on the backoftheplatetoholditagainstthewallafterinstallation.6. Iftheventpipeisinstalleduptothewall,withacouplingonthe endagainstthewallopening,thepipewiththeventterminalcan bepreparedforgluingbeforeinsertingthroughthewall.Slidethe pipethroughthewallandinsertintocouplingontheothersideof thewall,makingsurethattheventterminalendsuppointedinthe correctposition(Figure19).

FIGURE 19.

vertIcal vent terMInal InstallatIon

IMportantwhen terMInatInG throuGh a roof, the followInG specIfIcatIons pertaInInG to terMInal locatIon Must Be followed.

1. Propersupportmustbeprovidedforallpipeprotrudingthrough the roof.

2. Theverticalroofterminationsshouldbesealedwithaplumbing roofbootorequivalentflashing.

3. Theintakeventterminationandtheexhaustventterminationmust penetratethesamesideofroof.

4. Thecenterlineoftheintakeventterminationandthecenter line of the exhaust vent termination must be no closer than24”(61cm).

5. Theintakeventterminalandtheexhaustventterminalmustbe orientedfacingdownwardandthesamedirection.

ThespecificationsaredisplayedinFigures20&21.

NOTE: Exhaust vent terminal is installed using the sameprocedure.

FIGURE 20.

FIGURE 21.

22

InstallatIon of vent sYsteM, sIdewall

Withtherouteoftheventingsystemandselectionofmaterialscompleted,as discussed in the section of this manual titled PLANNING THE VENT SYSTEM,thethroughthewallventterminalinplaceandthefirstsectionofpiping,uptofirstelbow,installedatthebloweritistimetocompletetheinstallationoftheventingsystemforthesidewallinstallation.

FIGURE 22.

BeforecompletingtheinstallationoftheventingsystembesuretoreadthesectionsofthismanualdiscussingthepropermethodofcuttingandcementingPVCpipeandfittings:VENTPIPEPREPARATION.

Itisrecommendedthatthecompletionoftheventingsystemstartattheblowerassemblyandruntothecouplingontheinsidewalloftheventterminal,Figure18A.

Thevent systempiping shouldbe supportedevery5 feet (1.5m) of vertical run and every 3 feet (91cm)ofhorizontalrun.Allpiping andfittingsmustbe joinedbytheproperproceduresasdescribed under: VENT PIPE PREPARATION.

InstallatIon of vertIcal vent sYsteM

Aproperflashingor“BOOT”shouldbeusedtosealthepipewhereitexitstheroof.ThetotalventsystemshouldnotexceedtheequivalentfeetofpipeaslistedinTable1.

Provide support for all pipeprotruding through the roof.All pipingshould be properly secured.The vent system piping should besupportedevery5feet(1.5m)of vertical run and every 3 feet (91cm)ofhorizontalrun.Allpipingandfittingsmustbejoinedbytheproperproceduresasdescribedunder:VENTPIPEPREPARATION.

FIGURE 23.

IMportant

Theventsystemmustterminatesothatproperclearancesaremaintained as cited in local codes or the current edition of the National Fuel Gas Code (ANSIZ223.1)or theNaturalGasandPropaneInstallationCode(CAN/CSA-B149.1)andaslistedbelow:

1. VentTerminationmustextendaminimumof18inches(46cm)aboveroofor18inches(46cm)abovetheanticipatedsnowleveltopreventblockageoftheventtermination,asshowninFigures20and21.

concentrIc vent InstallatIon

Thisapplianceiscertifiedforconcentricventingwithconcentricventkit#9003910105.Followinstructionsbelowforproperinstallations.

KIt coMponents

Eachkitiscomprisedofthefollowing:

Item Description Qty. Rain Cap 3 in. 1 SDR-26 pipe 4 in. dia. 1 SDR-26 pipe 2½ in. dia. 1 Y Concentric Fitting 3 in. 1 Installation Instructions 194504 1

Field supplied pipe and fittings are required to complete theinstallation.

23

Thisconcentricventterminationkitmaybeusedwith3or4inchdiameterpipesystems.Whenconnectingtoa4in.diameterpipesystema3x4inchfieldsuppliedreducer is tobe installedat the intakeandexhaustconnectionoftheconcentricventterminationkit.

safetY consIderatIons

Installingandservicingwaterheatingequipmentcanbehazardousduetogasandelectricalcomponents.Installationandserviceoftheconcentricventterminationrequiresabilityequivalenttothatofaqualifiedinstallerorserviceagent,seepage2.Allprecautionsintheliterature,ontags,andlabels attached to the unit must be observed.

Followallsafetycodes.Wearsafetyglassesandworkgloves.

fIGure a.

fIGure B.

* Dimension 21 1/8 in. may be lengthened to 60 in. maximum. Dimension 21 1/8 in. may also be shortened by cutting the pipes, provided in the kit, to 12 in. minimum.

** Dimension 39 will change accordingly as dimension 21 1/8 in. is lengthened or shortened.

fIGure c.

INSTALLATION PROCEDURE 1 ROOF TERMINATION, see figure c.

1. Determinebestlocationforterminationkit.note: roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and less visible vent vapors.

2. Cut1hole(5in.diameter)

3. Partiallyassembleconcentricventterminationkit. a) Cement Y concentric fitt ing to larger diameter kit

pipe,seeFigureA. b) Cementraincaptosmallerdiameterkitpipe,seeFigureA.

fIGure d.

note: Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the 2 components together when field disassembly is desired for cleaning, see figure d.

warnInGwhen using alternate screw method, drill clearance hole in rain cap and pilot hole in vent pipe for screw size being used. failure to drill adequate holes may cause cracking of pvc components, allowing combustion products to be recirculated. failure to follow this warning could result in personal injury or death.

warnInGdo not operate the heater with rain cap removed or recirculation of combustion products may occur. water may also collect inside larger combustion-air pipe and flow to the burner enclosure. failure to follow this warning could result in product damage or improper operation, personal injury or death.

4. Install Y concentric fitting and pipe assembly through structure’sholeandfieldsuppliedroofboot/flashing.

fIGure e.

note: do not allow insulation or other materials to accumulate inside pipe assembly when installing through hole.

24

5. SecureassemblytoroofstructureasshowninFigureEusingfieldsuppliedmetalstrappingorequivalentsupportmaterial.

note: ensure termination height is above the roof surface or anticipated snow level (1 ft. in U.S.A. or 1-1/2 ft. in Canada) as shown in figure c.

6. Install rain cap and small diameter pipe assembly inroof penetrat ion assembly, Ensure smal l diameter pipe i s cemen ted and bo t t omed i n Y concen t r i c f i t t i ng .

7. Cementwater heater combustionair intakeand vent pipes to concentric vent termination assembly. See Figure E for properpipeattachment.

8. Operateheater through1heatcycle toensurecombustionairandventpipesareproperlyconnectedtoconcentricventterminationconnections.

note: all vent terminations must be the same height when installing multiple unit venting. If assembly is too short to meet height requirement, the 2 pipes supplied in the kit may be replaced by using same diameter, field supplied SDR-26 PVC (D2241) pipe. Do not extend the 21-1/8” dimension outer pipe to be more than 60 inches, see Figure B.

cautIonDo not use field-supplied couplings to extend pipes. Airflow restriction will occur and the heater pressure switch may cause intermittent operation.

PROCEDURE 2 SIDE WALL TERMINATION, see Figure F.

fIGure f.

1. Determinebestlocationforterminationkit.

NOTE: Consideration for the following should be used whendetermininganappropriatelocationfortheterminationkit:

• Termination kit positioned where the vent vapors will no t damage p l an t s / sh rubs o r a i r c ond i t i on i ng equipment. • Termination kit positioned so it will not be affected by wind eddy that may allow recirculation of combustion products,orairborneleaves,orlightsnow.

• Termination kit positioned where it will not get damaged or be subjected to foreign objects, such as stones, balls, etc. • Termination kit positioned where the vent vapors will notbeobjectionable.

NOTE: See the venting information (pages 16-20) in this manual for additional vent location requirements.

2. Cut1hole(5in.diameter)

3. Par t ia l ly assemble concentr ic vent terminat ion k i t .

a) Cement the Y concentric fitt ing to larger diameter kitpipe,seeFigureA.

b) Cement the rain cap to the smal ler diameter ki t pipe,seeFigureA.

note: Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the 2 components together when field disassembly is desired for cleaning, see figure d.

warnInGwhen using alternate screw assembly method, drill clearance hole in rain cap and pilot hole in vent pipe for screw being used. failure to drill adequate holes may cause cracking of pvc components, allowing combustion products to be recirculated. failure to follow this warning could result in personal injury or death.

warnInGdo not operate the heater with rain cap removed or recirculation of combustion products may occur. water may also collect inside larger combustion-air pipe and flow to the burner enclosure. failure to follow this warning could result in product damage or improper operation, personal injury or death.

4. Install Y concentric f itt ing and pipe assembly through structure’shole.

note: do not allow insulation or other materials to accumulate inside pipe assembly when installing through hole.

5. Install rain cap and small diameter pipe assembly in Y concentric fitt ing and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in Y concentricfitting.

6. SecureassemblytostructureasshowninFigureGusingfield-suppliedmetalstrappingorequivalentsupportmaterial.

note: ensure termination location clearance dimensions are as shown in the diagrams found in Figure 15 A through D. When extending the length of the 4” pipe, the added length beyond 21-1/8” must be deducted from the maximum equivalent feet of vent pipe.

note: If assembly needs to be extended to allow side wall thickness requirement, the 2 pipes supplied in the kit may be replaced by using same diameter, field-supplied SDR-26 PVC (D2241) pipe. Do not extend 21 1/8” dimension more than 60 in. (See Figure B.)

cautIonDo not use field-supplied couplings to extend pipes. Airflow restriction will occur and the heater pressure switch may cause intermittent operation.

7. Cement heater combustion-air and vent pipes to concentricvent termination assembly. See Figure G for proper pipeattachment.

25

8. Operateheaterthrough1heatcycletoensurecombustion-airandventpipesareproperlyconnectedtoconcentricventterminationconnections.

fIGure G.

MultI-concentrIc vent terMInatIons

Whentwoormoreappliancesaredirectedventedwithconcentricvent terminations near each other, each appliance must beindividuallyvented.NEVERcommonvent thisappliance.Whentwo ormore appliances are direct vented using concentric ventterminations, theappliancesmaybeventedasshown inFigureHandFigureI.

figure h.Concentric Vent Terminations forHorizontalDirectVenting.

figure I.Concentric Vent Terminations for Vertical

DirectVentingthrougharoof.

26

vent pIpe preparatIon

1. INITIAL PREPARATION.

A.)Make sure the solvent cement you are planning to use isdesignedforthespecificapplicationyouareattempting.

B.)Knowthephysicalandchemicalcharacteristicsandlimitationsofthe PVCandCPVCpipingmaterialsthatyouareabouttouse.

C.)Knowthereputationofyourmanufacturerandtheirproducts.

D.)Knowyourownqualificationsorthoseofyourcontractor.Thesolvent weldingtechniqueofjoiningPVCandCPVCpipeisaspecializedskill justasanyotherpipefittingtechnique.

E.)Closelysupervisetheinstallationandinspectthefinishedjobbefore start-up.

F.) Contactthemanufacturer,supplier,orcompetentconsulting agency if you haveany questions about the application or installationofPVCandCPVCpipe.

G.) Takethetimeandefforttodoaprofessionaljob.Shortcutswillonly causeyouproblemsanddelays instart-up.By far, themajorityof failures in PVC and CPVC systems are the result of shortcuts and/or improperjoiningtechniques.

2. SELECTION OF MATERIALS.

• CuttingDevice-SaworPipeCutter. • DeburringTool,Knife,File,orBevelingMachine(2”andabove).

• Brush - Pure Bristle.

• Rag-Cotton(NotSynthetic).

• Primer and Cleaner.

• SolventCement-PVCforPVCComponentsandCPVCforCPVC Components.

• Containers - Metal or Glass to hold Primer and Cement. Select the type ofPVCorCPVCmaterials to be usedon the basis of their applicationwith respect to chemical resistance, pressure rating, temperaturecharacteristics,etc.

• InsertionTool-Helpfulforlargerdiameterpipeandfittings6inches (15.2cm)andabove.

prIMer

ItisrecommendedthatTetrahydrofuran(THF)beusedtopreparethesurfacesofpipeandfittingsforsolventwelding.Donotusewater,rags,gasolineoranyothersubstitutes forcleaningPVCorCPVCsurfaces. A chemical cleaner such as MEK may be used.

ceMent

The cement should be a bodied cement of approximately 500 to1600centipoiseviscositycontaining10-20%(byweight)virginPVCmaterial solvatedwith tetrahydrofuran (THF). Small quantities ofdimethyl formamide (DMF)maybe included to act as a retardingagenttoextendcuringtime.Selectthepropercement;Schedule40cementshouldbeusedforSchedule40pipe.Neveruseall-purposecements,commercialgluesandadhesivesorABScementtojoinPVCorCPVCpipeandfittings.

applIcators

Selectasuitablepurebristletypepaintbrush.Useaproperwidthbrushorrollertoapplytheprimerandcement(seechartbelow).Speedyapplicationofcementisimportantduetoitsfastdryingcharacteristics.IMPORTANTNOTE:Adaubertypeapplicatorshouldonlybeusedonpipesizes2”andbelow.Forlargerdiameterpipe,abrushorrollermust be used.

RECOMMENDED BRUSH* SIZE FOR PRIMERand ceMent applIcatIons

NominalPipe(IPS) SizeBrushWidth

2 1.5”(3.8cm)

3 1.5”-2.5”(3.8cm-6.4cm)

*use onlY natural BrIstle

3. MAKING THE JOINT.

A.)CuttingPipemust be squarely cut to allow for the proper interfacingofthepipeendandthefittingsocketbottom.This canbeaccomplishedwithamiterboxsaworwheeltypecutter Wheeltypecuttersarenotgenerallyrecommendedforlarger diameterssincetheytendtoflarethecornerofthepipeend.If this type of cutter is used, the flare on the endmust be completelyremoved.

NOTE:Powersawsshouldbespecificallydesignedtocutplasticpipe.

step a

27

B. deburring Useaknife,plasticpipedeburringtool,orfiletoremoveburrsfrom

theendofsmalldiameterpipe.Besuretoremoveallburrsfromaroundtheinsideaswellastheoutsideofthepipe.Aslightchamfer(bevel)ofabout10°-15°shouldbeaddedtotheendtopermiteasierinsertionofthepipeintotheendofthefitting.Failuretochamfertheedgeofthepipemayremovecementfromthefittingsocket,causingthejointtoleak.

step B

C. Test dry fit of the joint Taperedfittingsocketsaredesignedsothataninterfacedfitshould

occurwhenthepipeisinsertedabout1/3to2/3ofthewayintothesocket.Occasionally,whenpipefittingdimensionsareatthetoleranceextremes,itwillbepossibletofullyinsertdrypipetothebottomofthefittingsocket.Whenthishappens,asufficientquantityofcementmustbeappliedtothejointtofillthegapbetweenthepipeandfitting.Thegapmustbefilledtoobtainastrong,leak-freejoint.

d. Inspection, cleaning, priming Visually inspect the insideof thepipeand fitting sockets and

removealldirt,greaseormoisturewithacleandryrag.Ifwipingfails to clean the surfaces, a chemical cleaner must be used. Checkforpossibledamagesuchassplitsorcracksandreplaceif necessary.

depth-of-entry Markingthedepthofentryisawaytocheckifthepipehas

reachedthebottomofthefittingsocketinStepF.MeasurethefittingdepthandmarkthisdistanceonthepipeO.D.Youmaywanttoaddseveralinchestothedistanceandmakeasecondmarkastheprimerandcementwillmostlikelydestroyyour first one.

Applyprimer to thesurfaceof thepipeandfittingsocketwithanaturalbristlebrush.ThisprocesssoftensandpreparesthePVCorCPVCforthesolventcementingstep.Movequicklyandwithouthesitationtothecementingprocedurewhilethesurfacesarestillwetwithprimer.

e. application of solvent cement • Apply the solvent cement evenlyandquickly around the

outsideofthepipeatawidthalittlegreaterthanthedepthofthefittingsocket.

• Applyalightcoatofcementevenlyaroundtheinsideofthefittingsocket.Avoidpuddling.

• Applyasecondcoatofcementtothepipeend.

step e

f. joint assembly Workingquickly,insertthepipeintothefittingsocketbottomand

givethepipeorfittinga1/4turntoevenlydistributethecement.Donotcontinuetorotatethepipeafterithashitthebottomofthefittingsocket.Agoodjointwillhavesufficientcementtomakeabeadallthewayaroundtheoutsideofthefittinghub.Thefittingwillhaveatendencytoslidebackwhilethecementisstillwetsoholdthejointtogetherforabout15seconds.

step f

G. cleanup and joint movement Removeallexcesscementfromaroundthepipeandfittingwitha

drycottonrag.Thismustbedonewhilethecementisstillsoft.

Thejointshouldnotbedisturbedimmediatelyafterthecementingprocedure,andsufficienttimeshouldbeallowedforpropercuringof the joint.Exactdrying time isdifficult topredict because itdependsonvariablessuchastemperature,humidityandcementintegrity.Formorespecificinformation,youshouldcontactyoursolvent cement manufacturer.

step G

28

controls and swItches

Thismodelisprovidedwiththreepressureswitches.Theseswitchesareessentialtothesafeandproperoperationoftheunit.Allswitchesarewiredinseries.Thecontrollerissetuptoshuttheunitdownwheneverthereisafailureofanyoftheswitches.Itisimportanttounderstandthepurposeofeachswitch.

FIGURE 12.

Blower prover swItch(SEEFIGURE12)

TheBlowerProverSwitchisprovidedontheheatertoverifythatthefanisoperating.Itisapositivepressureswitchwhoseelectricalcontactsarenormallyopen.Whenthefanincreasesthepressureintheburner,thepressureswitchwillallowtheelectricalcontactstoclose.Thepressureswitchisconnectedtotheburnertapbyapieceoftygontubing.Thistubingmustbeconnectedinorderfortheswitchtochangetheelectricalcontacts.Thecontrollerrequiresthattheelectricalcontactsonthisairflowswitchbeopenbeforeitwill allow the blower to come on.

BlocKed eXhaust swItch (SEEFIGURE12)

TheBlockedExhaustSwitchissetuptoshuttheunitoffwhenabuild-upofpositivepressureintheexhaustventpipeoccurs.Thisswitch is a positive pressure switch that requiresan increase inpressuretochangetheelectricalcontactsfromnormallyclosedto

open.Whenthisswitchpreventstheunitfromigniting,mostlikelytheexhaustisblockedbysomemeans.Checktoseeifthecondensateisallowedtoflowfreelyfromtheexhaustelbowandforobstructionsintheexhaustventingandexhaustventterminal.Alsoverifythattheventlengthdoesnotexceedthemaximumallowedasshowninthe Vent Section of this manual.

BlocKed IntaKe swItch (SEEFIGURE12)

TheBlockedIntakeSwitchissetuptoshuttheunitoffwhenabuild-upofnegativepressureintheintakeairpipeoccurs.Thisswitchisanegativepressureswitchthatrequiresanincreaseinnegativepressuretochangetheelectricalcontactsfromnormallyclosedtoopen.TheswitchisconnectedtothepressuretaponthePVCpipeconnectedtotheinletoftheblower.Whenthisswitchpreventstheunitfromigniting,mostlikelytheintakeisblocked.Verifythatthescreenontheintakeairconnection(conventionalvent),theintakeairpipeandtermination(directventinstallations)arefreeofobstructionsthatmaypreventairfromenteringtheunit.Insurethescreenonintakeairconnectionhasbeenremovedondirectvent installations,seeFigure18B.Alsoverifytheintakeairpipelengthdoesnotexceedthemaximumallowedasshownin the Vent Section of this manual.

on/off swItchTheON/OFFSwitchisasingle-pole,single-throwrockerswitch.Thisswitchprovides120Vfromthelinesourcetotheheater.

cautIonthe water heater Is polarItY sensItIve. Before applYInG electrIcItY to thIs heater Be certaIn that supplY neutral wIre to Ground checK IndIcates ZERO VOLTAGE.

hot surface IGnIter

TheHotSurfaceIgniterisadevicethatignitesthemainburnerbyhightemperature(>1800°For>982°C).When120VACisappliedtotheigniter,sufficientheatisgeneratedtoignitethemainburner.Althoughimprovementshavebeenmadetostrengthentheigniter,itisstillfragileandcaremustbetakenwhenhandlingtheignitertopreventbreakage.

29

cautIonLABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

POWER VENT WIRING SCHEMATIC - FIGURE 24.

THIS WATER HEATER IS POLARITY SENSITVE. BEFORE APPLYING ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE.

30

UP

Operating Set PointStatus: Heating

Menu Help

120 F

DN

OFF

GAS ON

warnInG: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. Thisappliancedoesnothaveapilot.Itisequippedwithanignitiondevicewhichautomaticallylightstheburner.do not try to light the burner by hand.

B. Before operatInG smell all around theapplianceareaforgas.Besuretosmellnexttothefloorbecausesomegasisheavierthanairandwillsettleonthefloor.

what to do If You sMell Gas:• Donottrytolightanyappliance.• Donottouchanyelectricswitch; Donotuseanyphoneinyourbuilding.• Immediatelycallyourgassupplier fromaneighbor’s

phone.Followthegassupplier’sinstructions.

• If you cannot reach your gas supplier, call the firedepartment.

C. Useonlyyourhandtopushinthegascontrolbuttons.Neverusetools.Ifthecontrolbuttonswillnotpushin,don’ttrytorepairthem,callaqualifiedservicetechnician.Forceorattemptedrepairmayresultinafireorexplosion.

D.Donotusethisapplianceifanyparthasbeenunderwater.Immediatelycontactaqualifiedinstallerorserviceagencytoreplaceafloodedwaterheater.Donotattempttorepairtheunit!Itmustbereplaced!

operatInG InstructIons

1. Setthethermostattothelowestsetting. 2. SettheON/OFFswitchonthecontrolpaneltothe“OFF”position.

3. Turnoffallelectricalpowertotheapplianceifserviceistobeperformed.

Before operatInG: entIre sYsteM Must Be fIlled wIth water and aIr purGed froM all lInes.

1. STOP!Readthesafetyinformationabove, on this label.

2. Set theON/OFFswitchonthecontrol panel to the“ON”position.

3. Setthethermostattothelowestsetting.

4.Set theON/OFF switch on the control box to the“OFF”position.

5. This appliance is equippedwith a device whichautomaticallylightstheburner.

do not trY to lIGht the Burner BY hand.

6. Wait five (5) minutes to clear out any gas.Ifyousmellgas, STOP!Follow“B” in the safety information above on this label. Ifyoudon’tsmellgas.

7. Turnonallelectricalpowertotheappliance.

8. SettheON/OFFswitchonthecontrolboxtothe“ON”position.

9. Setthethermostattothedesiredsetting. cautIon: hotter water increases the risk

of scald injury. consult the instruction manual before changing temperature.

10.If the appliance will not operate, follow theinstructions“TOTURNOFFGASTOAPPLIANCE”andcallyourtechnicianorgassupplier.

warnInG: turn off all electrIc power Before servIcInG

to turn off Gas to applIance

for Your safetY read Before lIGhtInG

on/off swItch

31

The water temperature is controlled using the TemperatureControlon theDisplayat the frontof theunit (SeeFigure1).Thiscontrolutilizesatemperatureprobetodeterminethetanktemperature.Theprimary temperatureprobe is locatedat thetopofthetank.

Thetemperaturemaybeadjustedfrom90°F/32°Cto160°F/71°C.Thethermostatwasadjustedto120°F/49°Cbeforetheheaterwasshippedfromthefactory.Itisrecommendedthatlowerwatertemperaturebeused toavoid theriskofscalding. It is furtherrecommended, inallcases, that thewater temperaturebesetforthelowesttemperaturewhichsatisfiesyourhotwaterneeds.Thiswillalsoprovidethemostenergyefficientoperationofthewaterheaterandminimizescaleformation.

Valvesforreducingthepoint-of-usetemperaturebymixingcoldand hotwater are available, see Figure 2.Also available areinexpensive devices that attach to faucets to limit hot watertemperatures.Contactalicensedplumberorthelocalplumbingauthority.

Thetablebelowshowstheapproximatetime-to-burnrelationshipfornormaladultskin.Shortrepeatedheatingcyclescausedbysmallhotwaterusescancausetemperaturesatthepointofusetoexceedthe thermostatsettingbyup to20°F/11°C. Ifyouexperience thistypeofuse,youshouldconsiderusinglowertemperaturesettingstoreducescaldhazards.

160°F(71°C) About1/2Second

150°F(65°C) About11/2Seconds

140°F(60°C) Lessthan5Seconds

130°F(54°C) Morethan30Seconds

120°F(49°C) Morethan5minutes

HI LIMIT SWITCH (E.C.O.)

Thetopimmersionwellofthedualbulbcontrolleralsocontainsthe high limit (energy cutoff) sensor. The high limit switchinterruptsmainburnergasflowshouldwatertemperaturereachapproximately202°F/94°C.

Should the high limit switch activate, the control systemwillautomaticallyresettheunitoncethewatertemperatureinthetankfallsbelow140°F/60°C.Iftheunitismanuallyshutdownandrestarted,aslongasthetemperatureinthetankislowerthan160°F/71°C,theunitwillresetandinitiateoperation.

Ifyouexperiencehigherthanusualwatertemperaturealongwithfrequentautomaticresettingofthesystem,thisisevidenceofhighlimitswitchoperation.Thefollowingarepossiblereasonsforhighlimitswitchoperation.

• Amalfunctioninthethermostaticcontrolswouldallowthegas valvetoremainopencausingwatertemperaturetoexceedthe thermostatsetting.Thewatertemperaturewouldcontinueto riseuntilhighlimitswitchoperation.

Contact your dealer or servicer if continued high limit switchoperationoccurs.

teMperature reGulatIon

time to produce 2nd & 3rd Degree temperature setting Burns on adult skin

Itisrecommendedthatlowerwatertemperaturesbeusedtoavoidtheriskofscalding.Itisfurtherrecommended,inallcases,thatthewatertemperaturesbesetforthelowesttemperaturewhichsatisfiesyourhotwaterneeds.Thiswillalsoprovidethemostenergyefficientoperationofthewaterheater.

HOTWATERCANSCALD:Waterheatersareintendedtoproducehotwater.Waterheatedtoatemperaturewhichwillsatisfyspaceheating,clotheswashing,dishwashing,andothersanitizingneedscanscaldandpermanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,theinfirm,orphysically/mentallyhandicapped. Ifanyoneusinghotwater from thisheaterfits intooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertain temperaturewaterat thehotwater tap, thenyoumusttakespecialprecautions. Inaddition tousing the lowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasamixingvalve,shallbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater.Mixingvalvesareavailableatplumbingsupply or hardware stores, seeFigure 2. Followmanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,readthe“TemperatureRegulation”sectionin this manual.

Neverallowsmallchildrentouseahotwatertap,ortodrawtheirownbathwater.Neverleaveachildorhandicappedpersonunattendedin a bathtub or shower.

Thewaterheatershouldbelocatedinanareawherethegeneralpublicdoesnothaveaccess.Ifasuitableareaisnotavailable,a cover should be installed over the thermostat to preventtampering. The water temperature setting was factory set atthe lowest temperature;THISWATERHEATERISEQUIPPEDWITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH INJURYOCCURSVARIESWITHTHEPERSON’SAGEANDTHETIME OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN, AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES.

SETTINGTHEWATERHEATERTEMPERATUREAT120°F/49°CWILL REDUCE THE RISK OF SCALDS. Some states require settingsatspecificlowertemperatures.

32

usInG the electronIc controller

1. OverviewInteractionwiththewaterheatercontrollerisdonethroughanup,adown,andthreeoperationbuttons.Thesebuttonsareillustratedtotheright.Operationofthethreelowerbuttonsisdefinedimmediatelyabovethemonthescreen.The[UP]and[DN]buttonsareusedtonavigatethroughthemenusandmakeadjustmentstothewaterheater.

Whilethewaterheaterisoperating,theuserinterfacewilldisplaythedesktopscreen(iftherearenoactivefaultsorwarnings).Anexampleofthisscreenisshowntotheright.ThetemperatureonthisscreenistheOperatingSetPoint.TheOperatingSetPointisthetemperatureatwhichthewaterheaterwillmaintainthewaterinsidethetank.ThesecondlineonthescreenisatextdescriptionoftheOperationalStateofthewaterheater(pleaseseeOperatingStatesformoredetails).

Thefollowingstatusiconsdescribegraphicallyoperationaldetailsoftheheater.Thelegendofallthestatusiconsislistedbelow.

33

3. Adjusting the Operating Set Point The Operating Set Pointofthiswaterheaterdeterminestheregulatedtemperatureforthewaterinthetank.ThisparameterisadjustedintheTemperaturemenu.ItemsinthismenuallowyoutomonitordifferenttemperaturereadingsinthetankalongwithadjustingtheOperating Set Point.

actIon: Fromthedesktopscreen,pressMenu.

dIsplaY:

2. Operating States Inthemaindesktopscreen,therearesomespecificOperatingStatesthatareindicatedonthestatusline.Thesearesummarizedbelow:

actIon: FromtheMainMenu,pressselecttoenterthe"Temperatures"screen.

dIsplaY:

actIon: Press change then use the up and down buttonstochangetheSetPoint.

34

3. Changing the Display UnitsThedisplayinterfacetotheheaterhastheoptionofselectingbetweendegrees Fahrenheit and degreesCelsius for temperature displays.Thiscanbefoundinthe“DisplaySettings”menu.Alsointhismenu,youmayadjusthow thebacklightoperatesand thecontrastof theLCD screen.

actIon: FromtheMainMenu,presstheDownbuttontohighlight"DisplaySettings"thenpressSelect.

dIsplaY:

actIon: UsetheUPandDOWNbuttonstohighlightthedesiredsetting.ThenpressChange.Again,usetheUPandDOWNbuttonstoscrollthroughtheoptionsforthatsetting.

dIsplaY:

actIon: Press updatetoacceptthechangeorcancel torejectit.

dIsplaY:

4. Fault and Warning ConditionsThiswaterheater isequippedwithelectroniccontrolsthathavetheabilitytomonitoralmostallaspectsofthewaterheateroperation.Inthe case that there is an undesirable or unsafe condition that occurs, the water heater controls will detect this condition and determine the appropriateaction.PartofthisisdisplayingtheinformationontheLCDinplaintext thataccuratelydescribestheconditionanddiagnosticsinformation that can be used to correct the issue.

Therearetwotypesofconditionsthatcanoccurduringoperation.TheseareWarningsandFaults:

•warnings: This is a non-safety related condition that the control has detectedthatmaycausethewaterheatertooperateinalessthanoptimalcondition,butdoesnotposeasafetyconcern.

note:When these conditions occur, continued heating cycleswillcontinueandtheheaterwillattempttoregulatethewaterinthetanktothe Operating Set Point.

example of a warning:

• Faults: This is a safety related condition that has been detected by the heater.

NOTE: When these conditions occur, the water heater will not continueany furtherheatingcyclesand thewaterwillno longerbeheateduntiltheconditioniscorrectedand,inmostcases,powerhasbeen cycled.

example of a fault:

advanced diagnostics InformationWhenafaultorwarninghasbeendeclared,advancedinformationcanbefoundinthecontrol.BypressingtheAdvancedbutton,detailedinformationcanbefoundregardingdiagnosingandresolvingtheproblem. warnInG: usage of the advanced information requires ability equivalent to that of a licensed tradesmen in the field involved.

5. Access to the Current Fault or WarningWhen a fault or warning has been detected by the control, it willautomaticallybedisplayedonthescreenandthebacklightwillblink.IfyouchoosetoleavethecurrentfaultorwarningbypressingtheBackkey,youcanalwaysreturntothefaultscreenthroughthemenu.

35

actIon: Togettothecurrentfaultinformationscreen,pressMenu.

dIsplaY:

actIon: Press the downbuttontohighlight"currentFault"andpressselect.

dIsplaY:

actIon: Press the down button for more information.

dIsplaY:

6. Viewing the Fault HistoryThe controller for this water heater will store a history of ten of the lastFaultandWarningconditionsthatoccurred.ThisisstoredintheFaultHistory.Alongwithalltheinformationaboutthefault,includingaestimatetimeofwhenthefaultoccurred,informationregardingtheadvanceddiagnosticsforthatfaultcanbeaccessedatanytime.

actIon: Press the down button for more information.

dIsplaY:

actIon: Press the downkeytoscrollthroughthefaulthistory.Ifyouselectaspecificfaultorwarning,youmaypressthevIew button to view detailsregardingthisfault.

dIsplaY:

7. Viewing Information About the HeaterTheelectroniccontrolforthiswaterheatermonitorsmanydifferentaspectsofthewatertoensuresafeandoptimaloperation.Muchoftheinformationmonitoredisavailabletoviewintwoareasofthecontrol.Thefirstisthe"HeaterStatus"and;thesecondis"HeaterInformation."Theseitemscanbeselectedthroughthemainmenuinthesamefashionasdescribedabove. In these menus, detailed information about the water heater and thecurrentstatusofspecificconditionscanbefound.

36

for Your InforMatIonstart up condItIons

sMoKe/odorItisnotuncommontoexperienceasmallamountofsmokeandodorduringthe initialstart-up.This isduetoburningoffofoilfrommetalparts,andwilldisappearinashortwhile.

therMal eXpansIon

Water supply systemsmay, because of such events as high line pressure, frequent cut-offs, the effects of water hammeramong others, have installed devices such as pressure reducing valves, check valves, back flow preventers, etc. to control these types of problems. When these devices are not equipped with an internal by pass, and no other measures are taken, the devices cause the water system tobeclosed.Aswaterisheated,itexpands(thermalexpansion) and closed systems do not al low for the expansion of heated water.

The water within the water tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater’s temperature-pressure reliefvalveisreached,thevalvewillreleaseexcesspressure.Thetemperature-pressurereliefvalveisnot intendedfortheconstantreliefofthermalexpansion.Thisisanunacceptableconditionand must be corrected. It is recommended that any devices instal led which could create a closed system have a by-pass and/or the system have an expansion tanko r dev ice to re l ieve the p ressure bu i l t by therma l expansion in the water system. Expansion tanks are ava i l a b l e f o r o r de r i n g t h r ough a l o ca l p l umb i ng cont rac tor. Contac t the loca l water heater supp l ie r orqualified serviceagency for assistance in controlling thesesituations.

stranGe soundsPossiblenoisesduetoexpansionandcontractionofsomemetalpartsduringperiodsofheat-upandcool-downdonotnecessarilyrepresentharmfulordangerousconditions.

Condensationcausessizzlingandpoppingwithintheburnerareaduringheatingandcoolingperiodsandshouldbeconsiderednormal.See“Condensate”inthissection.

operatIonal condItIons

sMellY waterIneachwaterheaterthereisinstalledatleastoneanoderod(seeparts section) for corrosionprotectionof the tank.Certainwaterconditions will cause a reaction between this rod and the water. Themostcommoncomplaintassociatedwiththeanoderodisoneofa“rotteneggsmell”inthehotwater.Thesmellisaresultoffourfactorswhichmustallbepresentfortheodortodevelop:

a. Aconcentrationofsulfateinthesupplywater.b. Littleornodissolvedoxygeninthewater.c. Asulfate reducingbacteriawhichhasaccumulatedwithin the

waterheater(thisharmlessbacteriaisnontoxictohumans).d. Anexcessofactivehydrogeninthetank.Thisiscausedbythe

corrosionprotectiveactionoftheanode.

Smelly water may be eliminated or reduced in some water heater modelsbyreplacingtheanode(s)withoneoflessactivematerial,andthenchlorinatingthewaterheatertankandallwaterlines.Contactthe localwater heater supplier or a qualified service agency forfurtherinformationconcerninganAnodeReplacementKitandthischlorination treatment.

Ifthesmellywaterpersistsaftertheanodereplacementandchlorinationtreatment,wecanonlysuggestthatchlorinationoraerationofthewatersupplybeconsideredtoeliminatethewaterproblem.

do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided.

“aIr” In hot water faucets

HYDROGENGAS:Hydrogengascanbeproducedinahotwatersystemthathasnotbeenusedforalongperiodoftime(generallytwoweeksormore).Hydrogengas is extremely flammable andexplosive.Topreventthepossibilityofinjuryundertheseconditions,we recommend the hot water faucet, located farthest away, be opened for several minutes before any electrical applianceswhichareconnectedtothehotwatersystemareused(suchasadishwasherorwashingmachine).Ifhydrogengasispresent,therewillprobablybeanunusualsoundsimilartoairescapingthroughthepipeasthehotwaterfaucetisopened.Theremustbenosmokingoropenflamenearthefaucetatthetimeitisopen.

37

ventInG sYsteM InspectIon

Atleastonceayearavisualinspectionshouldbemadeoftheventingsystem.Youshouldlookfor:

1.Obstructionswhichcouldcauseimproperventing.Thecombustionandventilationairflowmustnotbeobstructed.

2.Damageordeteriorationwhichcouldcauseimproperventingorleakageofcombustionproducts.

Besuretheventpipingisproperlyconnectedtopreventescapeofdangerousfluegasseswhichcouldcausedeadlyasphyxiation.

Obstructionsanddeterioratedventsystemsmaypresentserioushealthriskorasphyxiation.

Chemicalvaporcorrosionoftheflueandventsystemmayoccurifairforcombustioncontainscertainchemicalvapors.Spraycanpropellants, cleaning solvents, refrigerator and air conditionerrefrigerants,swimmingpoolchemicals,calciumandsodiumchloride,waxes,bleachandprocesschemicalsaretypicalcompoundswhicharepotentiallycorrosive.

If after inspection of the vent system you found sooting ordeterioration,somethingiswrong.Callthelocalgasutilitytocorrectthe problem and clean or replace the flue and venting beforeresumingoperationofthewaterheater.

Burner operatIon and InspectIon

Flood damage to awater heatermay not be readily visible orimmediatelydetectable.However,overaperiodoftimeaflooded

perIodIc MaIntenancewater heaterwill create dangerous conditionswhich can causeDEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualified installer or service agency to replace afloodedwaterheater.Donotattempttorepairtheunit!Itmustbereplaced!

At least oncea year a visual inspection should bemadeof themainburnerandthehotsurfaceigniterassemblyforproperflamecharacteristics and ignition sequences.Youshouldalsocheck forsooting.Sootisnotnormalandwillimpairpropercombustion.AvisualinspectionofthemainburnerandHSIigniterassemblyshouldalsobedone at least once a year.

Sootbuild-up indicatesaproblemthat requirescorrectionbeforefurtheruse.Turn“OFF”gastowaterheaterandleaveoffuntilrepairsaremade,becausefailuretocorrectthecauseofthesootingcanresultinafirecausingdeath,seriousinjury,orpropertydamage.

Burner cleanInG

In theeventyourburnerorburnerairopeningsrequirecleaning,turntheon/offswitchtothe“OFF”positionandallowtheunittocool.Callaqualifiedserviceagencytoremoveandcleantheburnerandcorrecttheproblemthatrequiredtheburnertobecleaned.

houseKeepInG

Vacuum around base of water heater for dust, dirt, and lint on a regularbasis.

38

INSTALLEDINSUITABLEAREA:Toinsuresufficientventilationandcombustionairsupply,properclearancesfromthewaterheatermustbemaintained. See “Facts toConsiderAboutLocation”section.Combustiblematerials such as clothing, cleaningmaterials, orflammableliquids,etc.mustnotbeplacedagainstoradjacenttothewaterheaterwhichcancauseafire.

anode rod InspectIon

Theanoderodisusedtoprotectthetankfromcorrosion.Mosthotwatertanksareequippedwithananoderod.Thesubmergedrodsacrificesitselftoprotectthetank.Insteadofcorrodingthetank,waterionsattackandeatawaytheanoderod.Thisdoesnotaffectthewater’stasteorcolor.Therodmustbemaintainedtokeepthetankinoperatingcondition.

Anodedeteriorationdependsonwaterconductivity,notnecessarilywatercondition.Acorrodedorpittedanoderodindicateshighwaterconductivityandshouldbecheckedand/orreplacedmoreoftenthanananoderodthatappearstobeintact.Replacementofadepletedanoderodcanextendthelifeofyourwaterheater.Inspectionshouldbeconductedbyaqualifiedtechnician,andataminimumshouldbecheckedannuallyafterthewarrantyperiod.

teMperature-pressure relIef valve operatIon

FIGURE 28.

When checking the temperature-pressure relief valve operation,makesurethat(1)nooneisinfrontoforaroundtheoutletofthetemperature-pressurereliefvalvedischargeline,and(2) that thewaterdischargewillnotcauseanypropertydamage,asthewatermaybeextremelyhot,seeFigure28.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetandcontinues to release water, immediately close the cold water inlet tothewaterheater,followthedraininginstructions,andreplacethetemperature-pressurereliefvalvewithanewone.

If the temperature-pressure relief valveon theapplianceweepsordischargesperiodically,thismaybeduetothermalexpansion.Youmayhaveacheckvalveinstalledinthewaterlineorawatermeterwithacheckvalve.Consultyourlocalwatersupplieroraqualifiedserviceagencyforfurtherinformation.Donotplugthetemperature-pressurereliefvalve.

draInInG

Thewater heater should be drained if being shut down duringfreezing temperatures. Also periodic draining and cleaning ofsedimentfromthetankmaybenecessary.

1.Setthepowerswitchtothe“OFF”position.

2. CLOSE the cold water inlet valve to the water heater.

3.OPENanearbyhotwater faucet and leaveopen to allow fordraining.

4. Connect a hose to the drain valve and terminate to an adequate drain.

5.OPENthewaterheaterdrainvalvetoallowfortankdraining.

note: If the water heater is going to be shut down and drained for an extended period, the drain valve should be left open with hose connected allowing water to terminate to an adequate drain.

6. CLOSE the drain valve.

7.Followinstructionsinthe“FillingTheWaterHeater”section.

8.Follow the lighting instructions on the label or see “LightingInstructions”inthismanualtorestartthewaterheater.

39

leaKaGe checKpoInts

Neverusethiswaterheaterunlessitiscompletelyfilledwithwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gasto the water heater.

A *Condensationmaybeseenonpipesinhumidweatherorpipeconnectionsmaybeleaking.

B.*Theanoderodfittingmaybeleaking.

C.Smallamountsofwaterfromtemperature-pressurereliefvalvemaybeduetothermalexpansionorhighwaterpressureinyourarea.

D.*The temperature-pressure relief valvemaybe leakingat thetankfitting.

E.Waterfromadrainvalvemaybeduetothevalvebeingslightlyopened.

F.*Thedrainvalvemaybeleakingatthetankfitting.

G.Combustionproductscontainwatervaporwhichcancondenseonthecoolersurfacesofthetank.Dropletsformanddripontotheburnerorrunonthefloor. This iscommonat thetimeofstart-upafterinstallationandwhenincomingwateriscold.

H.Water inthewaterheaterbottomoronthefloormaybefromcondensation, loose connections, or the relief valve. DO NOT replacethewaterheateruntilafullinspectionofallpossiblewatersourcesismadeandnecessarycorrectivestepstaken.

Leakage fromother appliances,water lines, or ground seepageshouldalsobechecked.

* To checkwhere threaded portion enters tank, insert cottonswabbetweenjacketopeningandfitting.Ifcottoniswet,follow“Draining”instructionsinthe“PeriodicMaintenance”sectionandthenremovefitting.Putpipedopeorteflontapeonthethreadsandreplace.Thenfollow“FillingtheWaterHeater”instructionsinthe“InstallingtheNewWaterHeater”section.

servIce

Ifaconditionpersistsoryouareuncertainabouttheoperationofthewaterheatercontactaqualifiedserviceagency.

Usethisguidetochecka“Leaking”waterheater.Manysuspected“Leakers”arenotleakingtanks.Oftenthesourceofthewatercanbe found and corrected.

Ifyouarenotthoroughlyfamiliarwithgascodes,yourwaterheater,andsafetypractices,contactyourgassupplierorqualifiedinstallertocheckthewaterheater.

Readthismanualfirst.Thenbeforecheckingthewaterheatermakesurethegassupplyhasbeenturned“OFF”,andneverturnthegas“ON”beforethetankiscompletelyfullofwater.

40

proBleMs

not enouGh hot water

1.)Blowerwillnotrun.

a.“ON/OFF”controlswitchturnedoff. Turnswitchtothe“ON”position.

b.Blowerunplugged. Plugblowerbackinto115VACoutlet.

c.Nopoweratoutlet. Repairservicetooutlet.

d. Thermostat defective. Replacethermostat.

e. Control harness defective. Replacecontrolharness.

f.Highlimitcontrolcircuitopen.

Reducethewatertemperaturebelow140°F.Turn the power switch to the off position.Wait10seconds.Turn thepowerswitch totheonposition.Reducethetemperaturesetpointtominimizelikelihoodofreoccurrence.If thisdoesnotsolvetheproblem,replacethethermostat.

g.Blowermotordefective. Replaceblowerassembly.

2.)Thermostatproblems

a. Thermostat set too low. Adjusttemperaturecontrolhigher.

b. Thermostat or ECO defective Replacethermostat.

3.)Others

a.Heaterundersized.. Reduce hot water use.

b.Lowgaspressure Contact dealer.

c.Incomingwaterisusuallycold. Allow more time for heater to reheat.

d.Leakinghotwaterpipesoffixtures. Haveplumbercheckandrepairleaks.

e. Heater not lit or thermostat not on. Refer to LIGHTING INSTRUCTIONS.

VENT PIPE TOO HOT (ABOVE 170°F [77°C]) Wrongburnerorifice. Turnoffheaterandgas,cleanburnerhead.

Yellow flaMe

Dirtinburnerports. Turnoffheaterandgas,cleanburnerhead.

Combustionairpathrestricted.Check exhaust venting and air openingsin bottom base pan for obstructions orblockage.

condensatIon Wateronthefloorunderheater. See CONDENSATION section.

water leaKs

Improperly sealed, hot or cold supplyconnections, relief valve, drain valve or thermostat threads.

Checkforleaks.SeeFigure1.

Leakagefromotherappliancesorwaterlines. Inspectotherappliancesnearwaterheater.

Condensationofflueproducts. Refer to CONDENSATION section.

leaKInG t & pThermalexpansioninclosedwatersystem. Install thermalexpansiontank(Donotplug

T&Pvalve).

Improperlysealedvalve. Checkreliefvalve forproperoperation (DonotplugT&Pvalve).

hot water odors(refer to cathodic protection)

High sulfate ormineral content in watersupply. Drainandflushheaterthoroughlythenrefill.

Bacteriainwatersupply. Chlorinatewatersupply.

hot water too hot Thermostatsettoohigh. Refer to TEMPERATURE REGULATION section.

water heater sounds Condensationdrippingonburner. Refer to CONDENSATION above.

SIZZLING - RUMBLING Sedimentatbottomofheatertank. Clean sediment from tank. Refer toDRAINING.

sootInG Impropercombustion. Refer to Air Requirements.

Burner wIll not staY lIt-Goes out 4-5 SECONDS

Outletpolarityisreversed. Testpolarityandcorrect.

Highambientroomtemperature. Contact a qualified service agency todetermine cause.

Defectivegasvalve. Replacegasvalve.

vent Gas odors

Lackofairsupply.

Shut off water heater immediately and contact a qualifiedserviceagencytodeterminecause.

Improperlyinstalledventpiping.

Downdraft

Poor Combustion

trouBleshootInG GuIdelInesTheseguidelinesshouldbeutilizedbyaqualifiedserviceagent.

41

notes

42

notes

43

limited warrantyStateWaterHeaters,thewarrantor,extendsthefollowingLIMITEDWARRANTYtotheownerofthiswaterheater.

1. the tanK Iftheglass-linedtankinthiswaterheatershallproveuponexaminationbythewarrantortohaveleakedduetonaturalcorrosionfrompotablewater

therein,duringthefirstTHREEyearsafterinitialinstallation,thewarrantorwillsupplyacompletenewStatewaterheaterofequivalentsizeandcur-rentmodel.Somegovernmentagenciesarerequiringenergyefficientstandardsforwaterheaters.Intheeventregulationsprohibitsaleofamodelofequivalentsizeandconstruction,StateWaterHeaterswillprovideamodelwhichcomplieswiththeregulationsofyourarea,inwhichcasetheconsumerwillbechargedthedifferenceinpricebetweenthelikereplacementandtheenergyefficientmodelrequired.Thewarrantyonthereplace-mentwaterheaterwillbelimitedtotheunexpiredtermoftheoriginalwarranty.

2. all other parts IfwithinONEyearafterinitialinstallationofthiswaterheater,anypartorportionshallproveuponexaminationbythewarrantortobedefectivein

materialorworkmanship,thewarrantorwillrepairorreplacesuchpartorportionatitsoption.

3. condItIons and eXceptIons Thiswarrantyshallapplyonlywhenthewaterheaterisinstalledinaccordancewithlocalplumbingandbuildingcodes,ordinancesandregulations,

theprintedinstructionsprovidedwithitandgoodindustrypractices.Inaddition,atemperatureandpressurereliefvalve,certifiedbyandofficiallysanctionedandrecognizedindependenttestingagencyandapprovedbytheAmericanSocietyofMechanicalEngineers,musthavebeeninstalled.

a.Thiswarrantyshallapplyonlywhentheheateris: (1) usedattemperaturesnotexceedingthemaximumcalibratedsettingofitsthermostat; (2) usedatwaterpressurenotexceedingtheworkingpressureshownontheheater; (3) filledwithpotablewater,freetocirculateatalltimesandwiththetankfreeofdamagingwatersedimentorscaledeposits; (4) usedinanon-corrosiveandnon-contaminatedatmosphere; (5) usedwithfactoryapprovedanode(s)installed; (6) initsoriginalinstallationlocation; (7) intheUnitedStates,itsterritoriesorpossessionsorCanada; (8) sizedinaccordancewithpropersizingtechniquesforcommercialand/orresidentialwaterheaters; (9) bearingaratingplatewhichhasnotbeenaltered,defacedorremoved,exceptasrequiredbythewarrantor; (10) usedinanopensystemorinaclosedsystemwithproperlysizedandinstalledthermalexpansiontank; (11) operatedwithproperlyinstalleddirtleg; (12) firedwiththefuelforwhichitwasfactorybuilt; (13) firedatthefactoryratedinput; (14) operatedwiththeinnerandoutercombustionchamberdoorsinplace. b. Anyaccidenttothewaterheater,anymisuse,abuse(includingfreezingorthermalexpansiondamage)oralterationof,anyoperationina

modifiedform,oranyattempttorepairtankleakswillvoidthiswarranty. c. Thiswarrantyisvoidifadeviceactingasabackflowpreventiondevice(checkvalvesetc.)isinstalledinthecoldwatersupplytheheateriscon-

nectedto,unlessaneffectivemethodofcontrollingthermalexpansionisalsoinstalledattheheater(s)andoperationalatalltimes.Thereliefvalveinstalledontheheaterisnotanacceptablemethod.

4. servIce and repaIr eXpenses Underthelimitedwarrantythewarrantorwillprovideonlyareplacementwaterheaterorpartthereof.Theownerisresponsibleforallothercosts.

Such costs may include but are not limited to: a. Laborchargesforserviceremoval,repairorreinstallationofthewaterheateroranycomponentpart; b. Shipping,delivery,handling,andadministrativechargesfor forwardingthenewheaterorreplacementpart fromthenearestdistributorand

returningtheclaimeddefectiveheaterorparttosuchdistributor. c. Allcostnecessaryorincidentalforanymaterialand/orpermitsrequiredforinstallationofthereplacementheaterorpart.

5. lIMItatIons on IMplIed warrantIes Impliedwarranties,includingthewarrantyofmerchantabilityimposedonthesaleofthisheaterunderstatelaworlocalcodearelimitedtoone(1)

yeardurationfortheheateroranyofitsparts.Someareasdonotallowlimitationonhowlonganimpliedwarrantylasts,sotheabovelimitationmaynotapplytoyou.

6. claIM procedure Anyclaimunderthewarrantyshouldbeinitiatedwiththedealerwhosoldtheheater,orwithanyotherdealerhandlingthewarrantor’sproducts.If

thisisnotpracticable,theownershouldcontact: U.S. Customers State Water Heaters 500TennesseeWaltzParkway Ashland City, TN 37015 Telephone:(800)365-0024 website: www.statewaterheaters.com a. Thewarrantorwillonlyhonorreplacementwithidenticalorsimilarwaterheaterorpartsthereofwhicharemanufacturedordistributedbythewarrantor. b. Dealerreplacementsaremadesubjecttoin-warrantyvalidationbywarrantor.

7. dIsclaIMers NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANT-

ABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.

a. Someareasdonotallowtheexclusionorlimitationoftheincidentalorconsequentialdamage,sotheabovelimitationsorexclusionsmaynotapplytoyou.

b. Thiswarrantygivesyouspecificlegalrights,andyoumayalsohaveotherrightswhichvaryfromareatoarea.

Fillinthefollowingforyourownreference.Keepit.Registrationisnotaconditionofwarranty.Themodelandserialnumberarefoundontheheater’sratingplate.Model No. ____________________Serial No. _____________________________________________Date Installed__________________________Dealer’sName___________________________________________________________________________________________________________Dealer’sAddress________________________________________________________________________PhoneNo.________________________CityandState__________________________________________________________________________Zip_____________________________

Keep thIs warrantY posted adjacent to the heater for future reference.

44

500TennesseeWaltzParkway,AshlandCity,TN37015Phone:800-365-0024•Fax:800-644-9306

Website: www.statewaterheaters.com