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A.O. Smith W/HOT Instruction Manual

1. ADANGER limiting valves are HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water from this heater fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a Mixing Valve shall be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual see Figure 26 N INA FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of t
2. B If pressure switch contacts are open and all wiring is correct turn the power off for 10 20 seconds then on again to clear the error code if the error code persists replace the Intelli Vent control WATER HEATER CONTROL Pressure switch circuit remains open longer than 5 seconds after the blower is energized Blower may run continuously in this condition Service Note To learn more about performing Air Pressure Switch tests visit our web site www hotwater com to download technical bulletin A 023 06 Air Pressure Switches N e oa M Ensure the blower is running check for 120 VAC to Check continuity of vent temperature limit switch replace Ensure there are no obstructions in the vent pipe Check air pressure switch performance check pressure If air pressure switch performance test results the blower when the heating cycle begins check the wiring If the control does not energize the blower replace the Intelli Vent control If the blower fails to start when energized replace the blower assembly Ensure the air pressure switch sensing tube is properly connected not kinked or damaged switch if contacts remain open under 160 F 71 C Ensure the correct size of vent pipe g 3 4 was used per installation manual for vent length Ensure maximum number of elbows or equivalent feet of vent pipe has not exceeded maximum limits with
3. see footnote 2 quur 3 ft 91 cm abovea mechanical air supply inlot within 10 ft 3 m horizontally Minimum 4ft 1 2 m below or side of 12 in 30 cm above non mechanical Minimum 4 ft 1 2m Minimum 4 ft 1 2 m ar auppiy inet ine pading or below a window that from side of window appliance or Minimum 9 in 23 cm Minimum 12 in 30 cm from sides o from side of window rmanentiy that may be open closed window Minimum 12 in 30 cm above i may be open thatmay be open or appliances with 10 000 btuh 3 Kw window or door that may be open fo 80 200 biuh 18 Kw inputs and 12 V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED in 30 cm for appliances greater than 50 000 btuh 15 Kw to an air supply inlet to a direct vent appliance 1 Permitted only if veranda porch deck or balcony is fully opened on a minimum of two sides beneath the floor 2 Avent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings CANADIAN HORIZONTAL VENT CLEARANCES Minimum 18 in 46 cm Mininum 42 in 30 cm for appliances with 10 000 btuh 3 Kw to 100 000 btuh 30 Kw input and 36 in 90 cm r an appliance greater than 100 000 btuh 30 Kw to a window or door that may be opened INSIDE CORNER DETAIL Minimum 3 ft 91 cm within a height of 45 ft 4 6 m above 12 in 30 cm meter regulator assemb
4. C Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area D The temperature pressure relief valve may be leaking at the tank fitting E Water from a drain valve may be due to the valve being slightly opened F The drain valve may be leaking at the tank fitting G Combustion products contain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold H Water in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken Leakage from other appliances water lines or ground seepage should also be checked Tocheck where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow Draining instructions in the Periodic Maintenance section and then remove fitting Put pipe dope or teflon tape on the threads and replace Then follow Filling the Water Heater instructions in the Installing the New Water Heater section n 1 VBCDEF eooeoo N TROUBLE SHOOTING Please check guidelines below For your safety water heater service should be performed only by a
5. The inlet gas pressure must not exceed 14 inch water column 3 5 kPa for natural and propane gas L P The minimum inlet gas pressure shown on the rating plate is that which will permit firing at rated input All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 whicheverapplies Copper or brass tubing and fittings except tin lined copper tubing shall not be used If the gas control valve is subjected to pressures exceeding 1 2 psi 3 5 kPa the damage to the gas control valve could result in a fire or explosion from leaking gas If the main gas line Shut off serving all gas appliances is used also turn off the gas at each appliance Leave all gas appliances shut off until the water heater installation is complete A gas line of sufficient size must be run to the water heater Consult the current edition of National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 and your gas supplier concerning pipe size There must be A readily accessible manual shut off valve in the gas supply line serving the water heater and A drip leg sediment trap ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve A flexible gas connector or a ground joint union between the shut off valve and contr
6. chloride water softener salt waxes and process chemicals are typical compounds which are potentially corrosive Do not store products of this sort near the heater Also air which is brought in contact with the heater should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outside sources The limited warranty is voided when failure of water heater is due to a corrosive atmosphere See limited warranty for complete terms and conditions WATER PIPING Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature available ADANGER limiting valves are Read instruction manual for safe temperature setting HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the h
7. of total input rating of all equipment in enclosure See Figure 9A FIGURE 9A 6 Louvers and Grilles In calculating free area consideration shall be given to the blocking effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch 6 4 mm mesh If the free area through a design of louver or grille is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will be 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation 7 Special Conditions Created by Mechanical Exhausting or Fireplaces operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment N A CHEMICAL VAPOR CORROSION CORROSIONOFTHEFLUEWAYSAND VENT SYSTEMMAY OCCURIFAIRFOR COMBUSTIONCONTAINS CERTAINCHEMICAL VAPORS SUCHCORROSION MAY RESULT IN FAILUREAND RISK OFASPHYXIATION Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium
8. the HOTTER e button increases the temperature Setting the water heater temperature at 120 F 49 C Approx Y mark on temperature setting of gas valve will reduce the risks of scalds Some states or local codes require settings at specific lower temperatures 27 A To avoid any unintentional changes in water temperature settings the control has a tamper resistant feature for changing the temperature setting To change the temperature setting follow these instructions 1 Wake Up the temperature indicators by holding down both COOLER and HOTTER temperature adjustment buttons at the same time for one second see Figure 26 One or two of the temperature indicators will light up These indicators will only remain on for 30 seconds if no further buttons are pressed After 30 seconds the control will go back to Sleep mode 2 Release both of the temperature adjustment buttons a To decrease the temperature press and release the COOLER button until the desired setting is reached b To increase the temperature press and release the HOTTER button until the desired setting is reached NOTE Holding down the button will not continue to lower or raise the temperature setting The button must be pressed and released for each temperature change desired Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance TEMPERATURE INDICATORS
9. CONTROL LED STAT PROBLEM Ignition flame failure The water heater has reached the maximum number of retries and is currently locked out for one hour Cycle the power to the water heater off and on to reset Service Note The resistance ohms of a hot surface ignitor will increase over time If the resistance at room temperature is near 18 8 ohms consider replacing the ignitor as a preventative measure SOLUTION 1 Gas supply is turned off pressure too low Ensure supply and manifold gas pressures are within requirements in the installation manual Manifold gas pressure is non adjustable if pressure is off by more than 0 3 W C 75 Pa replace the Intelli Vent control N Low supply voltage should be 115 125 VAC w Ensure flame sensor is making good contact with the burner flame ensure flame is steady see 8 below Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean flame sensor bas Ensure the hot surface ignitor is positioned to provide consistent ignition Check for any cracks in ignitor assembly ceramic insulators replace ignitor assembly if damaged Check resistance of ignitor at room temperature 77 F 25 C at the plug end Replace ignitor if resistance is not within 11 5 and 18 8 ohms at room temperature Ensure the correct size of vent pipe 2 3 4 was used per installation manual for vent length Using larger
10. TEMPERATURE ADJUSTMENT BUTTONS Time to Produce Display 2nd amp 3rd Degree Temperature Setting VBCDE FETU Mes F approx 180 F 82 C OO O O O6 Nearly Instantaneous E approx 170 F 77 C DO O O O Nearly Instantaneous D approx 160 F 71 C OO O 6 OO About 1 2 Second C approx 150 F 65 C OO 6 OOO About 1 1 2 Seconds B approx 140 F 60 C _ O OOOO Less than 5 Seconds Y B approx 130 F 54 C 60 O OO More than 30 Seconds w approx 120 F 49 C 600000 More than 5 Minutes FIGURE 26 START UP CONDITIONS SMOKE ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while THERMAL EXPANSION CAUTION Improper installation and use may result in property damage Avoid water heater damage Install thermal expansion tank or device if necessary Contact qualified installer or service agency Water supply systems may because of such events as high line pressure frequent cut offs the effects of water hammer among 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 to be closed As water is heate
11. a free area of not less than one square inch per 4000 Btu hr 5 5 cm kW of total input of all appliances in the enclosure If horizontal ducts are used each opening shall have a free area of not less than one square inch per 2000 Btu hr 11cm KW of the total input of all appliances in the enclosure A ALL AIR FROM INSIDE BUILDINGS See Figure 5 and 6 The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of one square inch per 1 000 Btu per hour 22 cm kW of the total input rating of all gas utilization equipment in the confined space but not less than 100 square inches 645 cm One opening shall commence within 12 inches 30 cm of the top and one commencing within 12 inches 30 cm of the bottom of the enclosures I i pu FIGURE6 B ALL AIR FROM OUTDOORS See Figures 7 8 and 9 mus lle m The confined space shall be provided with two permanent openings one commencing within 12 inches 30 cm of the top and one commencing within 12 inches 30 cm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or space
12. appliances are classified by building codes as vent connectors Required clearances from The vent system must terminate so that proper clearances are combustible materials must be provided in accordance with maintained as cited in local codes or the current edition of the National information in this manual under LOCATING THE NEW WATER Fuel Gas Code ANSI Z223 1 12 9 1 through 12 9 4 or the Natural HEATER and INSTALLING THE WATER HEATER and with the Gas and Propane Installation Code CAN CSA B149 1 National Fuel Gas Code and local codes PLANNING THE VENT SYSTEM Plan the route of the vent system from the discharge of the blower to the planned location of the vent terminal 1 Layout total vent system to use a minimum of vent pipe and elbows 2 This water heater is capable of venting flue gases equivalent to 25 7 6 m of 2 pipe 65 19 8 m of 3 pipe or 128 39 0 m of 4 pipe as listed in Table 1 TABLE 1 a special fitting that must be used with this appliance Any outlet piping fittings and glue used to vent this appliance that is not supplied by the manufacturer must comply with the ULC S636 requirements Ifthe water heater is being installed as a replacement for an existing power vented heater in pre existing venting a thorough inspection of the existing venting system must be performed prior to any installation work Verify that the correct material as detailed above has been used and that the minimum
13. approximately 8 diameter loop in the condensate hoses on top of the water heater to trap water and prevent the escape of combustion by products Do notelevate the condensate hose on the bottom of the water heater above the bracket attached to the side of the unit This must be true for the entire length of the hose including the exit into an appropriate drain Condensate lines must be free and clear of debris and must not allow back flow through the hose The condensate lines must be able to flow freely to an appropriate drain Do not allow condensate lines to become crimped closed Analyze the entire vent system to make sure A DANGER Avapors from flammable liquids may explode and catch fire causing death orsevere burns Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater Keep flammable products 1 faraway from heater 2 inapproved containers 3 tightly closed and 4 outofchildren s reach Water heater has a main burner and hot surface igniter The hot surface igniter X 2 can come on at any time and will ignite flammable vapors Vapors 4 2 3 cannot be seen are heavier than air go a long way on the floor and can be carried from other rooms to the hot surface igniter by air currents Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manu
14. carried from other rooms to the hot surface igniter by air currents atleast 18 above the floor This will reduce but not eliminate the risk of vapors being ignited by the main burner or hot surface igniter AWARNING For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged This water heater must not be installed directly on carpeting Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 7 6 cm in any direction or if the appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard A WARNING Fire or Explosion Hazard Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear 55 14 0 cm from the front and 12 30 5 cm from the top Standard clearance If clearances stated on the heater differ from standard clearances install water heater according to clearances stated on the heater Adequate clearance 24 61 0 cm for servicing this appliance should be considered before installation such as c
15. equipped with an anode rod The submerged rod sacrifices itself to protect the tank Instead of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition Anode deterioration depends on water conductivity not necessarily water condition A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by a qualified technician and at a minimum should be checked annually after the warranty period TEMPERATURE PRESSURE RELIEF VALVE OPERATION ADANGER Burn hazard Hot water discharge Keep clear of relief valve discharge outlet The temperature pressure relief valve must be manually operated at least once a year TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 28 30 When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 that the water discharge will not cause any property damage as the water may be extremely hot see Figure 28 If after manually operating the valve it fails to completely reset and continues to r
16. injury or death A WARNING Do not obstruct water heater air intake with insulating blanket Gas and carbon monoxide detectors areavailable Install water heater in accordance with the instruction manual P Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Do not apply insulation to the top of the water heater as this will interfere with safe operation of the blower assembly Do not cover the outer door thermostat or temperature amp pressure relief valve Do not allow insulation to come within 2 5 1 cm of the floor to prevent blockage of combustion air flow to the burner Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels Do inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow COMBUSTION AIR AND VENTILATION FOR APPLIANCES LOCATED IN UNCONFINED SPACES UNCONFINED SPACE is space whose volume is not less than 50 cubic feet per 1 000 Btu per hour 4 8 cubic meters per kW of the aggregate input rating of all appliances installed in that space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered
17. limited to a Labor charges for service removal repair or reinstallation of the water heater or any component part b Shipping delivery handling and administrative charges for forwarding the new heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor C Allcost necessary or incidental for any material and or permits required for installation of the replacement heater or part LIMITATIONS ON IMPLIED WARRANTIES Implied warranties including the warranty of merchantability imposed on the sale of this heater under state law or local code are limited to one 1 year duration for the heater or any of its parts Some areas do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you CLAIM PROCEDURE Any claim under the warranty should be initiated with the dealer who sold the heater or with any other dealer handling the warrantor s products If this is not practicable the owner should contact U S Customers A O Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City TN 37015 Telephone 800 323 2636 a The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF
18. or maximum vent lengths and terminal location as detailed in this manual have been met Carefully inspect the entire venting system for any signs of cracks or fractures particularly at the joints between elbows and other fittings and the straight runs of vent pipe Check the system for signs of sagging or other stresses in the joints as a result of misalignment of any components in the system If any of these conditions are found they must be corrected in accordance with the venting instructions in this manual before completing the installation and putting the water heater into service NOTE A For water heaters in locations with high ambient temperatures above 100 F itis recommended that CPVC or ABS pipe and fittings be used B A 22 5 degree elbow 2 vent pipe or a 45 degree elbow 3 and 4 vent Number of 2 Maximum 3 Maximum 4 Maximum 90 Elbows Pipe ft m Pipe ft m Pipe ft m T 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 The minimum vent lengths for each of the pipe sizes is one 90 on top of the unit plus 2 61 cm of straight pipe and the appropriate termination NOTE The equivalent feet m of pipe listed above are exclusive of the termination That is the termination with an installed screen is assumed to be in the system and the remainder of the system must not exceed
19. qualified service technician Read the GENERAL SAFETY INFORMATION section first INTELLI VENT TROUBLESHOOTING CHART RESIDENTIAL CONTROL LED STATUS PROBLEM Inadequate or no earth ground sensed by the Intelli Vent control fa N Ensure all ground connections wires on the SOLUTION Ensure the wall outlet is properly grounded water heater are secure v F BCDE eoeoceo Power supply to Intelli Vent control has reversed polarity or a high resistance to earth ground poo Ensure the wall outlet is properly wired Ensure all internal 120 VAC wiring connections and Ensure the wall outlet is properly grounded wiring harness have no reversed wires 120 VAC hot wire must connect to the on off switch Ensure all ground connections wires on the water heater are secure Pressure switch circuit remaining closed for more than 5 seconds after heating cycle begins Blower does not start Service Note Disconnect power disconnect one wire from the air pressure switch or the vent temperature limit switch Turn power back on blower should start N Ensure air pressure switch circuit wiring is correct Secure power to water heater check continuity of air and the air pressure switch is not jumpered pressure switch contacts with wires disconnected A If pressure switch contacts show continuity closed circuit replace the pressure switch
20. the roof The total vent system should not exceed the equivalent feet of pipe as listed in Table 1 Provide support for all pipe protruding through the roof All piping should be properly secured The vent system piping should be supported every 5 feet 1 5 m of vertical run and every 3 feet 91 cm of horizontal run All piping and fittings must be joined by the proper procedures as described under VENT PIPE PREPARATION l MIN 18 ABOVE ROOF MIN OF 18 ABOVE ANTICIPATED SNOW LEVEL MAXIMUM EQUIVALENT FEET SEE TABLE 1 BLOWER ASSEMBLY FORM TRAP IN PLASTIC TUBE AND RUNTO DRAIN ALL PIPE PROTRUDING THROUGHTHE ROOF SHOULD BE PROPERLY SUPPORTED FIGURE 21 IMPORTANT The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z223 1 or the Natural Gas and Propane Installation Code CAN CSA B149 1 and as listed below 1 Vent Termination must extend a minimum of 18 inches 46 cm above roof or 18 inches 46 cm above the anticipated snow level to prevent blockage of the vent termination as shown in Figures 20 and 21 VENT ATTENUATION ASSEMBLY INSTALLATION INSTRUCTIONS The Vent Attenuation Assembly VAA is designed to provide a reduction in fan noise created in the blower wheel This installation of this VAA is optional Review directions thoroughly prior to installing the new VAA P
21. thermostat to the lowest setting by first pressing the COOLER amp and HOTTER 2 buttons together and holding for 1 second Then press the COOLER amp button until the WARM indicator light appears Set the ON OFF switch on the blower control box to the OFF position Turn off all electric power to the appliance if service is to be performed 26 IV Itis recommended that lower water temperatures be used to avoid the risk of scalding It is further recommended in all cases that the water temperature be set for the lowest temperature which satisfies your hot water needs This will also provide the most energy efficient operation of the water heater Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20 F 11 C If you experience this type of use you should consider using lower temperature settings to reduce scald hazards Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available ADANGER Read instruction manual for safe temperature setting HOT WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperat
22. water heater is not operating The system is fully primed when the hose is lowered below the hose clamp on the side of the water heater and water begins to flow out of the hose In most installations the water heater will self prime the condensate trap during the first full heat up cycle If a sound of air bubbling through water gurgling is heard while the blower is operating after the first heat up cycle then turn the unit off and contact your plumber or service representative If these instructions are not followed the condensate build up will block the exhaust outlet which will cause improper operation de INLET SIDE OF BLOWER 4 EXHAUST TEE T CONDENSATE U ASSEMBLY NOTE NO PORTION OF THE CONDENSATE HOSE MAY BE ELEVATED HIGHER THAN THE CLAMP THAT IS SECURED TO THE SIDE OF THE JACKET THROUGHOUT THE ENTIRE LENGTH OF THE HOSE INCLUDING THE EXIT INTO AN APPROPRIATE DRAIN CONDENSATE SYSTEM FIGURE 16 Condensate is likely to form in the venting system attached to this water heater The vent pipe should be sloped downward away from the blower assembly not less than 1 8 3 2 mm nor greater than 1 2 12 7 mm per foot 30 cm maximum If the vent piping is vented level or sloped upwards away from the blower assembly then adequate means for draining and disposing of the condensate needs to be made by the installer In either case a 3 8 drain hose should be connected to the built in drain port Prio
23. water heater is shipped with condensate hose that attaches to the fitting on the condensate boot No other Tee or fitting is required See Figures 17 20 and 21 CONDENSATE This water heater is a condensing unit and requires a drain to be located in close proximity to allow the condensate to drain safely The condensate drains from the unit at the exhaust tee located at the bottom of the unit see figure 16 and from two places on the blower assembly see figure 17 Condensate from this water heater is mildly acidic Please note that some local codes require that condensate is treated by using a pH neutralizing filter prior to disposal NOTE Itis important that the condensate hose on the bottom of the unit is not installed elevated above the clamp that is secured to the side of the jacket see figure 16 This must be true for the entire length of the hose from the clamp to the exit into an appropriate drain If these instructions are not followed or if the condensate hose is blocked water will spill from the condensate trap As with every water heater installation a drain pan should be used to prevent water damage to the surrounding area If necessary a condensate pump with an incorporated reservoir may be used to pump the water to an appropriate drain To avoid condensate spillage select a pump with an overflow switch Caution must be used to ensure that the drain is free and clear of debris andwill not allow backflow through the cond
24. 40 DWV Cellular CoreASTM F628 The fittings other than the TERMINATION should be equivalent to PVC DWV fittings meeting ASTM D 2665 Use CPVC fittings ASTM F 438 for CPVC pipe and ABS fittings ASTM D 2661 3311 for ABS pipe If CPVC orABS pipe and fittings are used then the proper cement must be used for all joints including joining the pipe to the Termination PVC Material If local codes do not allow the use of the PVC termination when a material other than PVC is used for venting then an equivalent fitting of that material may be substituted if the screen in the PVC terminal is removed and inserted into the new fitting PVC Materials should use ASTM D 2564 Grade Cement CPVC Materials should use ASTM F 493 Grade Cement and ABS Materials should use ASTM D 2235 Grade Cement 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 This water heater has been design certified to be vented with PVC pipe certified and marked as complying with ULC S636 This water heater is supplied with a 2 inch 22 5 degree termination elbow that is pipe with an installed screen VENT TERMINAL must be used in all cases 4 There will be some installations where condensate will be formed in the horizontal runs of the vent system This condensate will run into the condensate boot attached to the blower and out the fitting The
25. 45 sq cm OPENING O 12 MAX 30 5 cm FRONT VIEW OF DOOR FIGURE 5 Ifthis water heater will be used in beauty shops barber shops cleaning establishments or self service laundries with dry cleaning equipment itis imperative that the water heater or water heaters be installed so that combustion and ventilation air be taken from outside these areas Propellants of aerosol sprays and volatile compounds cleaners chlorine based chemicals refrigerants etc in addition to being highly flammable in many cases will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater The results can be hazardous and also cause product failure INSULATION BLANKETS Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters Your water heater meets or exceeds the Energy Policy Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary Should you choose to apply an insulation blanket to this heater you should follow these instructions For identification of components mentioned below see Figure 1 Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal
26. Do not attempt to repair the unit It must be replaced OPERATING INSTRUCTIONS 1 STOP on this label Set the thermostat to the lowest setting by first pressing 4 con e Read the safety information above the COOLER amp j and HOTTER 53 buttons together and holding for 1 second Then press the COOLER amp button until the WARM indicator light appears Set the ON OFF switch on the blower control box to the OFF position 4 This appliance is equipped with a device which automatically lights the burner DO NOT TRY TO LIGHT THE BURNER BY HAND 5 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 6 Turn on all electrical power to the appliance 7 Setthermostat to desired setting by first pressing the COOLER amp and HOTTER e buttons together and holding for 1 second Then press the HOTTER button 8 Ifthe appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your technician or gas supplier 9 WATER TEMPERATURE ADJUSTMENT Y is approximately 120 F A A CAUTION Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature WARNING TURN OFF ALL ELECTRIC POWER BEFORE SERVICING TO TURN OFF GAS TO APPLIANCE Setthe
27. E 170 F 77 C Wrong burner orifice Install correct orifice Dirt in burner ports Turn off heater and gas clean burner head Water dripping from blower assembly YELLOW FLAME F 2 Check exhaust venting and air openings in Combustion ar path restricted bottom base pan for obstructions or blockage Water on the floor under heater See CONDENSATION section CONDENSATION Provide drip TEE to catch condensation see Figure 1 WATER LEAKS thermostat threads Improperly sealed hot or cold supply connections relief valve drain valve or Check for leaks at all condensate points See Figure 1 Also see LEAK CHECKPOINTS section Leakage from other appliances or water lines Inspect other appliances near water heater Condensation of flue products Refer to CONDENSATION section Thermal expansion in closed water system Install thermal expansion tank Do not plug T amp P valve refer to cathodic protection supply LEAKING T amp P 7 7 Check relief valve for proper operation Do Improperly sealed valve not plug T amp P valve HOT WATER ODORS High su fate oF mineral content iri water Drain and flush heater thoroughly then refill Bacteria in water supply Chlorinate water supply Refer to TEMPERATURE REGULATION SOOTING Improper combustion WATER TOO HOT Thermostat set too high section WATER HEA
28. ILLING THE WATER HEATER lez Ye Property Damage Hazard Avoid water heater damage Filltankwith water before operating Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water 1 Close the water heater drain valve by turning the handle to the right clockwise The drain valve is on the lower front of the water heater 2 Open the cold water supply valve to the water heater NOTE The cold water supply valve must be left open when the water heater is in use 3 To insure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping 4 Check all water piping and connections for leaks Repair as needed VENT PIPE ASSEMBLY There are three parts of the vent pipe assembly that connect the water heater exhaust located on the lower back side of the water heater to the inlet of the blower assembly mounted on top of the water heater as shown in Figure 1 These parts will need to be assembled according to the instructions in the VENT PIPE PREPARATION section of this manual These PVC parts should be assembled with ASTM D 2564 grade cement Assemble Vent Pipe Assemblies 1 2 a
29. IMUM TEMPERATURE RATING OF 105 C AND A MINIMUM SIZE OF NO 18AWG POWER VENT WIRING SCHEMATIC FIGURE 19 INSTALLATION OF VENT SYSTEM SIDEWALL With the route of the venting system and selection of materials completed as discussed in the section of this manual titled PLANNING THE VENT SYSTEM the through the wall vent terminal in place and the first section of piping up to first elbow installed at the blower it is time to complete the installation of the venting system for the sidewall installation MAXIMUM EQUIVALENT FEET SEE TABLE 1 VENT TERMINAL SED BLOWER ASSEMBLY MIN 18 ABOVE GRADE OR MIN 18 ABOVE FORM TRAP ANTICIPATED IN PLASTIC SNOW LEVEL TUBE AND RUNTO DRAIN FIGURE 20 Before completing the installation of the venting system be sure to read the sections of this manual discussing the proper method of cutting and cementing PVC pipe and fittings VENT PIPE PREPARATION It is recommended that the completion of the venting system start at the blower assembly and run to the coupling on the inside wall of the vent terminal Figure18 The vent system piping should be supported every 5 feet 1 5 m of vertical run and every 3 feet 91 cm of horizontal run All piping and fittings must be joined by the proper procedures as described under VENT PIPE PREPARATION INSTALLATION OF VERTICAL VENT SYSTEM A proper flashing or BOOT should be used to seal the pipe where 21 it exits
30. IPING WITH ALL BLACKIRONPIPE TO GAS CONTROL SEDIMENT TRAPS AWARNING Contaminants in gas lines can cause fire or explosion Clean all gas piping before installation Install drip leg in accordance with NFPAS54 or CANICSA B1491 A sediment trap shall be installed as close to the inlet of the water heater as practical at the time of water heater installation The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap If a tee fitting is used it shall be installed in conformance with one of the methods of installation shown in Figures 12 and 13 Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a drip leg sometimes called a sediment trap must be incorporated in the piping The drip leg must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 SHUT OFF VALVE 4 coup HOT 1 UNIO TEMPERATURE amp PRESSURE RELIEF VALVE DRAIN VALVE DISCHARGE PIPE DO NOT CAP OR PLUG FLOOR DRAIN FIGURE 14 F
31. Instruction Manual Vn A 7 CORA POWER VENTED GAS MODELS W HOT SURFACE IGNITION A O Smith a ter Hea Ashland City TN 37015 www hotwater com GAS FIRED EFFICIENCY RATING UL CERTIFIED UL ama LISTED WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DOIF YOU SMELL GAS Donottry tolightany appliance AWARNING Do not touch any electrical switch do Read and understand instruction notuse any phone in your building od i an ira os n Immediately call your gas supplier servicing this water heater from a neighbor s phone Follow the Failure to follow instructions and gas supplier s instructions safety messages Could test d death or serious injury e If you cannot reach your gas supplier Instruction manual must remain with call the fire department water heater Installation and service must be For Y Saf performed by a qualified installer For Your Safety i i AN ODORANT IS ADDED TO THE GAS USED service agency or the gas supplier SYTS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL PLEASE WRITE TO THE COMPANY LISTED ON THE
32. Propane L P gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individual Shut off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 pound per square inch 3 5 kPa It shall be isolated from the gas supply piping system by closing its individual manual Shut off valve during any pressure testing of the gas supply piping system attestpressures equalto or less than 1 2 pound per square inch 3 5 kPa Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 12 and 13 A WARNING Breathing Hazard Carbon Monoxide Gas High altitude models should be installed at elevations above 5 300 feet 1 615 m For operation above 10 100 feet 3 079 m a high altitude orifice must be installed Contact a qualified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual GAS CONTROL GROUND JOINT VALVE UNION OPTIONAL ERO s DRIP LEG ecm SEDIMENT TRAP CAP FIGURE 12 GAS PIPING WITH FLEXIBLE CONNECTOR GROUND JOINT UNION BLACK PIPE OPTIONAL EXT Gas CONTROL VALVE 3 MIN DRIP LEG 76cm SEDIMENT TRAP CAP FIGURE 13 GAS P
33. RATING PLATE ON THE WATER HEATER KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED PRINTED 1207 197086 002 A N A A A 2 Your 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 This is the safety alert symbol Itis used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death gt DANGER indicates an imminently A hazardous situation which if not avoided ANGER could resultin injury or death pum WARNING indicates a potentially hazardous A situation which if not avoided could result WARNING in injury or death CAUTION indicates a potentially hazardous CAUTION used without the safety alert situation which ifnot avoided may resultin TION Y symbol indicates a potentially hazardous CA TION situation which if not avoided could result minor or moderate injury in property damage All safety messages will generally tell
34. S MAY BE RESOLVED BY REPLACING THE HOSE BEYOND THE CLAMP ATTACHED TO THE SIDE OF THE WATER HEATER JACKET WITH A LARGER DIAMETER HOSE OR PIPE IN ORDER TO REDUCE THE BACK PRESSURE 1 0 25 RA MINIMUM TOP VIEW ZERO CLEARANCE ACCEPTABLE 27 69 cm MIN DIAMETER TEE SUPPLIED IN VENT KIT TEE SUPPLIED IN VAA KIT FIGURE 1 continued 7 te DIAMETER SIDE INLET THERMOSTAT TOP VIEW INSTALL IN ACCORDANCE WITH LOCAL CODES FRONT VIEW Rough In Dimensions Model Units A B C D E F G H J K Brx ao Inches 70 62 68 20 51 90 20 90 9 15 12 00 22 00 8 00 15 81 26 92 cm 179 37 173 23 131 83 53 09 23 24 30 48 55 88 20 32 40 16 68 38 Top Side Inlet and Outlet 3 4 NPT Gas Inlet 1 2 NPT Capacity and Gas and Electrical Characteristics Model Approximate Capacity Manifold Pressure Electrical Characteristics U S Gals Liters Gas Type WC kPA Volts Hz Amperes BTX 80 50 189 Nat 4 00 0 99 120 60 lt 5 All models Maximum Supply Pressure 14 inches W C 3 48kPa Minimum Supply Pressure Natural Gas 5 0 inches W C 1 24kPa Minimum Pressure must be maintained under both load and no load static and dynamic conditions Recovery Capacities U S Gallons Hr and Liters Hr at Temperature Rise Indicated Input Recovery Capacities Model Rat
35. TER SOUNDS Condensation dripping on burner Refer to CONDENSATION above SIZZLING RUMBLING Sediment at bottom of heater tank Clean sediment from tank Frater to DRAINING Refer to Air Requirements BURNER WILL NOT STAY LIT GOES OUT 4 5 SECONDS Outlet polarity is reversed Test polarity and correct High ambient room temperature Contact a service agency to determine cause Combustion air path restricted Check exhaust venting and air openings in bottom base pan for obstructions or blockage Defective gas valve Replace gas valve VENT GAS ODORS Lack of air supply Improperly installed vent piping Downdraft Poor Combustion Shut off water heater immediately and contact a service agency to determine cause 34 Limited Warranty A O Smith Corporation the warrantor extends the following LIMITED WARRANTY to the owner of this water heater T THE TANK If the glass lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein during the first THREE years after initial installation the warrantor will supply a complete new A O Smith water heater of equivalent size and current model Some government agencies are requiring energy efficient standards for water heaters In the event regulations prohibit sale of a model of equivalent size and construction A O Smith will provide a
36. 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 PROP ERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHER WISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN CONTRACT OR IN TORT a Some areas do not allow the exclusion or limitation of the incidental or consequential damage so the above limitations or exclusions may not apply to you b This warranty gives you specific legal rights and you may also have other rights which vary from area to area Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the heater s rating plate Model No Serial No Date Installed Dealer s Name Dealer s Address Phone No City and State Zip KEEP THIS WARRANTY POSTED ADJA HEATER FOR FUTURE REFERENCE
37. a digital manometer check continuity of contacts see service note in left column If the switch proves defective replace the air pressure switch and or the blower assembly as required rove the air pressure switch is working properly and error code 4 persists replace the Intelli Vent control The Intelli Vent control has detected an open ignitor circuit Service Note The resistance ohms of a hot surface ignitor will increase over time If the resistance at room temperature is near 18 8 ohms consider replacing the ignitor as a preventative measure 32 N e Check wiring to the hot surface ignitor replace ignitor Check ignitor assembly plug and the socket on the Check resistance of ignitor at room temperature 77 F If results from the above tests were assembly if wiring is damaged or worn Intelli Vent body for good connection Replace ignitor assembly and or control if necessary 25 C at the plug end Replace ignitor if resistance is not within 11 5 and 18 8 ohms at room temperature r e good and error code 5 persists replace the Intelli Vent control TROUBLE SHOOTING Please check guidelines below For your safety water heater service should be performed only by a qualified service technician Read the GENERAL SAFETY INFORMATION section first wBCDEF eooceeo INTELLI VENT TROUBLESHOOTING CHART RESIDENTIAL
38. a part of the unconfined space In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air may need to be provided using the methods described in Combustion Air and Ventilation for Appliances Located in Confined Spaces COMBUSTION AIR AND VENTILATION FOR APPLIANCES LOCATED IN CONFINED SPACES CONFINED SPACE is a space whose volume is less than 50 cubic feet per 1 000 Btu per hour 4 8 cm per kW of the aggregate input rating of all appliances installed in that space When drawing combustion air from inside a conventionally constructed building to a confined space such a space shall be provided with two permanent openings ONE WITHIN 12 INCHES 30 cm OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES 30 cm OF THE ENCLOSURE BOTTOM Each opening shall have a free area of one square inch per 1000 Btu hr 22 cm kW of the total input of all appliances in the enclosure but not less than 100 square inches 645 cm If the confined space is within a building of tight construction air for combustion and ventilation must be obtained from outdoors When directly communicating with the outdoors or communicating through vertical ducts two permanent openings located in the above manner shall be provided Each opening shall have
39. acteristics and limitations of the PVC and CPVC piping materials that you are about to use C Knowthe reputation of your manufacturer and their products D Know your own qualifications or those of your contractor The solvent welding technique of joining PVC and CPVC pipe is a specialized skill just as any other pipe fitting technique E Closely supervise the installation and inspect the finished job before start up F Contact the manufacturer supplier or competent consulting agency if you have any questions about the application or installation of PVC and CPVC pipe G Take the time and effort to do a professional job Shortcuts will only cause you problems and delays in start up By far the majority of failures in PVC and CPVC systems are the result of shortcuts and or improper joining techniques 2 SELECTION OF MATERIALS Cutting Device Saw or Pipe Cutter Deburring Tool Knife File or Beveling Machine 2 and above Brush Pure Bristle Rag Cotton Not Synthetic Primer and Cleaner Solvent Cement PVC for PVC Components and CPVC for CPVC Components Containers Metal or Glass to hold Primer and Cement Select the type of PVC or CPVC materials to be used on the basis of their application with respect to chemical resistance pressure rating temperature characteristics etc Insertion Tool Helpful for larger diameter pipe and fittings 6 inches 15 2 cm and above AWARNING Fire or Explosio
40. airs are made because failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage amo EU FIGURE 27 BURNER CLEANING In the event your burner or burner air openings require cleaning turn the blower switch to the OFF position and allow the burner to cool Call a service agency to remove and clean the burner and correct the problem that required the burner to be cleaned HOUSEKEEPING Vacuum around base of water heater for dust dirt and lint on a regular basis A DANGER Do not obstruct combustion air openings at the bottom ofthe water heater Do not use or store flammable vapor products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance Cancause serious injury or death INSTALLED IN SUITABLE AREA To insure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Locating the New Water Heater section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater which can cause a fire ANODE ROD INSPECTION oy NU ua e Property Damage Hazard Avoid waterheater damage Inspectionand replacement of anode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are
41. al that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of atleast 18 above the floor This will where flammable products will be reduce but not eliminate the risk stored or used unless the main ofvapors being ignited by the main burner and hot surface igniter are burner or hot surface igniter ABLE NTEN SAFE INSTALLATION USE AND SERVICE GENERAL SAFETY TABLE OF CONTENTS INTRODUCTION Preparing for the Installation 5 TYPICAL INSTALLATION 6 9 ROUGH IN DIMENSIONS 8 LOCATING THE NEW WATER HEATER 10 12 Facts to Consider About Location Insulation Blankets Combustion Air and Ventilation for Appliances Located in Unconfined Spaces Combustion Air and Ventilation for Appliances Located in Confined Spaces INSTALLING THE WATER HEATER Chemical Vapor Corrosion Water Piping Temperature Pressure Relief Valve Gas Piping Sediment Traps Filling the Water Heater Vent Pipe Assembly Venting Vent Pipe Termination Planning the Vent System Condensate Blower Assembly Installation INTR Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute NFPA National F
42. al Expansion Strange Sounds Operational Condition Smelly Water Air in Hot Water Faucets High Temperature Shut Off System PERIODIC MAINTENANCE Venting System Inspection Burner Operation and Inspection Burner Cleaning Housekeeping Anode Rod Inspection Temperature Pressure Relief Valve Operation Draining Service LEAKAGE CHECKPOINTS TROUBLESHOOTING WARRANTY TION codes the installation must comply with the current editions of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electrical Code NFPA 70 or CAN CSA B149 1 the Natural Gas and Propane Installation Code and CSA C22 1 the Canadian Electrical Code 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 1 Batterymarch Park Quincy MA 02269 3 The water heater when installed must be grounded in accordance with the local codes or in the absence of local codes the National Electrical Code NFPA 70 or the Canadian Electrical Code C22 1 4 If after reading this manual you have any questions or do not understand any portion of the instructions call the local gas utility or the manufacturer whose name appears on the rating plate 5 Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installat
43. alled at elevations above 5 300 feet 1 615 m For operation above 10 100 feet 3 079 m a high attitude orifice must be installed Do not operate if soot buildup Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emiting products near water heater Gas and carbon monoxide detectors are available Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation fire explosion or asphyxiation Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual U S HORIZONTAL VENT CLEARANCES Minimum 18 in 46 cm ISIDE RAER DETAIL Minimum 3 ft 91 cm within a col height of 15 ft 4 6 m above meter regulator assembly A WARNING VENT HOOD S MAY BE EXTREMELY HOT DURING OPERATION 12 in 30 cm above door v above grade or nem expected snow fall 12 in 30 cm to side or imum 3 ft 91 cm clearance from soffit 12 in 30 cm 1f to service regulator vent outlet Minimum Minimum 12 in 30 cm 7 ft 23m _ under veranda porch above deck or balcony public sidewalk see footnote 1 or paved driveway Misi
44. astic Top Outlet not shown O Inlet Dip Tube EE On Off Switch RR VentAttenuation P Temperature amp Pressure FF Exhaust Tee Assembly VAA Optional Relief Valve GG Elbow SS Access Door REPLACEMENT PARTS AND DELIMING Replacement parts and recommended delimer may be ordered through authorized servicers or distributors When ordering parts provide complete model and serial numbers see rating plate quantity and name of part desired Standard hardware items may be purchased locally CONDENSATE ASSEMBLY INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM U NATURAL GAS MAIN BURNER WITH IGNITER ASSEMBLY SIDE VIEW MAIN BURNER een ss SEE ACCESS PANEL CAUTION MM ACESS VACUUM RELIEF Caution This access panel covers a VALVE 2 NPT plug that was required during the manufacturing of this water heater This 2 NPT flange is not a cleanout fitting removing the 2 NPT plug and using this fitting as a cleanout could void your warranty INSTALL PER LOCAL CODES CAUTION HARNESS HAS 120 VAC IN OPERATION See PLANNING THE VENT SYSTEM CONDENSATE and BLOWER ASSEMBLY INSTALLATION for more information 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 speci
45. be easier to mark both the inside and outside wall Align the holes by drilling ahole through the center of the template from the inside through to the outside The template can now be positioned on the outside wall using the drilled hole as a centering point for the template 3 A MASONRY SIDE WALLS Chisel an opening approximately one half inch 1 3 cm larger than the marked circle B WOODEN SIDE WALLS Drill a pilot hole approximately one quarter inch 0 64 cm outside of the marked circle This pilot hole is used as a starting point for a saws all or sabre saw blade Cut around the marked circle staying approximately one quarter inch 0 64 cm outside of the line This will allow the vent to easily slide through the opening The resulting gap will be covered up by the Vent Terminal cover plate Repeat this step on inside wall if necessary SEQUENCE OF INSTALLATIONS FIGURE 18 Cut a length of PVC pipe about 3 5 inches 8 9 cm longer than the wall thickness at the opening Glue the vent terminal to this section of pipe Slide the wall plate over the pipe to stop against the vent terminal Place a bead of caulking not supplied around the gap between the pipe and cover plate Apply enough to fill some of the gap between the pipe and wall Place some of the caulking on the back of the plate to hold it against the wall after installation If the vent pipe is installed up to the wall with a coupling on the end against the wall opening th
46. clean or replace the flue and venting before resuming operation of the water heater BURNER OPERATION AND INSPECTION Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced At least once a year a visual inspection should be made of the main burner and the hot surface igniter assembly for proper flame 29 characteristics and ignition sequences This can be done by removing the Outer Door and viewing the main burner operation through the Viewport on the Inner Door see Figure 1 The main burner should provide complete combustion of gas ignite rapidly give reasonably quiet operation and cause no excessive flame lifting from the burner ports If the proper flame characteristics are not evident see Figure 27 make sure that the flow of combustion and ventilation air is not blocked You should also check for sooting Soot is not normal and will impair proper combustion Avisual inspection of the main burner and HSI igniter assembly should also be done at least once a year see Figure 27 Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and leave off until rep
47. ction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell in the hot water The smellis a result of four factors which must all be present for the odor to develop a A concentration of sulfate in the supply water Little or no dissolved oxygen in the water c A sulfate reducing bacteria which has accumulated within the water heater this harmless bacteria is nontoxic to humans d An excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode ov Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all water lines Contact the local water heater supplier or service agency for further information concerning an Anode Replacement Kit and this chlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem 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 A WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water
48. ctions are not reversed when making these connections F Ground heater properly This water heater must be grounded in accordance with the National Electrical Code NFPA 70 or the Canadian Electrical Code C22 1 and orlocal codes These must be followed in all cases The water heater must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the water heater see Figure 19 G Close the panel on the control box Make sure that the access panel is secured shut 9 The blower discharge boot is made to accept only straight sections of 2 pipe To start off with an elbow a short section of the furnished pipe a minimum of 2 inches 5 1 cm must be cut and glued into the end of the elbow that will mount on the discharge boot INSTALLATION OF VENT SYSTEM Before beginning installation of piping system thoroughly read the section of this manual VENT PIPE PREPARATION If you are installing your system so that it vents through roof please refer to section titled INSTALLATION OF VERTICAL VENT SYSTEM VENT TERMINAL INSTALLATION SIDEWALL 1 Install the vent terminal by using the cover plate as a template to mark the hole for the vent pipe to pass through the wall BEWARE OF CONCEALED WIRING AND PIPING INSIDE THE WALL 2 Ifthe Vent Terminal is being installed on the outside ofa finished wall it may
49. d it expands thermal expansion and closed systems do not allow 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 relief valve is reached the valve will release the excess pressure The temperature pressure relief valve is not intended for the constant relief of thermal expansion This is an unacceptable condition and must be corrected It is recommended that any devices installed which could create a closed system have a by pass and or the system have an expansion tank or device to relieve the pressure built by thermal expansion in the water system Expansion tanks are available for ordering through a local plumbing contractor Contact the local water heater supplier or service agency for assistance in controlling these situations STRANGE SOUNDS Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not necessarily represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See Condensate in this section OPERATIONAL CONDITIONS SMELLY WATER In each water heater there is installed at least one anode rod see parts section for corrosion protection of the tank Certain water 28 conditions will cause a rea
50. designed for the relief valve Position the valve downward and provide tubing so that any discharge will exit only within 6 inches 15 2 cm above or at any distance below the structural floor Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 feet 9 14 m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve see Figures 10 or 14 No valve or other obstruction is to be placed between the relief valve andthe tank Do not connect tubing directly to discharge drain unless a 6 15 2 cm air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage CAUTION Temperature pressure relief valve discharge pipe mustterminate at adequate drain The Discharge Pipe Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe Shall terminate at an adequate
51. drain Shall not have any valve between the relief valve and tank Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available ADANGER Read instruction manual for safe temperature setting The temperature pressure relief valve must be manually operated at least once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one GAS PIPING A WARNING Do not use water heater with any gas other than the gas shown on therating plate Excessive pressure to gas control valve can cause serious injury or death Turn off gas lines during installation Contact qualified installer or service agency Make sure the gas supplied is the same type listed on the model rating plate
52. e Secure all insulation using tape TEMPERATURE PRESSURE RELIEF VALVE A WARNING Explosion Hazard Temperature pressure relief valve must comply with ANSI 221 22 CSA 4 4 and ASME code Properly sized temperature relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death This heater is provided with a properly certified combination temperature pressure relief valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA 4 4 and the code requirements of ASME If replaced the valve must meet the requirements of local codes but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi 1 035 kPa and a discharge capacity not less than the water heater input rate as shown on the model rating plate For safe operation of the water heater the relief valve must not be removed from its designated opening nor plugged The temperature pressure relief valve must be installed directly into the fitting of the water heater
53. e pipe with the vent terminal can be prepared for gluing before inserting through the wall Slide the pipe through the wall and insert into the coupling on the other side of the wall making sure that the vent terminal ends up pointed in the correct position see Figure 18 MORTAR OR walt SATE SILICONE s OPTIONAL aye venr TERMINAL WITH MESH PROTECTIVE SCREEN INSE prom vene ta MENTER Arie OUTSIDE OF pyc COUPLING BUILDING WALL VENT TERMINATION FIGURE 18 A CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Eco ut i2 GND i Simron s al ns ag o amp 9 aa Dou THERMOSTAT ag 8 ujj aans Add SIS ji ME E g ev SZ zl POWER BLOWER VACUUM SWITCH BK zm s UJ BLOCKAGE BEU m ELOwER MOTOR BLOWER B ER W GAS VALVE BK E WATER HEATER CONTROL w d E 2 Unus S SERRE SWITCHES LEGEND FLAME SENSE ROD y YELLOW Bk BLACK NORMAL OPERATION SEQUENCE EGET ELIO MONTE INDICATED BY BOXED NUMERALS WARNING DISCONNECT FROM ELECTRICAL SUPPLY BEFORE SERVICING UNIT REPLACE ALL DOORS AND PANELS BEFORE OPERATING HEATER IF ANY OF THE ORIGINAL WIRES SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH APPLIANCE WIRE MATERIAL WITH MIN
54. ection of appliances within the building AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual mustremain with A WARNING For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged water heater Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available ADANGER Read instruction manual for safe temperature setting A WARNING Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in opening provided A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources awa
55. ed make sure the ON OFF switch is in the OFF position and then connect the outer harness from the blower control box to the connector on the bottom side of the gas valve A WARNING Before servicing the water heater make sure the blower assembly is unplug or the electrical supply to the water heater is tumed OFF Label all wires prior to disconnection when servicing controls Wiring error can cause improper and dangerous operation Verify proper operation after servicing Failure to do this could result in death serious bodily injury or property damage 8 Donotplug in power cord until vent system is completely installed The Power Vent operates on 110 120 Vac therefore a grounded outlet must be within reach of the 6 foot 1 8 m flexible power cord supplied with the vent See Figure 1 The power cord supplied may be used on a unit only where local codes permit If local codes do not permit use of flexible power supply cord A Make sure the unit is unplugged from the wall outlet Remove the plastic top cap Remove screws and open panel on the front of the control box on the blower B Cut the flexible power cord leaving enough to be able to make connections Remove the strain relief fitting from the box C Install a suitable conduit fitting inside the enclosure D Splice field wiring into existing wiring using code authorized method wire nuts etc E Becertain that neutral and line conne
56. elease water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult your local water supplier or service agency for further information Do not plug the temperature pressure relief valve DRAINING ADANGER Burnhazard Hotwater discharge Keep hands clear of drain valve discharge The water heater should be drained if being shut down during freezing temperatures Also periodic draining and cleaning of sediment from the tank may be necessary 1 Set the blower switch to the OFF position 2 CLOSE the cold water inlet valve to the water heater 3 OPEN a nearby hot water faucet and leave open to allow for draining 4 Connect a hose to the drain valve and terminate to an adequate drain 5 OPEN the water heater drain valve to allow for tank draining NOTE If the water heater is going to be shut down and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain 6 CLOSE the drain valve 7 Follow instructions in the Filling The Water Heater section 8 Follow the lighting inst
57. ensate hose Consideration must be given to avoid freezing of the condensate lines which could result in excessive build up of condensate inside the water heater Waterproof heat tape may be required to prevent freezing of the condensate lines Please ensure that the outlet of the condensate drain does not create a slippery condition which could lead to personal injury A WARNING Breathing Hazard Carbon Monoxide Gas Form an approximately 8 diameter loop in the condensate hoses on top of the water heater to trap water and prevent the escape of combustion by producis Do not elevate the condensate hose on the bottom of the water heater above the bracket attached to the side ofthe unit This must be true for the entire length of the hose including the ext into an appropriate drain Condensate lines must be free and clear of debris and must not allow back flow through the hose The condensate lines must be able to flow freely to an appropriate drain Do not allow condensate lines to become crimped closed Analyze the entire vent system to make sure that condensate will not become trapped in a section of Vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual The condensate trap may be primed by filling the CONDENSATE U ASSEMBLY with tap water using the supplied hose while the
58. fic installation Otherwise as with all connections check for leaks while filling the tank with water and after completing the installation FIGURE 1 6 TEMPERATURE INDICATORS TEMPERATURE ADJUSTMENT BUTTONS A N A N CONDENSATE HOSE AND DRAIN PAN N Note Condensate Trap Loops must be oriented in a vertical plane as shown The traps also must be primed by filling half of the loop with water prior to operating the water heater Carefully plan the location of the loops and straight sections of hose prior to cutting hoses If necessary secure the hoses to the side of the water heater or some other rigid structure to prevent crimping While securing the hoses do not pierce or crimp the hoses VENT ATTENUATION ASSEMBLY VAA 3 8 HOSE BARB SUPPLIED IN VAA KIT 8 DIAMETER CONDENSATE TRAP LOOPS 3 8 HOSE SUPPLIED IN VAA KIT 3 8 HOSE SUPPLIED IN VENT KIT L 1 4 HOSE ATTACHED TO BLOWER REDUCING TEE SUPPLIED IN VENT KIT N HOSES SHOULD BE CUT AS NECESSARY TO MAKE 4 CONNECTING PIECES THIS CONDENSATE HOSE AND TEE MAY NOT BE NECESSARY IF THE VAA IS ABSENT OR ORIENTED VERTICALLY IF THE VAA IS INSTALLED A VERTICAL ORIENTATION IS PREFERRED CONNECT TO A SUITABLE DRAIN IF WATER SPILLS FROM THE VENT HOLES IN THE TOP OF THE CONDENSATE ASSEMBLY WHEN THE WATER HEATER TURNS OFF THEN THERE MAY BE INSUFFICIENT HEAD PRESSURE IN YOUR CONDENSATE HOSE SYSTEM THI
59. hanging the anodes etc A minimum clearance of 5 5 14 0 cm must be allowed for access to replaceable parts such as the thermostats drain valve and relief valve When installing the heater consideration must be given to proper location Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible TOP VIEW TOP VIEW OF CLOSET WITHOUT DOOR 0 MIN FIGURE 4 A gas water heater cannot operate properly without the correct amount of air for combustion Do not install in a confined area such as a closet unless you provide air as shown in the Locating The New Water Heater section Never obstruct the flow of ventilation air If you have any doubts or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death serious bodily injury or property damage A WARNIN Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the instruction manual and NF PAS4 or OCAN CSA B1491 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical vapor emitting products near water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 12 MAX 30 5 cm n RECTANGULAR VENTILATION AR DUCT AIR DUCT 100 sq in 6
60. he appliance This water heater is not for use in manufactured mobile homes or outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed 1 Selecta location indoors as close as practical to the vent terminal or location to which the water heater vent piping is going to be connected and as centralized with the water piping system as possible 2 Selected location must provide adequate clearances for servicing and proper operation of the water heater Property Damage Hazard Allwater heaters eventually leak Donotinstall without adequate drainage Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor When such locations cannot be avoided a suitable drain pan should be installed under the water heater Drain pans are available at your local hardware store Such a drain pan must have a clearance of at least 1 0 2 5cm greater than any point on the water heater s outer jacket and must be piped to an adequate drain The pan must not restrict combustion air flow For example if a circular pan is used it must be a minimum of 27 69cm in diameter See Figure 1 Water heater life depends upon water quality water pres
61. ing Rating Temp Fe 30 40 50 60 70 80 90 100 110 120 130 140 Btu hr kW Rise c 17 22 28 33 39 44 50 56 61 67 72 78 GPH 275 206 165 138 118 104 92 83 75 69 64 59 BTX 807 516 000 2225 LPH 1041 780 625 522 447 394 348 314 284 261 242 223 Recovery capacity based on 90 thermal efficiency N N A MIXING VALVE USAGE NON SCALD TEMPERING VALVE SUGGESTED PIPING ARRANGEMENT FOR TOP CONNECTIONS NON TEMPERED WATER SUPPLY lt DRAIN PAN DISCHARGE PIPE SHUT OFF VALVE TEMPERATURE PRESSURE RELIEF VALVE DO NOT CAP OR PLUG THIS MODEL IS EQUIPPED WITH SIDE PLUMBING CONNECTIONS FOR SPACE HEATING THE HOT AND COLD FITTING ASSEMBLIES PART 9001262 CAN BE ORDERED THROUGH THE MANUFACTURER FIGURE 2 This appliance has been design certified as complying with American National Standard CSA Standard for water heaters and is considered suitable for Water Potable Heating and Space Heating All models are considered suitable for water potable heating and space heating Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature available Read instruction manual for safe temperature setting
62. int to leak C Test dry fit of the joint Tapered fitting sockets are designed so that an interfaced fit should occur when the pipe is inserted about 1 3 to 2 3 of the way into the socket Occasionally when pipe fitting dimensions are at the tolerance extremes it will be possible to fully insert dry pipe to the bottom of the fitting socket When this happens a sufficient quantity of cement must be applied to the joint to fill the gap between the pipe and fitting The gap must be filled to obtain a strong leak free joint D Inspection cleaning priming Visually inspect the inside of the pipe and fitting sockets and remove all dirt grease or moisture with a clean dry rag If wiping fails to clean the surfaces a chemical cleaner must be used Check for possible damage such as splits or cracks and replace if necessary Depth of entry Marking the depth of entry is a way to check if the pipe has reached the bottom of the fitting socket in Step F Measure the fitting depth and mark this distance on the pipe O D You may want to add several inches to the distance and make a second mark as the primer and cement will most likely destroy your first one Apply primer to the surface of the pipe and fitting socket with a natural bristle brush This process softens and prepares the PVC or CPVC for the solvent cementing step Move quickly and without hesitation to the cementing procedure while the surfaces are still wet with primer E Applicati
63. ion are very important in preventing death from possible carbon monoxide poisoning and fires see Figures 1 and 2 Examine the location to ensure the water heater complies with the Locating the New Water Heater section in this manual 6 For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California Office of the State Architect 400 P Street Sacramento CA 95814 7 Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 8 Complies with SCAQMD rule 1146 and districts having equivalent NOx requirements GET TO KNOW YOUR WATER HEATER GAS MODELS N N A A PRODUCTS A Vent Pipe Q Rating Plate HH Bushing B Anode R Insulation Il Nipple C Hot Water Outlet S Vent Terminal JJ Condensate Tee D Outlet 120 VAC T Drain Valve KK Hose Barb F Gas Supply U Igniter And Main Burner LL Plug G Main Manual Gas Shut Off Valve W Drain Pan MM Vent Pipe Assembly 1 H Ground Joint Union X Control NN Vent Pipe Assembly 2 J Dirt Leg Y Control Harness OO Vent Pipe Assembly 3 K Outer Door AA Motor amp Blower PP Side Recirculation Loop L Union CC Condensate Fitting Inlet M Inlet Water Shut Off Valve 4 Places Shown QQ Side Recirculation Loop N Cold Water Inlet DD Pl
64. ions The VAAis designed to accommodate only 2 inch vent pipe The installer must use 2 inch vent pipe between the blower assembly and the inlet into the VAA On the outlet side of the VAA a short run of 2 inch vent pipe is required From this point on a 2 inch to 4 inch adapter may be used From the 2 inch to 4 inch adapter the installer may use up to 102 equivalent feet 81 1 m of pipe This is 18 equivalent feet 5 5 m less than the original 120 equivalent feet 36 6 m specified with one elbow due to the 2 inch elbow instead of a 4 inch elbow required for the vent from the blower to the inlet of the VAA see Figure 25 for typical installation Remember to operate the unit for at least one heat cycle to ensure there are no air leaks in the vent joints of the VAA and the vent pipe system Air leaks will allow flue gas by products to disseminate into the room creating an unsafe environment and could cause illness asphyxiation and or even death VENT ATTENUATION 6 MAX ASSEMBLY 3 OR 4 INCH BV ATFEE 6 MAX VENT PIPE VENT TERMINAL 6 MAX APPROXIMATELY BLOWER 3 FEET ASSEMBLY 8 CONDENSATE LOOP RUN HOSE WATER HEATER TO DRAIN FIGURE 25 Typical Installation for Horizontal Vent with 3 or 4 inch VENT PIPE PREPARATION 1 INITIAL PREPARATION A Make sure the solvent cement you are planning to use is designed for the specific application you are attempting B Knowthe physical and chemical char
65. ipe system Air leaks will allow flue gas by products to disseminate into the room creating an unsafe environment and could cause illness asphyxiation and or even death 23 VENT 4 3 OR4INCH TERMINAL VENT PIPE max 2 INCH TO 3 OR 4 INCH ADAPTER VENT ATTENUATION ASSEMBLY AT PE BLOWER ASSEMBLY WATER HEATER FIGURE 24 Typical Installation for Vertical Vent with 3 or 4 inch Pipe Installation of VAA with 3 amp 4 inch Pipe for Horizontal Vent Some applications may require the use of 3 or 4 inch vent pipe for longer ventlengths Please refer to the Figure 25 as you review these instructions Refer back to the horizontal VAA installation steps but with the following changes to the vent construction 3 inch vent Horizontal VAA Installations The VAA is designed to accommodate only 2 inch vent pipe The installer must use 2 inch vent pipe between the blower assembly and the inlet into the VAA On the outlet side of the VAA a short run of 2 inch vent pipe is required From this point on a 2 inch to 3 inch adapter may be used From the 2 inch to 3 inch adapter the installer may use up to 52 equivalent feet 15 8 m of pipe This is 8 equivalent feet 2 4 m less than the original 60 equivalent feet 18 3 m specified with one elbow due to the 2 inch elbow instead of a 3 inch elbow required for the vent from the blower to the inlet of the VAA see Figure 25 for typical installation 4 inch vent Horizontal VAA Installat
66. ire Protection Association ASME American Society of Mechanical Engineers GAMA Gas Appliance Manufacturer s Association UL Underwriters Laboratories Inc This gas fired water heater is design certified by Underwriters Laboratories Inc under American National Standard CSA Standard for Gas Water Heaters ANSI Z21 10 3 CSA 4 3 current edition PREPARING FOR THE INSTALLATION 1 Read the General Safety section page 3 and 4 of this manual first and then the entire manual carefully If you don t follow the safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER 2 The installation must conform with these instructions and the local code authority having jurisdiction In the absence of local Installation of Vent System Vent Attenuation Assembly Installation Instructions Vent Pipe Preparation LIGHTING amp OPERATING LABEL TEMPERATURE REGULATION FOR YOUR INFORMATION Start Up Conditions Smoke Odor Therm
67. lease contact the manufacturer of the water heater as shown in the instruction manual with any questions or for additional product support VENT ATTENUATION ASSEMBLY KIT PARTS LIST The kit consists of the following items If a part is missing use the contact information in the instruction manual to acquire missing component s vent attenuation assembly flexible tubing hose barb hex plug installed on VAA instruction sheet VENT ATTENUATION ASSEMBLY INSTALLATION The VAA is designed for both vertical and horizontal installations The vertical installation does not require the additional hose barb and flexible tubing However the horizontal installation will require the hose barb and flexible tubing to release condensate buildup from the VAA See instructions and diagrams that follow for a more detailed description A WARNING Breathing Hazard Carbon Monoxide Gas Form an approximately 8 diameter loop in the condensate hoses on top of the water heater to trap water and prevent the escape of combustion by products Condensate lines must be free and clear of debris and must not allow back flow through the hose The condensate lines must be able to flow freely to an appropriate drain Do not allow condensate lines to become crimped closed Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the ven
68. lves 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 to be closed As water is heated it expands thermal expansion and closed systems do not allow for the expansion of heated water The water within the water heater 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 relief valve is reached the valve will relieve the excess pressure The temperature pressure relief valve is not intended for the constant relief of thermal expansion This is an unacceptable condition and must be corrected N Itis recommended that any devices installed which could create a closed system have a by pass and or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system Expansion tanks are available for ordering through a local plumbing contractor Contact the local water supplier and or a service agency for assistance in controlling these situations 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 All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code ANSI Z223 1 NFPA 54 or
69. ly above grade or expected snow fall um 3 ft 91 cm clearance to service regulator vent outlet ze 12 in 30 cm from soffit Minimum Minimum 12 in 30 cm under veranda porch deck or balcony Minimum see footnote 1 7 ft 2 3 m above Minimum public sidewalk ft 1 83 m or paved toa driveway mechanical air soo footnote 2 supply inlet 1 n G0 em Minimum 12 in 30 cm for appliances with 10 000 btuh 3 Kw Pe rae to 100 000 btuh 30 Kw input and 36 in 90 cm for appliances greater delere peranan than 100 000 btuh 30 Kw to a non mechanical air supply inlet fet a seated into building or combustion air inlet to another appliance V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED 1 Permitted only if veranda porch deck or balcony is fully opened on a minimum of two sides beneath the floor 2 A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings FIGURE 15 VENT PIPE TERMINATION Instructions on proper installation through a sidewall are provided in Figure 15 The first step is to determine where the vent pipe will terminate See Plan ie venbaystem layout Soctnat proper clearances are Figures 15 20 and 21 The vent may terminate through a sidewall p g 9 as shown in Figure 20 or through the roof as shown in Figure 21 Vent pipes serving power vented
70. model which complies with the regulations of your area in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required The warranty on the replacement water heater will be limited to the unexpired term of the original warranty ALL OTHER PARTS If within ONE year after initial installation of this water heater any part or portion shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor will repair or replace such part or portion at its option CONDITIONS AND EXCEPTIONS This warranty shall apply only when the water heater is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices In addition a temperature and pressure relief valve certified by and officially sanctioned and recognized independent testing agency and approved by the American Society of Mechanical Engineers must have been installed a This warranty shall apply only when the heater is 1 used at temperatures not exceeding the maximum calibrated setting of its thermostat 2 used at water pressure not exceeding the working pressure shown on the heater 3 filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits 4 used in a non corrosive and non contaminated atmosphere 5 used with facto
71. n Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid allignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearancesto combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater 24 PRIMER It is recommended that Tetrahydrofuran THF be used to prepare the surfaces of pipe and fittings for solvent welding Do not use water rags gasoline or any other substitutes for cleaning PVC or CPVC surfaces A chemical cleaner such as MEK may be used CEMENT The cement should be a bodied cement of approximately 500 to 1600 centipoise viscosity containing 10 20 by weight virgin PVC material solvated with tetrahydrofuran THF Small quantities of dimethyl formamide DMF may be included to act as a retarding agent to extend curing time Select the proper cement Schedule 40 cement should be used for Schedule 40 pipe Never use all purpose cements commercial glues and adhesives or ABS cement to join PVC or CPVC pipe and fittings AWARNING Primers and cements are extremely flammable and must not be stored or used near heat or open flame Also use only in a well ventilated area APPLICATORS Select a s
72. nd 3 See Figure 1 prior to cementing The preferred orientation of Vent Pipe Assembly 1 Condensate U Assembly is shown in Figure 16 However this assembly may be rotated to a different orientation as needed for the specific installation requirements Note the rotational orientation of each part by marking a line several inches long across the joints The long tube of Vent Pipe Assembly 2 should be approximately vertical If itis found that either of the two pieces of pipe in Vent Pipe Assembly 2 are too long for proper fit up then remove as little material as possible to improve the fit up Keep in mind that the pipes will insert slightly further into the elbows when cement is applied as it acts as a lubricating agent The vertical distance from the bottom of the Condensate U Assembly to the floor that supports the water heater should be approximately 0 25 0 64 cm see Figure 16 Disassemble the parts and cement back together using the alignment marks After the cement dries attach the assembly to the blower and the water heater exhaust using the supplied rubber boots and hose clamps Acondensate trap is incorporated in the bottom of this vent pipe assembly See the CONDENSATE section of this manual for further details VENTING A WARNING Breathing Hazard Carbon Monoxide Gas Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude models should be inst
73. o prevent any combustion gases escaping into the room Locate flexible tubing Slide one end of tube over the hose barb located on the center pipe of the VAA The ridges on the hose barb should prevent the tube from sliding off however to ensure there are no leaks and possible dislocation from hose barb use a wire tie or hose clamp not supplied with kit and secure Take the other end of the flexible tubing and form an 8 inch 20 cm diameter circle approximately 3 feet 91 cm down from the hose barb located in the VAA To ensure that the circle loop maintains its shape use two wire ties not supplied with kit to secure it Take the end of the tube at the bottom of the floor and route it to a suitable drain This will provide an area where the condensate can drain without affecting the area around the appliance Once installed along with the rest of the vent configuration make sure to operate the unit through at least one heat up cycle to ensure there is no leakage around the hose barb or any joints of the VAA or vent pipe system VENT ATTENUATION ASSEMBLY 6 MAX VENT TERMINAL 2 VENT PIPE INSTALLED HOSE BARB or maf BLOWER ASSEMBLY APPROXIMATELY RUN HOSE WATER HEATER TO DRAIN FIGURE 23 Typical Horizontal Installation Installation for VAA with 3 amp 4 inch Pipe for Vertical Vent Some applications may require the use of 3 or 4 inch vent pipe for longer vent lengths Please
74. ol valve to permit servicing of the unit Be sure to check all the gas piping for leaks before lighting the water heater Use a soapy water solution not a match or open flame Rinse off soapy solution and wipe dry This heater is approved for operation up to 5 300 feet 1 615 m without alteration High altitude models are available from the factory for elevations between 5 300 feet 1 615 m and 10 100 feet 3 079 m For elevations above 10 100 feet 3 079 m the input rating should be reduced at the rate of 4 percent for each 1 000 feet 305 m above sea level which requires replacement of the burner orifice in accordance with National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 Contact your local gas supplier for further information Failure to replace the standard orifice with a high altitude orifice when installed above 10 100 feet 3 079 m could result in improper and inefficient operation of the appliance producing carbon monoxide gas in excess of safe limits which could result in serious injury or death Contact your gas supplier for any specific changes which may be required in your area AWARNING Use joint compound or tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum
75. on of solvent cement Apply the solvent cement evenly and quickly around the outside of the pipe at a width a little greater than the depth of the fitting socket Apply a light coat of cement evenly around the inside of the fitting socket Avoid puddling Apply a second coat of cement to the pipe end AWARNING Cans of cement and primer should be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement Theyare also very flammable and should be kept away from heat or flame 25 STEPE F Joint assembly Working quickly insert the pipe into the fitting socket bottom and give the pipe or fitting a 1 4 turn to evenly distribute the cement Do not continue to rotate the pipe after it has hit the bottom of the fitting socket A good joint will have sufficient cement to make a bead all the way around the outside of the fitting hub The fitting will have a tendency to slide back while the cement is still wet so hold the joint together for about 15 seconds STEPF G Cleanup and joint movement Remove all excess cement from around the pipe and fitting with a dry cotton rag This must be done while the cement is still soft The joint should not be disturbed immediately after the cementing procedure and sufficient time should be allowed for proper curing of the joint Exact drying time is difficult to predict because it depends on variables such as temperature humidity and cement in
76. orrosive chemicals in vicinity of water ter Chemical corrosion of flue and vent system can cause serious injury or death Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Atleast once a year a visual inspection should be made of the venting system You should look for 1 Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed 2 Damage or deterioration which could cause improper venting or leakage of combustion products Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent systems may present serious health risk or asphyxiation Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If after inspection of the vent system you found sooting or deterioration something is wrong Call the local gas utility to correct the problem and
77. ot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve shall be used at the hot water taps used by these people or at the water heater see Figure 2 Valves for reducing point of use temperature by mixing cold and hot water are also available Consult a Qualified Installer or Service Agency Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual A WARNING Toxic Chemical Hazard Do not connect to non potable water system This water heater shall not be connected to any heating systems or component s used with a non potable water heating appliance All piping components connected to this unit for space heating applications shall be suitable for use with potable water Toxic chemicals such as those used for boiler treatment shall not be introduced into this system When the system requires water for space heating at temperatures higher than required for domestic water purposes a tempering valve must be installed Please refer to Figure 2 for suggested piping arrangement iV VV A Water supply systems may because of such events as high line pressure frequent cut offs the effects of water hammer among others have installed devices such as pressure reducing va
78. pipe than required may cause excessive air turbulance in the combustion chamber WATER HEATER CONTROL Self diagnostic tests have found a problem with the gas valve driver circuit internal microprocessor or other internal circuits Flame signal has been sensed out of proper sequence Turn the power off for 10 20 seconds then on again to clear these error codes N If any of these error codes persist or cannot be cleared replace the Intelli Vent control Turn the power off for 10 20 seconds and then on again again to clear this error code Replace the Intelli Vent control if this error code persists Water temperature in the tank has exceeded 195 F 91 C and has activated the ECO Turn the power off for 10 20 seconds then on again to clear this error code Replace the Intelli Vent if the error code persists The self diagnostic check detected one or both of the temperature adjust buttons are stuck Press and release temperature adjust buttons If the above action does not clear the error the control will continue to regulate water temperature at the last setting However settings will no longer be adjustable the control should be replaced The self diagnostic test has detected the water temperature sensor thermistor is either open or shorted 33 Turn the power off for 10 20 seconds then on again to clear this error code Replace the In
79. r to operating the water heater make sure the removable cap is installed on the second drain port see Figure 17 BLOWER ASSEMBLY INSTALLATION 1 Thispowervented water heater comes withthe blower assembly installed 2 Afterthe unit is set in place make sure the blower assembly is still mounted securely Also make sure that one of the drain ports of the rubber boot vent adapter is capped off Lastly make sure there is no damage to the blower 3 Condensate drains from two locations on the blower assembly as shown in figure 17 A condensate hose must be secured to form a trap as shownin figure 17 for these condensate drain connections These two hoses may be connected together The hose s should be routed to a suitable drain A fitting that may be used to join the two hoses from the blower assembly is included in a supplied kit FORM TRAP IN PLASTIC TUBE AND RUN Y DRAIN CONDENSATE DRAINS 4 Make sure there is no packing material in the inlet or discharge of the blower FIGURE 17 5 Make sure that the plastic tubing is still attached from the air pressure switch to the port on the blower housing Make sure the plastic tubing is not folded anywhere between the pressure Switch and the blower housing 6 Make sure the ON OFF switch is in the OFF position and that the outer harness is connected from the blower control box to the connector on the bottom side of the gas valve 7 If the outer harness is not factory install
80. refer to the Figure 24 as you review these instructions Refer back to the vertical VAA installation steps but with the following changes to the vent construction 3 inch vent Vertical VAA Installations The VAA is designed to accommodate only 2 inch vent pipe The installer must use 2 inch vent pipe between the blower assembly and the inlet into the VAA On the outlet side of the VAA a short run of 2 inch vent pipe is required Each of the short pieces of 2 inch pipe entering and exiting the VAA must not exceed 6 inches 15 cm in length From this point on a 2 inch to 3 inch adapter may be used From the 2 inch to 3 inch adapter the installer may use up to 65 equivalent feet 19 8 m of pipe see Figure 24 for typical installation 4 inch vent Vertical VAA Installations The VAA is designed to accommodate only 2 inch vent pipe The installer must use 2 inch vent pipe between the blower assembly and the inlet into the VAA On the outlet side of the VAA a short run of 2 inch vent pipe is required Each of the short pieces of 2 inch pipe entering and exiting the VAA must not exceed 6 inches 15 cm in length From this point on a 2 inch to 4 inch adapter may be used From the 2 inch to 4 inch adapter the installer may use up to 128 equivalent feet 39 0 m of pipe see Figure 24 for typical installation Remember to operate the unit for at least one heat cycle to ensure there are no air leaks in the vent joints of the VAA and the vent p
81. round the plug or any joints of the VAA or vent pipe system VENT VENT TERMINAL ATTENUATION a ASSEMBLY ARG WATER HEATER FIGURE 22 Typical Vertical Installation Horizontal VAA Installations t The VAA is designed to accept two inch PVC pipe into the adapters on both ends The VAA can be installed to the piping from either side there is no specific inlet or outlet For optimum performance install VAA as close as possible to the blower assembly Use standard PVC cement not included with kit and glue the two inch PVC pipe coming from the blower into the VAA Make sure the 1 2 fitting is on the bottom side of the VAA This will be used to run the condensate hose to a suitable drain See typical vent installation in Figure 23 Perform the same sequence on the PVC pipe coming from the exhaust side vent terminal side of the VAA Make sure the VAAand vent pipe is supported securely to a permanent fixture stud or wall Use standard support straps not supplied with kit that may be found at a local hardware store Failure to properly support the VAA and the surrounding vent pipe could create a hazardous situation DO NOT puncture any surface of theVAA Remove hex plug from the center pipe of the VAA Locate the hose barb and install into the 1 2 fitting on the center of the VAA Using Teflon tape on the threads install hose barb into 1 2 fitting securely It is imperative that the hose barb is secure and tight t
82. ructions on the label or see Lighting Instructions in this manual to restart the water heater SERVICE If a condition persists or you are uncertain about the operation of the water heater contact a service agency Use this guide to check a Leaking water heater Many suspected Leakers are not leaking tanks Often the source of the water can be found and corrected If you are not thoroughly familiar with gas codes your water heater and safety practices contact your gas supplier or qualified installer to check the water heater Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water LEAKAGECHECKPONNIS lt AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction Manual must remain with water heater 31 Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Condensation may be seen on pipes in humid weather or pipe connections may be leaking B The anode rod fitting may be leaking
83. ry approved anode s installed 6 _ in its original installation location 7 in the United States its territories or possessions or Canada 8 sized in accordance with proper sizing techniques for commercial and or residential water heaters 9 bearing a rating plate which has not been altered defaced or removed except as required by the warrantor 10 used in an open system or in a closed system with properly sized and installed thermal expansion tank 11 operated with properly installed dirt leg 12 fired with the fuel for which it was factory built 13 fired at the factory rated input 14 operated with the inner and outer combustion chamber doors in place b Any accident to the water heater any misuse abuse including freezing or thermal expansion damage or alteration of any operation in a modified form or any attempt to repair tank leaks will void this warranty c This warranty is void if a device acting as a backflow prevention device check valves etc is installed in the cold water supply the heater is connected to unless an effective method of controlling thermal expansion is also installed at the heater s and operational at all times The relief valve installed on the heater is not an acceptable method SERVICE AND REPAIR EXPENSES Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is responsible for all other costs Such costs may include but are not
84. s crawl or attic that freely communicate with the outdoors 1 When directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu per hour 5 5 cm kW of total input rating of all equipment in the enclosure see Figure 7 vamuanon ug FIGURE 7 2 When communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 Btu per hour 5 5 cm kW of total input rating of all equipment in the enclosure see Figure 8 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 Btu per hour 11 cm kW of total input rating of all equipment in the enclosure see Figure 9 Bh enne lide FIGURE8 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum short side dimension of rectangular air ducts shall not be less than 3 inches 7 6 cm see Figure 9 ml z EL ree Eres FIGURES 5 Alternatively a single permanent opening may be used when communicating directly with the outdoors or with spaces that freely communicate with the outdoors The opening shall have a minimum free area of 1 square inch per 3 000 BTU per hour 8 3 cm kW
85. sure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the drain pan that turn off the water supply to the entire building when water is detected in the drain pan Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS VAPORS ARE LIKELY TO BE PRESENT OR STORED GARAGES STORAGE AND UTILITY AREAS ETC Flammable liquids such as gasoline solvents propane LP or butane etc and other substances such as adhesives etc emit flammable vapors which can be ignited by a gas water heater s hot surface igniter or main burner The resulting flashback and fire can cause death or serious burns to an
86. system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open HIGH WATER TEMPERATURE SHUT OFF SYSTEM This water heater is equipped with an automatic reset type high limit Energy Cutoff sensor The high limit switch interrupts the main burner gas flow should the water temperature reach 195 F 91 C The high limit will automatically reset when the water temperature drops below 140 F 60 C After cooling the tank temperature turn off the water heater for at least 10 seconds by using the switch on top of the unit Turn on the water heater If this fails to correct the problem contact your plumber or service representative VENTING SYSTEM INSPECTION A WARNING Breathing Hazard Carbon Monoxide Gas Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system fo avoid serious injury or death E De not store c
87. t Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Vertical VAA Installations Recommended 1 The VAA is designed to accept two inch PVC pipe into the adapters on both ends The VAA can be installed to the piping from either side there is no specific inlet or outlet For optimum performance install VAA as close as possible to the blower assembly Use standard PVC cement not included with kit and glue the two inch PVC pipe coming from the blower into the VAA Perform the same sequence on the PVC pipe coming from the exhaust side vent terminal side of the VAA Make sure the VAA and vent pipe is supported securely to a permanent fixture stud or wall Use standard support straps not supplied with kit that may be found at a local hardware store Failure to properly 22 5 support the VAA and the surrounding vent pipe could create a hazardous situation DO NOT puncture any surface of the VAA Confirm that the hex plug is securely installed in the 1 2 fitting found on the center of the VAA pipe It is imperative that the plug is secure and air tight to prevent any combustion gases escaping into the room If the plug is not securely tightened remove and reinstall using Teflon tape on the threads Once installed along with the rest of the vent configuration make sure to operate the unit through at least one heat up cycle to ensure there is no leakage a
88. tegrity For more specific information you should contact your solvent cement manufacturer FOR YOUR SAFETY READ BEFORE OPERATING This appliance does not have a pilot WARNING A life If you do not follow these instructions exactly a fire or explosion may result causing property damage personal ii D ury or loss of 8 BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES It is equipped with an ignition device which automatically lights the burner Do NOT try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to push in the gas control buttons Never use tools If the control buttons will not push in don ttry to repair them call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater
89. telli Vent control if this error code persist These guidelines should be utilized by a qualified service agent PROBLEM NOT ENOUGH HOT WATER 1 Blower will not run SOLUTION a ON OFF control switch turned off Turn switch to the ON position b Blower unplugged Plug blower back into 115 VAC outlet c No power at outlet Repair service to outlet d Thermostat defective Replace thermostat e Control harness defective Replace control harness f High limit control circuit open Reduce the water temperature below 140 F Turn the power switch to the off position Wait 10 seconds Turn the power switch to the on position Reduce the temperature set point to minimize likelihood of reoccurrence If this does not solve the problem replace thermostat 9 Blower motor defective Replace blower assembly 2 Thermostat problems a Thermostat set too low Adjust temperature control higher b Thermostat or ECO defective Replace thermostat 3 Others a Heater undersized Reduce hot water use b Low gas pressure Contact dealer c Incoming water is usually cold Allow more time for heater to reheat d Leaking hot water pipes of fixtures Have plumber check and repair leaks e Heater not lit or thermostat not on Refer to LIGHTING INSTRUCTIONS VENT PIPE TOO HOT ABOV
90. the Natural Gas and Propane Installation Code CAN CSA B149 1 whichever applies Copper and brass tubing and fittings except tin lined copper tubing shall not be used CAUTION Property Damage Hazard Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to cold water inlet Contact qualified installer or service agency HOT WATER COLD WATER INLET i it G SHUTOFF VALVE UNION UNION 34 SWEAT 3 4 SWEAT FITTINGS gt FITTINGS TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG FIGURE 10 Figure 10 shows the typical attachment of the water piping to the water heater The water heater is equipped with 3 4 inch NPT water connections If using copper tubing solder tubing to an adapter before ig 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 amp P Valve and Pipe Insulation if supplied Remove insulation for T amp P valve and pipe connections from carton INSULATED INLET INSULATED OUTLET FIGURE 11 Fit pipe insulation over the incoming cold water line and the hot water line Make sure that the insulation is against the top cover of the heater Fit T amp P valve insulation over valve Make sure that the insulation does not interfere with the lever of the T amp P valv
91. the lengths discussed above 3 The blower discharge adapter is made to accept only straight sections of 2 pipe To start a minimum of 2 inches 5 1 cm of 2 pipe must be attached to the blower discharge see Figure 17 If using 2 inch vent pipe A minimum of 2 inches 5 1 cm must be attached to the blower before the first elbow After the first elbow add the additional venting required for the installation The total system cannot exceed the lengths discussed above where each elbow is equal to 5 feet 1 5 m of straight pipe If using 3 or 4 inch vent pipe Two inches 5 1 cm of pipe must be attached to the blower discharge before adding a reducer to acquire the desired pipe diameter An appropriately sized 45 degree elbow supplied locally a schedule 40 DWV ventterminal must be obtained with an equivalent screen supplied inventkit The total system cannot exceed the equivalent pipe lengths discussed above where each elbow is equal to 5 feet 1 5 m of straight pipe 3 vent pipe or 8 feet 2 4 m of straight pipe 4 vent pipe U S Installations NOTE This unit can be vented with PVC pipe materials Cellular Core ASTM F891 DWV ASTM D2665 or CSAB181 2 Schedule 40 80 120 ASTM D1785 or CSAB137 3 or SDR Series ASTM D2241 or CSAB137 3 CPVC pipe materials CPVC41 ASTM D2846 or CSAB137 6 Schedule 40 80ASTM F441 or CSAB137 6 or SDR Series ASTM F442 ABS pipe materials Schedule 40 DWV ASTM D2661 or CSAB181 1 or Schedule
92. uitable pure bristle type paint brush Use a proper width brush or roller to apply the primer and cement see chart below Speedy application of cement is important due to its fast drying characteristics IMPORTANT NOTE A dauber type applicator should only be used on pipe sizes 2 and below For larger diameter pipe a brush or roller must be used RECOMMENDED BRUSH SIZE FOR PRIMER AND CEMENT APPLICATIONS Nominal Pipe Size Brush Width IPS 2 1 5 3 8 cm 3 1 5 2 5 3 8 cm 6 4 cm USE ONLY NATURAL BRISTLE 3 MAKING THE JOINT A Cutting Pipe must be squarely cut to allow for the proper interfacing of the pipe end and the fitting socket bottom This can be accomplished with a miter box saw or wheel type cutter Wheel type cutters are not generally recommended for larger diameters since they tend to flare the corner of the pipe end If this type of cutter is used the flare on the end must be completely removed NOTE Power saws should be specifically designed to cut plastic pipe B Deburring Use a knife plastic pipe deburring tool or file to remove burrs from the end of small diameter pipe Be sure to remove all burrs from around the inside as well as the outside of the pipe A slight chamfer bevel of about 10 15 should be added to the end to permit easier insertion of the pipe into the end of the fitting Failure to chamfer the edge of the pipe may remove cement from the fitting socket causing the jo
93. ure which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water from this heater fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve shall be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware Stores see Figure 2 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat in this manual see Figure 26 Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub or shower The water heater should be located in an area where the general public does not have access If a suitable area is not available a cover should be installed over the thermostat to prevent tampering The water temperature setting was factory set atthe lowest temperature Pressing the COOLER amp button decreases temperature and pressing
94. y from faucets after extended period of non use Read instruction manual before installing using or servicing water heater CAUTION Improper installation and use may result in property damag Do not operate water heater if flood damaged Inspect and replace anode Install in location with drainage Fill tank with water before operation Bealert for thermal expansion Refer to instruction manual for installation and service Before servicing the water heater make sure the blower assembly is unplugged water heater is tumed OFF operation Verify proper operation after servicing Failure to do this could result in death serious bodily injury or property damage or the electrical supply to the A WARNIN Breathing Hazard Carbon Monoxide Gas Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude models should be installed at elevations above 5 300 feet 1 615 m For operation above 10 100 feet 3 079 m a high altitude orifice must be installed Do not operate if soot buildup is present Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are available No vent damper installation is compatible with this power vented water heater Form an
95. yone in the area Also the water heater must be located and or protected so it is not subject to physical damage by a moving vehicle IVA A AWARNIN Fire or Explosion Hazard pressure period of non use Donotstore or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid allignition sources if you smell LP gas Do not expose water heater control to excessive gas Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended Read instruction manual before installing using or servicing water heater 4 DANGER Flammable Vapors A vapors from flammable liquids may explode and catch fire causing death orsevere burns Do not use or store flammable products such as gasoline Solvents or adhesives in the Same room or area near the water heater Keep flammable products 1 far away from heater 2 inapproved containers 3 tightly closed and 4 outof children s reach Installation Do not install the water heater where flammable products will be stored or used unless the main burner and hot surface igniter are Water heater has a main burner and hot surface igniter The hot surface igniter 4 can come on at any time and 2 will ignite flammable vapors Vapors 1 cannot be seen 2 are heavier than air 3 go along way on the floor and 4 can be
96. 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 IMPORTANT DEFINITIONS Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified installer must also be familiar with the design features of water heaters and have a thorough understanding of this instruction manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and insp

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