A.O. Smith 197835-001 User Manual

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Instruction Manual

RESIDENTIAL GAS WATER HEATERS

POWER VENT/POWER DIRECT VENT GAS MODELS

WITH HOT SURFACE IGNITION

Ashland City, TN 37015

www.hotwater.com

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS 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, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.

Keep this manual in the pocket on heater for future reference whenever maintenance adjustment or service is required.

PRINTED IN THE U.S.A 1208

1

197835-001

SAFE INSTALLATION, USE AND SERVICE

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

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

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

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low level exposure to some of the substances listed.

IMPORTANT DEFINITIONS

Qualified Installer or Service Agency: Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined by ANSI below) in the field involved. Installation skills such as plumbing, air supply, venting, gas supply, electrical supply are required in addition to electrical testing skills when performing service.

ANSI Z223.1 2006 Sec. 3.3.83: “QualifiedAgency” - “Any individual, firm, corporation or company that either in person or through a representative is engaged in and is responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all the requirements of the authority having jurisdiction.”.

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.

2

GENERAL SAFETY

3

GENERAL SAFETY

4

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE............................

2

Installation Sequence......................................................

21

GENERAL SAFETY..................................................................

3

Vertical Vent Terminal Installation....................................

21

TABLE OF CONTENTS............................................................

5

Installation of Vent System, Sidewall...............................

22

INTRODUCTION.......................................................................

5

Installation of Vertical Vent System.................................

22

Preparing for the Installation..............................................

5

Vent Pipe Preparation......................................................

26

Get to Know Your Water Heater........................................

6

Controls and Switches.....................................................

28

INSTALLATION CONSIDERATIONS........................................

7

Power Vent Wiring Schematic.........................................

29

Rough In Dimensions........................................................

7

LIGHTING & OPERATING LABEL..........................................

30

Commonwealth of Massachusetts.....................................

8

TEMPERATURE REGULATION.............................................

31

Water Piping - Mixing Valve Usage...................................

9

USING THE ELECTRONIC CONTROLLER...........................

32

Facts to Consider About Location....................................

10

FOR YOUR INFORMATION...................................................

36

Insulation Blankets..........................................................

11

Start Up Conditions

 

Combustion Air and Ventilation........................................

11

Smoke/Odor.............................................................

36

Appliances in Unconfined Spaces...........................

11

Thermal Expansion..................................................

36

Appliances in Confined Spaces...............................

11

Strange Sounds.......................................................

36

INSTALLING THE WATER HEATER.....................................

13

Operational Conditions....................................................

36

Chemical Vapor Corrosion...............................................

13

Smelly Water............................................................

36

Water Piping....................................................................

13

“Air” in Hot Water Faucets.......................................

36

Temperature-PressureRelief Valve.................................

14

PERIODIC MAINTENANCE....................................................

37

Gas Piping.......................................................................

15

Venting System Inspection..............................................

37

Sediment Traps...............................................................

16

Burner Operation and Inspection.....................................

37

Filling the Water Heater...................................................

16

Burner Cleaning...............................................................

37

Venting.............................................................................

16

Housekeeping..................................................................

37

Vent Pipe Termination................................................

16-17

Anode Rod Inspection.....................................................

38

Planning the Vent System...............................................

19

Temperature-PressureRelief Valve Operation................

38

Condensate.....................................................................

19

Draining...........................................................................

38

Installation of Vent System..............................................

20

Service.............................................................................

39

Vent Terminal Installation, Sidewall.................................

20

LEAKAGE CHECKPOINTS....................................................

39

Sequence of Installations, Figure 18A.............................

20

TROUBLESHOOTING............................................................

40

Direct Venting..................................................................

20

NOTES.............................................................................

41-42

Direct Vent Terminal Installation......................................

20

WARRANTY............................................................................

43

INTRODUCTION

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 Fire Protection Association

ASME - American Society of Mechanical Engineers

GAMA - Gas Appliance Manufacturer’s Association

UL - Underwriters Laboratories Inc.

This gas-firedwater 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-firedwater 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 codes, the installation must comply with the current editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National ElectricalCode,NFPA70orCAN/CSA-B149.1,theNaturalGasandPropane Installation Code and CSAC22.1, the Canadian Electrical Code. All documents are available from the Canadian Standards

Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

NFPAdocumentsarealsoavailablefromtheNationalFireProtection 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 installation 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 “Facts to Consider About Location” 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-CMR2.00: State Plumbing Code and248-CMR5.00, See page 8.

8.Complies with SCAQMD rule #1146 and districts having equivalent NOx requirements.

5

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A

Control Assembly

M

Display Enclosure

B

Blocked Inlet Switch

** N

Exhaust Elbow Assembly

C

Blocked Outlet Switch

** O

Condensate Tubing

D

Fan Prover Switch

P

Off/On Switch

E

Blower Assembly

Q

Display Label

F

Burner Assembly

R

Hot Water Outlet

G

Flame Sensor

*S

Electrical Outlet (120VAC)

H

Hot Surface Igniter

T

Gas Supply

I

Junction Box

U

Main Manual Gas Shutoff Valve

J

Gas Control Valve Thermostat

V

Union

K

Display Board

W

Inlet Water Shutoff Valve

L

Top Plastic Enclosure

X

Cold Water Inlet

YInlet Dip Tube

Z T/P Relief Valve

AARating Plate

BBLabels

CCDrain Valve

**DD Vent Terminal

EEMetal Drain Pan

FFAnode

GGInsulation

HHUpper Temperature Probe

IIAccess Door

REPLACEMENT PARTS AND DELIMING PRODUCTS

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.

ACCESS PANEL

Caution: Thisaccesspanelcovers a 2” NPT plug that was required during the manufacturing of this water heater. This 2” NPT flange isnotacleanoutfitting,removingthe 2”NPTplugandusingthisfittingasa cleanout could void your warranty.

VACUUM RELIEF

VALVE

*INSTALL PER LOCAL CODES

* CAUTION HARNESS HAS 120 VAC. IN OPERATION.

** See “Planning the Vent System,” “Installation of Vent System” and “Condensate” for more information.

FIGURE 1.

6

INSTALLATION CONSIDERATIONS

ROUGH IN DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 1A.

 

 

 

 

 

 

 

 

 

 

 

 

Rough-In-Dimensions

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

Units

 

A

 

B

C

 

 

D

 

 

 

E

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

Inches

 

68.50

 

49.25

 

 

22.00

 

15.75

 

3.00

 

8.00

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

cm

 

174

 

125.09

 

 

55.88

 

40.00

 

7.62

 

20.32

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Top/Side Inlet and Outlet: 3/4” NPT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Inlet: 1/2” NPT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Capacity, Gas and Electrical Characteristics

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

Approximate Capacity

 

Manifold Pressure

 

Electrical Characteristics

 

 

 

 

 

 

 

 

 

 

 

U.S. Gals.

 

Liters

 

Gas Type

 

“WC

 

kPA

 

 

Volts/Hz

Amperes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

 

 

50

 

 

189

 

 

Nat./LP

 

 

0”

 

 

0”

 

 

120/60

 

 

<5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.

 

 

 

 

 

Recovery Capacities - U.S. Gallons/Hr. and Liters/Hr. at Temperature Rise Indicated

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Input

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Recovery Capacities

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

Rating

 

Rating

 

 

Temp.

 

F

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

 

100,000

 

29.3

 

 

GPH

 

 

 

387

 

 

291

 

233

 

194

 

166

145

 

129

 

116

106

97

90

83

 

 

 

 

LPH

 

 

1465

 

1102

 

882

 

734

 

628

549

 

488

 

439

401

367

341

314

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Recovery capacity based on 96% thermal efficiency

7

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueledequipment,theinstallingplumberorgasfittershallobservethatahardwiredcarbonmonoxidedetectorwithanalarmandbatteryback-upis installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-upmay be installed on the next adjacent floor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certified.

SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less thanone-half(1/2) inch in size,“GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1.The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2.Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1.Detailed instructions for the installation of the venting system design or the venting system components; and

2.A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:

1.The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2.The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

8

WATER PIPING - MIXING VALVE USAGE

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

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.

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, and the physically or developmentally disabled. 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, should be used at the hot water taps used by these people or at the water heater, see Figure 2. 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.

9

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 the 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.Select a location indoors as close as practical to the vent terminal or locationtowhichthewaterheaterventpipingisgoingtobeconnected, 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.

Installationofthewaterheatermustbeaccomplishedinsuchamanner 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 metal 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 pressure 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-offdevice 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-offdevices 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 anyone 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.

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

10