Bradford-White DS150S User Manual

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DIRECT VENT GAS WATER HEATER

A Spanish language version of these instructions is available by contacting the company listed on the rating plate.

La version espanola de estas instrucciones se puede obtener al escribirle a la fabrica cuyo nombre aparece en la placa de especificaciones.

 

 

ONLY

DS140S & DS150S

 

 

 

REFERENCE

 

 

INSTALLATION & OPERATING

 

 

INSTRUCTION MANUAL

 

 

WARNING: If the information in these instructions is not

followed exactly, a fire or explosion may result causing

 

FOR

property damage, personal injury or death.

 

 

VERSION

 

FOR YOUR SAFETY

Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.

INTERNETWHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

For your family’s comfort, safety and convenience we recommend Bradford White water heaters to be installed and serviced by a plumbing professional.

238-41099-00JREV 12/03

CONGRATULATIONS!

 

 

ONLY

You have just purchased one of the finest water heaters

on the market today!

REFERENCE

 

 

 

This installation, operation and instruction manual will explain in detail the installation and maintenance of your new Direct Vent Gas Water Heater. We at Bradford White strongly recommend that you contact a plumbing professional for the installation of this water heater.

We require that you carefullyFORread this manual, as well as

whom your water heater was purchased. For your records we recommend that you write the model, serial

the enclosed warranty, and refer to it when questions arise. If you haveVERSIONany specific questions concerning your warranty, please consult the plumbing professional from

This manual should be kept with the water heater.

number and installation date of your water heater in the maintenanceINTERNETsection in the back of this manual.

At Bradford White we’re committed to providing you with the finest water heater made.

2

 

TABLE OF CONTENTS

 

 

 

 

 

page

GENERAL INFORMATION ........................................................

 

 

4

INSTALLATION

 

 

 

 

Locating The Water Heater ......................................................

 

 

6

Minimum Clearances.................................................................

 

 

9

 

 

 

 

ONLY

Optional Direct Vent-AirIntake Terminal Guard....................

9

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

 

 

 

12

 

 

 

REFERENCE

 

Horizontal and Vertical Vent-AirIntake Lengths ...................

14

Vent-AirIntake System Installation..........................................

 

17

Water Connections....................................................................

 

 

25

Gas Connections .......................................................................

 

 

29

GENERAL OPERATION ............................................................

 

 

30

 

 

FOR

 

 

Lighting and Shutdown Instructions.......................................

31

Thermostat Adjustment.............................................................

 

 

32

 

VERSION

 

 

 

Burner Flame Checks ...............................................................

 

 

33

MAINTENANCE...........................................................................

 

 

 

34

PARTS LIST .................................................................................

 

 

 

37

INTERNET

 

 

 

 

PARTS LIST DRAWINGS

 

 

 

Direct Vent Water Heater..........................................................

 

 

38

Vent-AirIntake Kits....................................................................

 

 

39

INSTALLATIONS FOR POTABLE WATER AND SPACE

HEATING.......................................................................................

 

 

 

40

3

GENERAL INFORMATION

This gas-firedwater heater’s design is certified by CSA International under theAmerican National Standard Z21.10.1 - (as indicated on the rating plate) andCSA 4.1-M - (as indicated on the rating plate).

This water heater must be installed in accordance with local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1-LatestEdition) and/or in CanadaCAN/CGA B149 Installation Codes (LatestONLYEditions). The warranty for this water heater is in effect only when the water heater is installed, adjusted, and operated in accordance with these Installation and Operating Instructions. The manufacturer will not be held liable for any damage resulting from alteration and/or failure to comply with these instructions.

This water heater is not design certified for installation in a mobile home. Such an installation may create a hazardous condition and will nullify the warranty.

This water heater has been designed and certified for the purpose of heating

potable water. The installation and use of this water heater for any purpose

 

REFERENCE

other than the heating of potable water may cause damage to the water heater

and create a hazardous condition and nullify the warranty.

FOR

 

CAUTION

Incorrect operation of this appliance may create a hazard to life

and property and will nullify the warranty.

contact a qualified serviceVERSIONtechnician to inspect the appliance and to replace

Do not use this appliance if any part has been submerged in water. You should

any part of the control system including the combination gas control which has been submerged in water.

DoINTERNETnot store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other

DANGER

appliance.

4

General Information continued-

IMPORTANT

Before proceeding, please inspect the water heater and its components for possible damage. DO NOT install any damaged components. If damage is evident then please contact the supplier where the water heater was purchased or the manufacturer listed on the rating plate for replacement parts.

Make sure that you check the rating plate and combination gas controlONLYon the

water heater to be certain that the type of gas being supplied corresponds with

the marking on the rating plate and combination gas control.

A sacrificial anode is used to extend tank life. REFERENCEThe removal of this anode, for

any reason, will nullify the warranty. In areas where water is unusually active, an odor may occur at the hot water faucet due to a reaction between the sacrificial anode and the impurities in the water. If this should happen, an

alternative anode may be purchased from the supplier that installed this water

heater. This will minimize the odor while protecting the tank. Additionally, the

 

 

FOR

water heater should be flushed with appropriate dissolvers to eliminate any

bacteria.

 

 

INTERNET

VERSION

 

 

 

5

INSTALLATION

LOCATING THE WATER HEATER

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-airintake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater andvent-airintake components.UNDER NO CIRCUMSTANCES

MUST FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINTONLY THINNER BE USED OR STORED IN THE VICINITY OF THIS WATER HEATER,VENT-AIRINTAKE SYSTEM OR IN ANY LOCATION FROM

DO NOT install the water heater in any location where gasoline or flammable vapors are likely to be present.

WHICH FUMES COULD REACH THE WATER HEATER OR VENT-AIRINTAKE SYSTEM.REFERENCE inches(46 cm) above the floor and shall be located, or protected, to

Water Heaters in residential garages shall be installed so that all burner(s) and burner ignition device(s) are located not less than 18

avoid physical damage. For otherFORinstallations refer to local codes. In the absence of local codes, the water heater shall be installed in

compliance with the National Fuel Gas Code, ANSI Z223.1- (Latest VERSION

Edition) and/or in Canada, CA /CGA B149 Installation Codes (Latest Editions).

The location of this water heater is of the utmost importance. Before installing this water heater, read the installation section of these instructions. After

reading these installation and operating instructions, select a location for the waterINTERNETheater where the floor is level and is easily accessible to gas and water supply lines.DO NOT locate the water heater where water lines could

be subjected to freezing temperatures. Make sure the cold water pipes are not located directly above the gas control so that condensate during humid weather does not drip on the controls.

6

Installation (Locating The Water Heater) continued-

Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals. These materials are corrosive at very low concentration levels with little or no

odor to reveal their presence. NOTE: DAMAGE TO THE WATER HEATER

CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY

THE WARRANTY. DO NOT OPERATE THE WATER HEATER IF

ONLY

 

EXPOSURE HAS OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY

CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER.

REFERENCE

 

WARNING

 

Liquefied petroleum gases/propane gas are heavier than air and will remain at floor level if there is a leak. Basements, crawl spaces, closets and areas below ground level will serve as pockets for accumulation of leaking gas. Before lighting, smell all around the appliance area for gas. Be sure to smell next to the floor.

IF YOU SMELL GAS:

FOR

 

VERSION

 

Do not try to light any appliance.

Do not touch any electric switch; do not use any

 

telephone in your building.

Immediately call your gas supplier from a neighbor’s

 

telephone. Follow the gas supplier’s instructions.

INTERNET

If you cannot reach your gas supplier, call the fire

department.

DO NOT OPERATE APPLIANCE UNTIL THE LEAKAGE IS CORRECTED!

7

Installation (Locating The Water Heater) continued-

WARNING

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING:

Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas.

Most people recognize this odor as a “sulfur” or “rotten ONLYegg” smell.

Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or ”fade”, and not be as readily

detectable. REFERENCE

If you have a diminished sense of smell, or are in any way unsure of the presence of gas, immediately contact your gas supplier from a neighbor’s telephone.

Gas detectors are available. Contact your gas supplier, or plumbing professional, for more information.

The water heater must be located closeFORenough to the outside wall to keep the venting distance within the maximum distance described in the installation

This water heater must be located in an area where leakage of the tank or water line connections and the combination temperature and pressure relief

instructions. Note: The direct vent-airintake terminal must be installed on a vertical wall. Read theVERSIONventing section in this installation instruction manual before locating the water heater.

valveINTERNETwill not result in damage to the area adjacent to the water heater or to lower floors of the structure. When such locations cannot be avoided, a

suitable drain pan, adequately drained, be installed under the water heater. The pan must not restrict combustion airflow. The drain pan must be no greater than 1-½inches(3.8 cm) deep and have a minimum length and width of at least four (4) inches(10.2 cm) measured from the jacket of the water heater. The drain pan, as described above, can be purchased from your plumbing professional. The drain pan must be piped to an adequate drain. The piping must be at least 3/4 inch(1.9 cm) in diameter and pitched for proper drainage.

It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

8

Installation continued-

MINIMUM CLEARANCES

WARNING

Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty.

This installation shall allow access to the front of the water heater andONLY adequate clearance shall be provided for servicing and operating this

water heater. The water heater may be installed on either a combustible or

non-combustiblefloor. If the water heater is toREFERENCEbe installed directly on carpeting, it shall be installed on top of a metal or wood panel extending

beyond the full width and depth of the appliance by at least three (3) inches (7.6 cm) in any direction or, if the appliance is to be installed in an alcove or closet, the entire floor shall be covered by the panel. The minimum clearances to combustibles for this water heater is: zero (0) inch(0 cm) from the sides and rear, four (4) inches(10.2 cm) from the front of the jacket, zero (0) inch(0 cm) from the plenum, zero (0) inch(0 cm) from the air intake elbow and

 

FOR

telescopic tubes and twelve (12) inches (30.5 cm) from the directvent-air

intake terminal. (See Figure 1).

 

VERSION

 

OPTIONAL DIRECT VENT-AIRINTAKE TERMINAL GUARD

WARNING

The direct vent-airintake terminal is HOT while the water heater is in operation. Do not touch. Keep children, combustibles, gasoline

It is recommended that a vent-airintake terminal guard be installed when thevent-airintake terminal is located where it can be touched accidentally, or accessed by children. (See Figure 2).

andINTERNETother liquids having flammable vapors away.

A chain link or louvered fence may be used instead of the vent-airintake terminal guard. Maintain proper clearances as specified in this instruction manual to thevent-airintake terminal. (See Figure 3).

9

Installation (Minimum Clearances) continued-

INTERNET

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

Figure 1

10

Installation continued-

 

 

REFERENCE

ONLY

 

FOR

 

 

 

 

Figure 2

 

 

VERSION

 

 

 

INTERNET

 

 

 

Figure 3

11

Installation continued-

VENTING

This is a Direct Vent Gas Water Heater where all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere.

 

 

 

WARNING

ONLY

 

 

 

 

 

 

 

The vent-airintake system must be properly installed. Failure to properly install thevent-airintake system properly could result in property damage, personal injury or death.

DO NOT install any damaged vent-airintake system components. Contact the manufacturer of the water heater for replacement parts.

Direct Vent-AirIntake Terminal(See Figure 4)

Shall be installed with at least a 9 in.(22.9 cm) vent termination

 

clearance from any air opening into a building.

 

REFERENCE

The bottom of the direct vent-airintake terminal shall be located at

 

least 12 in. (30.5 cm) above grade.

 

Installed at least 3 ft.(91.4 m) from any gas meter, gas valve or

 

FOR

 

 

other gas regulating equipment.

 

Note: Provide protection of the building materials from degradation by flue gases from the direct vent-air intake terminal.

Must be installedVERSIONin a location where it will not be blocked by snow.

Exceptions for Installations in Canada

The direct vent-airintake terminal shall not terminate:

(a)directly above a paved sidewalk or paved driveway which is located between two single-familydwellings and serves both dwellings;

(b)less than 7 ft. (2.1 m) above a paved sidewalk or a paved driveway located on public property;

(c)within 6 ft. (1.8 m) of a mechanicalair supply inlet to anybuilding;

(d)above a gas meter/regulator assembly within 3 ft.(91.4 cm) horizontally of the vertical centerline of theregulator;

(e)within 6 ft. (1.8 m) of any gasservice regulator vent outlet;

(f)less than 12 in. (30.5 cm) above grade level;

(g)within 12 in. (30.5 cm) of a window or door which can be opened in any

building, any non-mechanical air supplyinlet to any buildingor the combustion airinlet of any other appliance:INTERNET

12

Installation (Venting) continued-

(h)underneath a verandah, porch or deck, unless:

(i)the verandah, porch or deck is fully open on a minimum of two sides beneath the floor, and

(ii)the distance between the top of the vent-air intake termination and the underside of the verandah, porch or deck is greater than 12 in. (30.5 cm).

INTERNET

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

Figure 4

13

Installation (Venting) continued-

The co-axialvent-airintake tubes of this water heater can be installed in any 360° configuration as long as the proper clearances for installation, plumbing, operation and servicing are maintained. (See Figure 5).

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

Figure 5

 

 

Note: Maintain proper clearances for installation, plumbing, operation

and service.

 

 

 

HORIZONTALINTERNETAND VERTICALVENT-AIRINTAKE LENGTHS

This Direct Vent Gas Water Heater comes with one (1) vent-airintake “Kit C”. Optionalvent-airintake kits are available that can extend the horizontal length and/or vertical height of thevent-airintake system. Table A lists the various vertical and horizontalvent-airintake system configurations.

14

Installation (Horizontal and Vertical Vent-AirIntake Lengths) continued-

The water heater is shipped with the following standard vent and air intake system: 239-41097-00.The components of this vent and air intake systems is as follows:

 

 

3” Vent Tube*

 

 

Vent Terminal Hardware

 

 

5” Air Intake Tube*

 

 

RTV Silicone Sealant

 

 

 

 

Vent Terminal

 

 

3” Vent Elbow

 

 

 

 

 

Inner Wall Term. Mounting Flange

5” Vent Elbow

 

ONLY

 

 

Outer Wall Term. Mounting Flange

REFERENCE

 

 

 

 

 

 

 

 

 

 

 

 

 

*The vent and air intake telescopes from 13 3/4" to 23 11/16”.

 

 

 

 

 

 

Table A

 

 

 

 

 

 

 

 

 

 

Horizontal "X"

 

 

 

 

 

 

 

13 1/4

15

 

22 1/4

 

36

58 5/16

 

 

 

 

14 3/16

17 11/16

 

32 3/16

 

55 7/8

104 5/16

 

 

 

 

order

order

FOR

 

 

order

order

 

 

 

 

10

kit A

kit B

 

kit req'd

 

kit C

kit D

 

 

 

 

 

 

 

 

 

 

 

14 3/4

*order

order

 

order

 

order

order

 

 

 

 

15 11/16

VERSION

 

kit A

kit A & C

kit A & D

 

 

 

kit A (2)

kit A & B

 

 

"Y"

 

16 1/2

order

*order

 

order

 

order

order

 

 

Vertical

 

19 3/16

kit A & B

kit B (2)

 

kit B

kit B & C

kit B & D

 

 

33 11/16

kit A

kit B

 

kit C

 

 

kit C (2)

kit D

 

 

 

23 3/4

order

order

 

order

 

*order

order

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INTERNET

order

 

*order

 

*order

order

 

 

 

37 1/2

order

 

 

 

 

 

57 3/8 kit A & C

kit C & B

 

kit C (2)

 

kit C (3)

kit C & D

 

 

 

59 13/16

order

order

 

order

 

order

*order

 

 

 

105 13/16

kit D & A

kit D & B

 

kit D

kit D & C

kit D (2)

 

* (2) = Order two of the kits referenced. * (3) = Order three of the kits referenced.

The bold text above show what kit(s) are needed in addition to the standard vent and air intake tubes. If the standard vent and air intake tubes are not used in the venting system (those that do not have bold text) they can be discarded or saved.

15

Installation (Horizontal and Vertical Vent-AirIntake Lengths) continued-

 

 

REFERENCE

ONLY

 

FOR

 

 

 

 

 

VERSION

 

 

INTERNET

Figure 6

 

 

 

 

 

16

Installation continued-

VENT-AIRINTAKE SYSTEM INSTALLATION

WARNING

The vent-airintake system must be properly installed. Failure to properly install thevent-airintake system could result in property damage, personal injury or death.

Do not install any damaged vent-airintake system components.

 

Contact the manufacturer of the water heater for replacement parts.

 

 

ONLY

 

 

 

 

IMPORTANT

 

When the following instructions specify, to seal a vent-airintake joint,

 

use only Loctite Ultra Blue 587 RTV Silicone sealant. A tube of Loctite

 

Ultra Blue 587 RTV Silicone sealant is supplied with every direct vent

 

water heater and each optional vent-airintake kit. Make sure that all

 

joints are completely sealed.

 

 

When drilling pilot holes for the #8 sheet REFERENCEmetal screws through the

 

five (5) inch (12.7 cm) diameter components, be careful not to drill into

 

the inner three (3) inch (7.6 cm) diameter components.

 

 

FOR

 

Tools Required For Vent-AirIntake Installation

 

VERSION

 

 

The following minimum tools are required to properly install the vent-

 

air intake system. Note: Wall construction will determine tool usage.

 

Tape Measure

Drill

 

3/16 inch Diameter Drill Bit(s)

1/8 inch Diameter Drill Bit(s)

Masonry Drill Bit(s) (For Poured Concrete, Concrete Block and Brick Wall

Construction)

Reciprocating Saw w/appropriate Blade(s) (Dependent on Wall

INTERNET

Construction)

Chisel

(For Poured Concrete, Concrete Block and Brick Wall Construction)

Hammer (For Poured Concrete, Concrete Block and Brick Wall Construction)

1/4 & 5/16 inch Nut Drivers (Preferred) or Slotted Head Screwdriver

Phillips Head Screwdriver

17

Installation (Vent-AirIntake System Installation) continued-

1. Measure the vertical height “Y” required in your installation. (See Figure 6). Reference the appropriate Table A to determine number of vent-airintake kits required in your installation.

2. Measure the horizontal length “X” required in your installation (See Figure 6). Reference Table A to determine number of vent-airintake kits required in your installation.

 

 

ONLY

3. Cut a 5-1/2inch(14 cm) diameter minimum clearance hole in the wall at

the point where the vent-airintake tubes will pass through the outside wall

and connect with the direct vent-airintake terminal

 

(See Figure 6).

REFERENCE

 

 

 

4. From outside the building, position the outer wall mount plate and direct vent-airintake terminal over the center of the opening. Mark the mounting screw hole locations. With a 3/16 inch diameter drill bit (not supplied), drill holes for the wall anchors (supplied). Install the wall anchors butDO NOT affix the outer wall mount plate and directvent-airintake terminal to the wall at this time (See Figure 7). Note: Certain construction of walls may

 

 

FOR

require the use of a different type of wall anchoring means than supplied.

DO NOT modify the directvent-airintake terminal or outer wall mount

plate.

 

 

INTERNET

VERSION

 

 

 

Figure 7

 

 

18

Installation (Vent-AirIntake System Installation) continued-

IMPORTANT

The following instructions detail the installation of the standard horizontal vent-airintake kit supplied with the water heater.

5. Insert the straight end of the three (3) inch (7.6 cm) diameter elbow into

the flue reducer until firmly seated and oriented in the correct direction.

 

 

 

 

ONLY

With a 1/8 inch diameter drill bit (not supplied), drill three (3) holes, 120o

apart, through the flue reducer into the three (3) inch (7.6 cm) diameter

elbow. Fasten with three (3) #8 sheet metal screws (supplied). Using the

 

 

 

REFERENCE

 

supplied special RTV silicone sealant, apply a sufficient amount to seal

the joint (See Figure 8).

 

 

 

 

VERSION

FOR

 

 

INTERNET

 

 

 

Figure 8

 

 

6.Place the straight end of the five (5) inch (12.7 cm) diameter elbow over the three (3) inch(7.6 cm) diameter elbow and plenum collar until seated on top of the plenum box. Make certain that the five (5) inch(12.7 cm) diameter elbow is oriented in the same direction as the three (3) inch(7.6

cm) diameter elbow and both are oriented in the correct direction. Drill three (3) 1/8 inch diameter holes, 120o apart, through the five (5) inch (12.7 cm)diameter elbow into the plenum collar. Fasten with three (3) #8 sheet metal screws (supplied) (See Figure 9).

19

Installation (Vent-AirIntake System Installation) continued-

 

REFERENCE

ONLY

FOR

 

 

 

VERSION

 

 

Figure 9

 

 

7. Extend the three (3) inch (7.6 cm) diameter telescopic tube to its maximum length and slide the backing plate over it. Place the large end of the three (3) inch(7.6 cm) diameter telescopic tube through the hole in the

outside wall. Insert the smaller end of the three (3) inch diameter (7.6 cm) INTERNETtelescopic tube into the flared end of the three (3) inch(7.6 cm) diameter

elbow, one (1) inch (2.5 cm) (or until seated). Drill three (3) 1/8 inch diameter holes, 120o apart, through the three (3) inch(7.6 cm) diameter elbow into the three (3) inch(7.6 cm) diameter telescopic tube. Fasten with three (3) #8 sheet metal screws (supplied). Adjust the overall length of the three (3) inch(7.6 cm) diameter telescopic tube so that2-1/2inches(6.4 cm) extends beyond the outside wall. Drill three (3) 1/8 inch diameter holes, 120o apart, through the three (3) inch(7.6 cm) diameter telescopic tubes where the small and large sections overlap. Fasten with three (3) #8 sheet metal screws (supplied). Using the supplied special RTV silicone sealant, apply a sufficient amount to seal the joints (See Figure 10).

20

Installation (Vent-AirIntake System Installation) continued-

 

 

REFERENCE

ONLY

 

 

 

Figure 10

 

 

FOR

 

 

8. Extend the five (5) inch (12.7 cm) diameter telescopic tube to its maximum

length. Place the large end of the five (5) inch (12.7 cm) diameter

VERSION

 

 

 

telescopic tube over the collar on the outer wall mount plate. Drill three (3)

1/8 inch diameter holes, 120o apart, through the five (5) inch(12.7 cm)

diameter telescopic tube into the collar on the outer wall mount plate.

Fasten with three (3) #8 sheet metal screws (supplied). Using the

supplied special RTV silicone sealant, apply a sufficient amount to seal

the joint (See Figure 11).

 

 

 

INTERNET

 

 

 

Figure 11

 

 

 

21

Installation (Vent-AirIntake System Installation) continued-

9.From outside the building, slide the five (5) inch (12.7 cm) diameter telescopic tube through the opening in the wall until the outer wall mount plate is flush with the wall (See Figure 12).

 

 

REFERENCE

ONLY

 

FOR

 

 

 

 

 

VERSION

 

 

INTERNET

Figure 12

 

 

 

 

10. Using the supplied special RTV silicone sealant, apply a bead one (1) inch (2.5 cm) from the end of the three (3) inch(7.6 cm) diameter tube that is part of thevent-airintake terminal. Slide the directvent-airintake terminal into the three (3) inch(7.6 cm) diameter telescopic tube that extends through the wall and position it so it is flush with the outer wall mount plate. Make sure that the rain guard and the word “HOT” on the end of the directvent-airintake terminal are oriented properly. Secure the directvent-airintake terminal to the outer wall mount plate and wall with four (4) #10 x 1 inch screws (supplied) (See Figure 13). Note: Certain construction of walls may require the use of different type of anchoring means than supplied.DO NOT modify the directvent-airintake terminal or outer wall mount plate.

22

Installation (Vent-AirIntake System Installation) continued-

REFERENCE

ONLY

 

Figure 13

 

11. From inside the building, slide the backing plate over the five (5) inch (12.7 cm) diameter telescopic tubeFORuntil it is flush with the wall. Adjust the length of the five (5) inch(12.7 cm) diameter telescopic tube and insert the end into the flared end of the five (5) inch(12.7 cm) diameter

elbow into the five (5) inch (12.7 cm) diameter telescopic tube and through the tubes where the small and large sections overlap. Fasten with three (3) #8 sheet metal screws (supplied). Using the supplied

elbow one (1) inchVERSION(2.5 cm) (or until seated). Drill three (3) 1/8 inch diameter holes, 120o apart, through the five (5) inch(12.7 cm) diameter

special RTV silicone sealant, apply a sufficient amount to seal all joints INTERN(See FigureET14).

Figure 14

23

Installation (Vent-AirIntake System Installation) continued-

12.Mark the mounting screw hole locations for the backing plate. Rotate the backing plate in order to gain access to the markings. With a 3/16 inch diameter drill bit (not supplied), drill holes for the supplied wall anchors.

Install the wall anchors and secure the backing plate to the wall with four (4) #10 x 1 inch screws (supplied) (See Figure 15). Note: Certain construction of walls may require the use of a different type of anchoring means than supplied.

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

WhenINTERNETthe installation is complete, visually inspect the air intake

Figure 15

 

IMPORTANT

 

system to insure that all joints are completely sealed.

 

24

Installation continued-

WATER CONNECTIONS

Note: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE.

After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved,

outlet are dielectric waterway fittings with 3/4” NPT male thread. MakeONLYthe proper plumbing connections between the water heater and the plumbing system to the house. Install ashut-offvalve in the cold water supply line.

close the faucet. The COLD water inlet and HOT water outlet are identified on

the top of the water heater. The fittings at the cold water inlet and hot water

CAUTION

If sweat fittings are to be used, DO NOT apply heat to the nipples on top of the water heater. Sweat the tubing to the adapter before fitting the adapter

to the water connections. It is imperative that heat is not applied to the

nipples containing a plastic liner.

FOR

REFERENCE

 

 

 

VERSION

 

 

INTERNET

 

 

25

WARNING

For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22 and the StandardCAN1-4.4 Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves. The combination temperature and pressure relief valve shall be marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The hourly

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater.

BTU discharge capacity or the rated steam relief capacity of the

ONLY

 

 

combination temperature and pressure relief valve shall not be less than

the input rating of the water heater.

REFERENCE

 

 

 

Note: Some models may already be equipped or supplied with a combination temperature and pressure relief valve. Verify that the combination temperature and pressure relief valve complies with local codes. If the combination temperatureFORand pressure relief valve does not comply with local codes, replace it with one that does. Follow the

installation instructions above on this page.

combination temperature and pressure relief valve. DO NOT allow water from the discharge line to contact any live electrical part. The discharge line is to be installed to allow for complete drainage of both the

Install a discharge VERSIONline which terminates six (6) inches(15 cm) above the floor, or any distance below the structural floor, to the outlet of the

WATER HEATER.” The discharge opening must not be subjected to blockage or freezing. DO NOT thread, plug or cap the discharge line.

combination temperature and pressure relief valve and the discharge line. TheINTERNETwater from the discharge line must be directed to a suitable drain or area that will not be damaged by water (Refer to page 6 “LOCATING THE

It is recommended that a minimum clearance of four (4) inches (10.2 cm) be provided on the side of the water heater for servicing and maintenance of the combination temperature and pressure relief valve.

Do not place a shutoff valve between the combination temperature and pressure relief valve and the water heater, or on discharge pipes between such valves or the atmosphere.

26

Installation (Water Connections) continued-

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X 3/4” TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM EXCESSIVE TEMPERATURES AND PRESSURES.

If this water heater is installed in a closed water supply system, suchONLYas the

one having a back-flowpreventer in the cold water supply, provisions shall be made to control thermal expansion.DO NOT operate

this water heater in a closed system without provisions for controlling thermal expansion. Your water supplier or local plumbingREFERENCEinspector should be contacted on how to control this situation

After installation of the water lines, open the main water supply valve and fill the water heater. While the water heater is filling, open several hot water faucets to allow air to escape from the water system. When a steady stream of water flows through the faucets, close them and check all water connections for possible leaks. NEVER OPERATE THE WATER HEATER WITHOUT

FIRST BEING CERTAIN IT IS FILLEDFORWITH WATER.

Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these

VERSIONWARNING

conditions,INTERNETwe recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical

appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipes as hot water begins to flow. Do not smoke or have open flame near the faucet at the time it is open.

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothing washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install an ASSE approved mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold

27

Installation (Water Connections) continued-

and hot water in branch supply lines. Such valves are available from the manufacturer of this water heater or a local plumbing supplier. Please consult with a plumbing professional.

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

INTERNET

 

 

 

 

28

 

 

GAS CONNECTIONS

The gas supply lines must meet all requirements of the National Fuel Gas Code, ANSI Z223.1 - (Latest Edition) and/or in Canada,CAN/CGA B149 Installation Codes - (Latest Editions).

The minimum permissible gas supply pressure for the purpose of input adjustment is one (1.0) inch (.25kPa) water column above the operating manifold pressure. See the rating plate and combination gas control for the

manifold pressure and gas type. The maximum permissible gas supply pressure is fourteen (14.0) inches (3.5kPa) water column for natural gas and liquefied petroleum gases/propane gas.

 

 

 

ONLY

1. Connect this water heater only to the type of gas (natural or propane

gas) as shown on the rating plate. Use clean 1/2 inch black iron

pipe. (Dirt and scale from the pipe can enter the combination control and

cause it to malfunction). The inlet gas line must have a drip leg (sediment

trap) installed as close as possible to the water heater’s combination gas

control having a minimum length of three (3) inches (7.6 cm). A ground

joint union must be installed in the gas supply line feeding the water heater

to permit servicing of the water heater. Compounds used on the threaded

 

 

REFERENCE

 

joints of the gas piping must be resistant to the action of liquefied

petroleum gases/propane gas.

FOR

 

 

 

 

 

2. This water heater and its gas connection must be leak tested before

placing the water heater in operation. Check for gas leaks with a

soap and water solution and a brush or a commercial leak detector

fluid. NEVER USE A MATCH OR OPEN FLAME FOR TESTING!

VERSIONCAUTION

 

The water heater and its individual shutoff valve must be disconnected from

the gas supply piping system during any pressure testing of the system at

test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be

isolated from the gas supply piping system by closing its manual shutoff

valve during any pressure testing of the gas supply system at test

pressures equal to or less than 1/2 psi (3.5 kPa). The supply line must be

INTERNET

 

 

 

capped when not connected to the water heater.

 

29

GENERAL OPERATION

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-airintake system. Use proper care to avoid unnecessary contact (especially by children) with the water heater andvent-airintake system.UNDER NO

CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS

 

 

 

 

ONLY

 

GASOLINE OR PAINT THINNER BE USED OR STORED IN THE

 

VICINITY OF THIS WATER HEATER, VENT-AIRINTAKE SYSTEM OR

 

IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER

 

HEATER OR VENT-AIRINTAKE SYSTEM.

 

 

 

 

 

 

 

TO FILL THE WATER HEATER

 

REFERENCE

 

 

 

 

1.

Close the water heater drain valve by turning the knob clockwise.

2.

Open the cold water supply shut-offvalve.

 

3.

Open several hot water faucets to allow air to escape from the system.

4.

When a steady stream of water flows from the faucets, the water heater is

 

filled. Close the faucets and check for water leaks at the water heater

 

 

FOR

 

 

 

drain valve, combination temperature and pressure relief valve and the hot

 

and cold water connections.

 

 

 

 

VERSION

 

 

 

TO DRAIN THE WATER HEATER

 

 

 

Should it become necessary to completely drain the water heater, make sure you follow the steps below:

1.Rotate the thermostat dial clockwise to the “PILOT LIGHTING” position.

2.Rotate and partially depress gas control knob clockwise to the “OFF” position.

3.Shut off the gas supply to the water heater.

4.Close the cold water supply shut-offvalve.

5.Open the drain valve on the water heater by turning the knob counterclockwise. The drain valve has threads on the end that will allow the connection of a standard hose coupling.

6.Open a hot water faucet to allow air to enter the system.INTERNET

To refill the water heater, refer to “To Fill the Water Heater.”

30

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

INTERNET

 

 

 

31

General Operation continued-

THERMOSTAT ADJUSTMENT

The thermostat dial is set to its lowest temperature setting when shipped from the factory. Remember that lower temperature settings are more energy efficient. Adjust the temperature by turning the thermostat dial. It is suggested that the starting point setting not be greater than the “” mark on the thermostat dial (approximately 120°F [49°C]) as indicated below. Rotate

the thermostat dial clockwise

 

ONLY

to increase the temperature setting.

Rotate the thermostat dial counterclockwise

to decrease the

temperature setting. Adjust the dial until the minimum acceptable temperature is achieved (See figure below for approximate temperature settings).

FOR

REFERENCE

 

VERSIONFigure 16

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within five (5) seconds at a temperature setting of 135° F(57° C). To protect

against hot water injury, install an ASSE approved mixing valve in the

professional or local plumbing authority should be consulted.

waterINTERNETsystem. This valve will reduce point of discharge temperature by mixing cold and hot water in branch water lines. A licensed plumbing

Note: This water heater is equipped with an energy cut out device to prevent overheating. Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance and call a qualified service technician.

Note: Whenever the water heater is filled with cold water, condensate will form on the cool tank surface and drops of water will fall on the hot burner and combustion chamber surfaces producing a “sizzling” noise.

Condensation is normal and does not indicate a leak. It will disappear when the tank becomes heated.

32

General Operation continued-

BURNER FLAME CHECKS

At the time of installation and at periodic intervals (not more than six (6) months), a visual check of the pilot and main burner flames should be conducted. The flames should be similar to those pictured below. The main burner should light smoothly from the pilot. (See Figure 17).

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

INTERNET

 

 

 

Figure 17

33

MAINTENANCE

WARNING

Water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the water heater or vent-airintake system.

Use proper care to avoid unnecessary contact (especially by children) with

the water heater and vent-airintake system.UNDER NO

 

CIRCUMSTANCES MUST FLAMMABLE MATERIALS, SUCH AS

GASOLINE OR PAINT THINNER BE USED OR STORED IN THE

 

ONLY

VICINITY OF THIS WATER HEATER, VENT-AIRINTAKE SYSTEM OR

IN ANY LOCATION FROM WHICH FUMES COULD REACH THE WATER

HEATER OR VENT-AIRINTAKE SYSTEM.

 

 

 

 

 

REFERENCE

 

IMPORTANT

 

The water heater should be inspected at a minimum annually by a qualified service technician for damaged components and/or joints not sealed. DO NOT operate this water heater if any part is found damaged or if any joint is found not sealed.

The following maintenance should be FORperformed by a qualified service technician at the minimum periodic intervals suggested below. In some installations the maintenanceVERSIONinterval may be more frequent depending on upon the amount of use and the operating conditions of the water heater. Regular inspection and maintenance of the water heater andvent-airintake system will help to insure safe and reliable operation.

1. Annually check the operation of the thermostat.

2. INTERNEThe flow of combustion and ventilation airMUST NOT be restricted. Annually inspect the directvent-airintake terminal to insure it is not

blocked or damaged. Clear the direct vent-airintake terminal openings of any dirt, dust, or other restrictions.WARNING! Certain areas of the directvent-airintake terminal areHOT.

3.Annually inspect the vent-airintake system to insure that all components are securely fastened and all joints and seams are properly sealed.

4.At all times keep the water heater area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

5.Bi-annuallyconduct a visual check of the main and pilot burner flames to determine that they are burning properly. See information on page 33 “BURNER FLAME CHECKS.”

34

Maintenance continued-

6. Annually remove the inner door and main burner assembly to clean orifices and related parts of any dirt or other foreign material. Inspect the burner ports for obstructions or debris and clean with a wire brush as needed. Wire brush and/or vacuum clean the combustion chamber as needed to remove scale deposits and debris. Inspect the inner door gasket for wear and tear and replace if necessary. NOTE: It is imperative for proper operation of the water heater that the inner door be properly sealed.

 

 

ONLY

7. At least once a year, check the combination temperature and pressure

relief valve to insure that the valve has not become encrusted with lime.

Lift the lever at the lever at the top of the valve several times until the valve

seats properly without leaking and operates freely.

 

 

REFERENCE

 

 

WARNING

 

When lifting lever of the combination temperature and pressure

relief valve, hot water will be released under pressure. Be careful

that any released water does not result in bodily injury or property

damage.

 

 

8.Monthly, drain off a gallon of water to remove silt and sediment by using the water heater’s drain valve. FOR

WARNING! THIS WATER MAY BE HOT.

9.If the combination temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the combination temperature and pressure relief valve outlet.

10.A combination sacrificial anode rod/hot water outlet nipple has been installed to extend tank life. The anode rod should be inspected periodically (every two years) and replaced when necessary to prolong tank life. Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode replacement information. The use of a water softener may increase the speed of anode

consumption. More frequent inspection of the anode is needed when using softened (or phosphate treated) water.VERSION

Maintenance (continued)-

35

CAUTION

FOR YOUR SAFETY. DO NOT ATTEMPT REPAIR OF COMBINATION GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN.

Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on the rating plate of the water heater.

 

 

ONLY

Provide the part name, model and serial numbers of the water heater when

ordering parts.

REFERENCE

 

 

 

READ THE WARRANTY FOR A FULL EXPLANATION OF THE L NGTH OF TIME THAT PARTS AND THE WATER HEATER ARE WARRANTED.

Manufactured under one or more of the following U.S. Patents: 4,416,222; 4,628,184; 4,669,448; 4,672,919; 4,808,356; 4,829,983; 4,861,968; 4,867,106; 4,904,428; 5,000,893; 5,023,031; 5,052,346; 5,081,696; 5,092,519; 5,115,767; 5,199,385; 5,277,171; 5,341,770; 5,372,185; 5,485,879; 5,574,822; 5,596,952; 5,660,165; 5,682,666;

 

 

 

 

 

 

FOR

 

5,943,984. Other U.S. and Foreign patent applications pending. Current

 

Canadian Patents: 1,272,914; 1,280,043; 1,289,832; 2,045,862;

 

2,107,012; 2,108,186; 2,112,515.

 

 

 

 

 

 

 

 

 

 

VERSION

 

 

 

 

 

 

Complete the following information and retain for future reference:

 

Model No:

 

 

 

 

 

 

 

 

INTERNET

 

 

 

 

 

 

 

 

Serial No :

 

 

 

 

 

 

 

 

Installation Date:

 

 

 

 

 

 

 

 

Service Phone No.

 

 

 

 

 

 

 

 

 

Days:

 

 

Nights:

 

Address:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Supplier:

 

 

 

 

 

 

 

 

 

Supplier’s Phone No:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PART NAME & DESCRIPTION

36

1.

Direct Vent-AirIntake Terminal

21.

 

Piezo Ignitor Assembly

2.

Outer Wall Mount Plate

 

22.

 

Drain Valve

 

3.

Backing Plate

 

23.

 

Outer Door

 

4.

Five (5) inch (12.7 cm)

 

24.

 

Jacket

 

 

Diameter Telescopic Air Intake

 

 

 

 

 

Tube

 

 

 

 

 

5.

Three (3) inch (7.6 cm)

 

25.

 

Inner Door Assembly

 

Diameter Telescopic Vent

 

 

 

 

 

 

Tube

 

 

 

 

 

6.

Five (5) inch (12.7 cm)

 

26.

 

Air Intake Boot

ONLY

 

 

 

 

Diameter Elbow

 

 

 

 

 

7.

Three (3) inch (7.6 cm)

 

27.

 

Air Intake Boot Gasket

 

Diameter Elbow

 

 

 

 

 

8.

Plenum

 

28.

 

REFERENCE

 

 

 

Pilot Assembly w/Electrode

9.

Plenum Gasket

 

29.

 

Gas Feed Line (Burner)

10.

Flue Reducer

 

30.

 

Main Burner Orifice

11.

Jacket Top

 

31A.

42 Port Steel Burner

12.

Insulation

 

31B.

65 Port Cast Iron Burner

 

 

 

 

 

(Certain Models)

 

13.

Glass Lined Tank

 

32.

 

Radiation Shield

 

14.

Flue Baffle Assembly

 

33A.

Direct Vent-AirIntake Kit A

 

 

FOR

 

(Optional)

 

 

 

 

 

 

 

15.

Dip Tube & Nipple

 

33B.

Direct Vent-AirIntake Kit B

 

VERSION

 

 

 

(Optional)

 

 

 

 

 

 

 

16.

Anode Rod & Nipple

 

33C.

Direct Vent-AirIntake Kit C

 

 

 

 

 

(Supplied & Optional)

17.

Temperature-PressureRelief

 

33D.

Direct Vent-AirIntake Kit D

 

Valve (Certain Models)

 

 

 

(Optional)

 

18.

Air Intake Tube

 

33E.

Direct Vent-AirIntake Kit E

 

INTERNET

 

 

 

(Optional)

 

 

 

 

 

 

 

19.

Combustion Chamber

 

34.

 

Loctite Ultra Blue 587 RTV

 

Assembly

 

 

 

Silicone Sealant

 

20.

Combination Gas Control

 

35.

 

Direct Vent-AirIntake Terminal

 

w/E.C.O.

 

 

 

Guard (Optional)

 

Note: Provide the part name, model and serial numbers of the water heater when ordering parts.

THIS MANUAL SHOULD BE KEPT WITH THE WATER HEATER

37

DIRECT VENT WATER HEATER

INTERNET

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

38

VENT-AIRINTAKE KITS

 

 

REFERENCE

ONLY

 

FOR

 

VERSION

 

 

 

 

 

INTERNET

 

 

 

 

39

 

 

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:

GAS WATER HEATERS

SUITABLE FOR WATER (POTABLE) HEATING AND SPACE

HEATING

1. All piping components connected to this water heater for space heating applications must be suitable for use with potable water. In Massachusetts, space heating piping must not exceed 50 feet.

 

 

 

ONLY

2. Toxic chemicals, such as those used for boiler treatment, must not

be introduced into potable water used for space heating;

 

3. This water heater must not be connected to an existing heating system

 

 

REFERENCE

 

or component(s) previously used with a non-potablewater heating

appliance;

 

 

 

4. When the system requires water for space heating at temperatures higher

than required for other means, such as an ASSE approved mixing valve

must be installed to temper the water for those uses in order to reduce the

scald hazard potential.

FOR

 

 

 

 

 

Please refer to the illustration for suggested piping arrangements.

VERSION

 

 

 

INTERNET

 

 

 

40