American Water Heater Power Flex 50-60K BTU, Power Flex 40-42K BTU User Manual

Flammable Vapor Ignition Resistant Compliant

Power Direct Vent
Gas Water Heater

Installation

Instructions and

Use & Care Guide

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 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.

To obtain technical, warranty, or service assistance during or
after the installation of this water heater, visit our website at:

http://www.americanwaterheater.com

or call toll free

1-800-456-9805

When calling for assistance, please have the
following information ready:

1. Model number

2. 7 digit product number

3. Serial number

4. Date of installation

5. Place of purchase

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLER:

• AFFIX THESE INSTRUCTIONS TO OR ADJACENT
TO THE WATER HEATER.

OWNER:

• RETAIN THESE INSTRUCTIONS AND WARRANTY
FOR FUTURE REFERENCE. RETAIN THE
ORIGINAL RECEIPT AS PROOF OF PURCHASE.

6510418

September 2007

1

WATER HEATER SAFETY

This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.

DANGER indicates an imminently hazardous

DANGER

WARNING

CAUTION

CAUTION

• Do not use this appliance if any part has been under water. Immediately call a qualified service technician. Water
heaters subjected to flood conditions or any time the gas controls, main burner or pilot have been submerged in
water require replacement of the entire water heater.

• Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.

situation which, if not avoided, could result
in death or injury.

WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.

CAUTION indicates a potentially hazardous
situation which, if not avoided, may result
in minor or moderate injury.

CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.

Important Instructions

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.

WARNING: 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 included in the Act.

Table Of Contents

Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installing Your Gas Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Unpacking the Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vent Pipe System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Inlet/Outlet Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operating Your Water Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17

Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operational Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance of Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . 18-20

Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Repair Parts Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24

PAGE

2

INSTALLING YOUR GAS WATER HEATER

Consumer Information

This water heater is design-certified by CSA International
as a Category I, direct vented water heater which takes
its combustion air from the outside of the structure and
exhausts all products of combustion to the outside of the
structure.

This water heater must be installed according to all local
and state codes or, in the absence of local and state
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition.

CSA America, Inc.
8501 Pleasant Valley Road
Cleveland, OH 44131

National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169-7471

Check your phone listings for the local authorities
having jurisdiction over your installation.

Consumer Responsibilities

This manual has been prepared to acquaint you with the
installation, operation, and maintenance of your gas water
heater and provide important safety information in these
areas.

Read all of the instructions thoroughly before attempting
the installation or operation of this water heater.

Do not discard this manual. You or future users of this
water heater will need it for future reference.

Service to the Power Direct Vent System should only be
performed by a qualified person.

If you lack the necessary skills required to properly install
this water heater, or you have difficulty following the
instructions, you should not proceed but have a qualified
person perform the installation of this water heater.

Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing and
Fuel Gas Code 248 CMR Section 2.00 and 5.00.

A data plate identifying your water heater can be found
next to the gas control valve/thermostat. When referring to
your water heater, always have the information listed on
the data plate readily available.

Retain your original receipt as proof of purchase.

IMPORTANT: Do not remove any permanent instructions,
labels, or the data label from either the outside of the water
heater or on the inside of water heater panels.

Unpacking the Water Heater

WARNING

Excessive Weight Hazard

Use two or more people to move and install
water heater.

Failure to do can result in back or
other injury.

• Remove exterior packaging and place installation com­ponents aside.

• Inspect all parts for damage prior to installation and
start-up.

• Completely read all instructions before attempting to
assemble and install this product.

• After installation, dispose of/recycle all packaging
materials.

3

WARNING

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Storage of or use of gasoline or other
flammable vapors or liquids in the vicinity
of this or any other appliance can result in
serious injury or death.

Read and follow water heater warnings and
instructions.

Flammable Vapors

Location Requirements

WARNING

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home.

Doing so can result in death or
carbon monoxide poisoning.

Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas
burning appliances in the vicinity must be shut off and their
pilot lights extinguished. Open the doors and windows for
ventilation while flammable substances are in use.

If flammable liquids or vapors have spilled or leaked in
the area of the water heater, leave the area immediately
and call the fire department from a neighbor’s home. Do
not attempt to clean the spill until all ignition sources have
been extinguished.

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.

Keep combustibles such as boxes, magazines, clothes,
etc. away from the water heater area.

Site Location

• Select a location near the center of the water piping
system. The water heater must be installed indoors
and in a vertical position on a level surface.

• Consider the inlet and exhaust vent system piping and
combustion air supply requirements when selecting
the water heater location. The venting system must
be able to run from the water heater to the termina­tion with a minimal length and number of elbows. The
venting system must comply with the requirements set
forth in the venting section of this manual.

• Locate the water heater near the existing gas
piping. If installing a new gas line, locate the water
heater to minimize the pipe length and elbows.

NOTE: This water heater must be installed according to all
local and state codes or, in the absence of local and state
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition.

4

CAUTION - PROPERTY DAMAGE HAZARD

The water heater should be located in an area where
leakage of the tank or connections will not result in
damage to the area adjacent to the water heater or to
lower floors of the structure. Due to the normal corrosive
action of the water, the tank will eventually leak after
an extended period of time. Also any external plumbing
leak, including those from improper installation, may
cause early failure of the tank due to corrosion if not
repaired. If the owner/operator is uncomfortable with
making the repair a qualified person should be contacted.
A suitable metal drain pan should be installed under
the water heater as shown below, to help protect the
property from damage which may occur from condensate
formation or leaks in the piping connections or tank.
The pan must limit the water level to a maximum depth
of 1-3/4” and be two inches wider than the heater and
piped to an adequate drain. NOTE: The pan must not
restrict combustion air flow. Locate the water heater
near a suitable indoor drain. Outside drains are subject
to freezing temperatures which can obstruct the drain
line. The piping should be at least 3/4” ID and pitched for
proper drainage.

Pipe to an
adequate drain

1-3/4”

max.

Clearances and Accessibility

FIGURE 1
Minimum Clearance
Locations

Back

Top View

Top to
ceiling

Sides

Sides

Front
24” min.
for service

Vent

NOTE: Minimum clearances from combustible materials
are stated on the data plate adjacent to the gas control
valve/thermostat of the water heater.
The water heater is certified for installation on a
combustible floor.

• IMPORTANT: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath
the water heater. The protective panel must extend
beyond the full width and depth of the water heater
by at least 3 inches (76.2mm) in any direction or if in
a alcove or closet installation, the entire floor must be
covered by the panel.

WARNING

Fire Hazard

At least 2” greater

than the water heater and the

inlet air pipe.

• The water heater should be located in an area not
subject to freezing temperatures. Water heaters
located in unconditioned spaces (i.e., attics,
basements, etc.) may require insulation of the
water piping and drain piping to protect against
freezing. The drain and controls must be easily
accessible for operation and service. Maintain

proper clearances as specified on the data plate.

For continued protection
against the risk of fire:

Do not install water heater
on carpeted floor.

Do not operate water heater
if flood damaged.

• Figure 1 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches of front clearance and 4 inches on each side
should be provided for inspection and service.

State of California

NOTE: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area or call
1-800-456-9805 and request instructions.

5

Gas Supply

WARNING

Explosion Hazard

Use a new CSA approved gas supply line.

Install a shut-off valve.

Figure 2
Gas Piping

Manual gas
shut-off valve

Install a readily acces­sible manual shut-off
valve in the gas supply
line as recommended
by the local utility.

Do not connect a natural gas water heater to
an L.P. gas supply.

Do not connect an L.P. gas water heater to a
natural gas supply.

Failure to follow these instructions can
result in death, explosion, or
carbon monoxide poisoning.

Gas Requirements

Read the data plate to be sure the water heater is made
for the type of gas you will be using in your home. This
information will be found on the data plate located near the
gas control valve/thermostat. If the information does not
agree with the type of gas available, do not install or light.
Call your dealer.

NOTE: An odorant is added by the gas supplier to the gas
used by this water heater. This odorant may fade over an
extended period of time. Do not depend upon this odorant
as an indication of leaking gas.

Gas Piping

The gas piping must be installed according to all local and
state codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current
edition.

Tables 1 and 2 on the following page provide a sizing
reference for commonly used gas pipe materials. Consult
the “National Fuel Gas Code” for the recommended gas
pipe size of other materials.

Refer to Figure 2
NOTE: When installing gas piping, apply approved pipe
joint compound.

1. Install a readily accessible manual shut-off valve in
the gas supply line as recommended by the local utility.
Know the location of this valve and how to turn off the
gas to this unit.

2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no
less than three inches long for the accumulation of dirt,
foreign material, and water droplets.

3. Install a ground joint union between the gas control
valve/thermostat and the manual shut-off valve. This is to
allow easy removal of the gas control valve/thermostat.

4. Turn the gas supply on and check for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show a leak. Correct
any leak found.

Gas Pressure

IMPORTANT: The gas supply pressure must not exceed
the maximum supply pressure as stated on the water
heater’s data plate. The minimum supply pressure is for

the purpose of input adjustment.

Gas Pressure Testing

IMPORTANT: This water heater and its gas connection
must be leak tested before placing the appliance in
operation.

• If the code requires the gas lines to be tested at a
pressure exceeding 14” W.C., the water heater and
its manual shut-off valve must be disconnected from
the gas supply piping system and the line capped.

• If the gas lines are to be tested at a pressure less
than 14” W.C., the water heater must be isolated
from the gas supply piping system by closing its
manual shut-off valve.

U.L. recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and should
be installed using the manufacturer’s instructions and local
codes, rules, or regulations.

NOTE: Air may be present in the gas lines and could
prevent the burner from lighting on initial start-up. The gas
lines should be purged of air by a qualified person after

installation of the gas piping system.

L.P. Gas Only

WARNING

Explosion Hazard

Have a qualified person make sure L.P. gas
pressure does not exceed 13” water column.

Examples of a qualified person include:
licensed plumbers, authorized gas company
personnel, and authorized service
personnel.

Failure to do so can result in death,
explosion, or fire.

6

VENT PIPE SYSTEM

WARNING

Carbon Monoxide Warning

Follow all the local and state codes or, in
the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1
(NFPA 54)- latest edition to properly install
vent system.

Failure to do so can result in death,
explosion, or carbon monoxide poisoning.

Venting

This water heater has a direct vent system in which all air
for combustion is taken from the outside atmosphere and
all combustion products are discharged to the outdoors.

This water heater must be properly vented for removal
of exhaust gases to the outside atmosphere. Correct
installation of the vent pipe system is mandatory for the
safe and efficient operation of this water heater and is an
important factor in the life of the unit.

Vent pipe installation must be performed in accordance
with state and local codes, or in the absence of such, the
National Fuel Gas Code, NFPA 54, ANSI Z223.1-current
edition. IMPORTANT: Check to make sure the vent pipe is
not blocked in any way.

NOTE: Do not common vent this water heater with any
other appliance. Do not install in the same chase or

chimney with a metal or high-temperature plastic from
another gas or fuel burning appliance.

When assembling the air inlet and vent outlet pipe system,
BOTH pipe diameters MUST be the same size. For
example, if a 2 inch diameter pipe is used on the air inlet
pipe then a 2 inch diameter pipe MUST be used on the vent
outlet. This requirement also applies to 3 inch diameter

piping configurations.

Vent Pipe Material

The following plastic materials may be used for both the
combustion air inlet and exhaust outlet piping subject to
state and local codes:

• 2 or 3 inch Schedule 40 PVC or ABS

• 2 or 3 inch Schedule 40 or 80 CPVC

• DWV Pipe is acceptable
NOTE: Use only solid (not foam core) piping. Plastic pipe
and fittings are available through most plumbing suppliers.
Always check the marking on the pipe to make sure you

are using the correct material.

Vent Pipe Connection to Blower

A 3”x2” condensate drain coupler is supplied with every
40-42K BTU model to connect either 2” or 3” venting to the
blower. A 3” condensate drain coupler is supplied with every
50-60K BTU model to connect 3” venting to the blower.
IMPORTANT: These connections must be properly sealed
to prevent the leakage of the products of combustion into
the living area. If needed 3”x2” & 3” condensate drain
couplers are available through the Parts Department for new
installations or retrofits where condensate may run back to
the blower.

7

Vent Pipe Installation

The following guidelines should be followed when installing
the air inlet and exhaust outlet piping:

• Venting should be as direct as possible with a
minimum number of pipe fittings.

• Vent diameter must not be reduced unless
specifically noted in the installation instructions.

• Support all horizontal pipe runs every four feet
and all vertical pipe runs every six feet or
according to local codes.

• Vents run through unconditioned spaces where below
freezing temperatures are expected should be prop­erly insulated to prevent freezing. For horizontal runs,
wrap the vent pipe with self-regulating 3 or 5 watt heat
tape. The heat tape must be U.L. listed and installed
per the manufacturer’s instructions.

• Do not connect this venting system with an existing
vent or chimney.

• Do not common vent with the vent pipe of any other
water heater or appliance.

The combustion air inlet and exhaust outlet piping and
termination may be installed in one of the following type
terminations:

1. Standard Horizontal (2 Pipe)

2. Vertical (2 Pipe)

3. Concentric Vent - Through the Wall

All pipe, fittings, pipe cement, primers and procedures
must conform to American National Standard Institute and
American Society for Testing and Materials (ANSI/ASTM)
standards in the United States. This water heater has been
design certified by CSA International for use with the listed
plastic vent pipe material.

IMPORTANT: Do not use vent elbows in this vent pipe
installation (see figure 3 below).

Figure 3
Correct and Incorrect
Pipe Fittings

Mesh Metal

Rodent Screen

CORRECT FITTINGS

90° Medium

Sweep Elbow

45° Sweep

Elbow

INCORRECT FITTINGS

90° Long

Sweep Elbow

Note: It is important to select the proper pipe cement
for the type plastic pipe being used.

3. Assemble the parts quickly while the cement is still
wet. Twist the pipe 1/4 turn during insertion and hold
for 30 seconds.

Vent Pipe Length

Size the exhaust outlet and combustion air inlet pipes as
specified in Table 3 below. This table lists the maximum
allowable length in feet of the exhaust outlet and combus­tion air inlet pipes as related to the number of required
elbows and the termination. The specified maximum
lengths are for the separate inlet and exhaust pipe systems
and not the combined length of both systems. Minimum
pipe length is 3 feet with one elbow per side.

1. Determine termination type and pipe size.

2. Determine number of elbows in exhaust pipe (Do not
include elbows in the termination.) Corresponding
number indicates the maximum length of exhaust pipe.

3. Determine number of elbows in inlet pipe. (Do not
include elbows in the termination.) The corresponding
number indicates the maximum length of inlet pipe.

Table 3 - Maximum Allowable Length in Feet of Exhaust and

Pipe

Size

(in)

2 40 35 30 25 20 15 10 Std. Horizontal

2 40 35 30 25 20 15 10 Vertical

3 120 115 110 105 100 95 90 Std. Horizontal

3 115 110 105 100 95 90 85 Vertical

Table 4 - Maximum Allowable Length in Feet of Exhaust and

Pipe

Size

(in)

2 N/A Std. Horizontal

2 N/A Vertical

3 45 40 35 30 25 20 15 Std. Horizontal

3 55 50 45 40 35 30 25 Vertical

NOTE:s:

1. N/A - Not Applicable

2. The above maximum lengths are for outlet pipe systems.

3. Maximum of 6 elbows may be used. Use only medium or long
sweep elbows. See figure 8 for details.

4. Two 45° elbows are considered equivalent to one 90° elbow.

5. Minimum length is 3 foot with 1 elbow.

6. Use schedule 40 or 80 CPVC, 40 ABS, or 40 PVC pipe and fittings.

Inlet Air Pipe - (42K BTU/Hr models only)

Number of 90° Elbows (medium or long sweep only)

0123456

Inlet Air Pipe - (50K/60K BTU/Hr models only)

Number of 90° Elbows (medium or long sweep only)

0123456

Termination

Options

Termination

Options

Tee Connector

45° Vent

Elbow

90° Vent

Elbow

All joints in the inlet and outlet piping must be properly
cemented. Size and cut all piping before cementing.

1. Cut the pipe end square and remove all ragged edges
and burrs. Make sure the inside of the pipe is clean
and free of cuttings and loose dirt. Chamfer the end
and apply primer to the fitting and pipe.

2. Using a suitable grade of pipe cement, apply a moder­ate, even coat inside the fitting. Apply a liberal amount
of cement to the outside of the pipe to socket depth.

8

Vent Termination Locations

The air inlet and exhaust outlet must be installed with
the following minimum clearances (see figure 4):

• Twelve inches above grade or maximum
anticipated snow level.

• Twelve inch minimum clearance on top or four foot
clearance below or to the side of door or
window that may be open.

• Four feet horizontally and vertically from gas
or electric meters, gas regulators, dryer vents,
vent hoods, bathroom fan exhaust, attic fans
and turbines.

• Two feet from an inside corner formed by two
exterior walls.

• Two feet from porches, decks, overhangs and
other obstructions.

Figure 4
Minimum Termination Clearance for
Outlet Vent

In addition to maintaining the minimum clearances , the
vent should terminate according to the following guidelines:

1. Use only a 3” concentric vent on the vent termination.
Do not expose any 3” X 2” reducers or bushings to
outdoor ambient temperatures.

2. The air inlet and exhaust outlet must not terminate
under a patio, deck or any covered area.

3. Do not terminate the vent near walkways or into
alleys or other publicly accessible areas.

4. Do not terminate the vent in an area where
children or animals could block pipes.

5. Do not locate the vent terminal too close to shrubs or
bushes.

6. Caulk all cracks, seams and joints within 6 feet
horizontally above and below the vent.

US Installations
A. 12 in (30 cm) min. clearance above grade,

veranda, porch, deck, balcony, or maximum
anticipated snow level.

B. 12 in. (30 cm) min. clearance on top or 4 ft.

clearance below or to the side of door or window
that may be open.

C. Clearance to permanently closed window.**
D. 12 in (30 cm) min. vertical clearance to ventilated

soffit located above the terminal within a horizontal
distance of 2 ft (61 cm) from the center line of the
terminal.

E. 12 in (30 cm) min. clearance to unventilated soffit.

**Clearance in accordance with local installation codes and the requirements of the gas supplier.

**Clearance in accordance with local installation codes and the requirements of the gas supplier.

F. Clearance to outside corner. **
G. 2 ft (61 cm) clearance to inside corner formed by two

exterior walls.

H. 4 ft (122 cm) clearance to each side of center line

extending above meter/regulator assembly.

I. 4 ft (122 cm) clearance to service regulator vent outlet.
J. 12 in (30 cm) clearance on top or 4 ft (122 cm) clear-

ance below or to the side of nonmechanical air supply
inlet to building or the combustion air inlet to any other
appliance.

K. 3 ft (91 cm) above if within 10 ft (3 m) horizontally of

mechanical air supply inlet.

9

INLET/OUTLET VENT TERMINATIONS

Standard Horizontal Termination

The standard horizontal air inlet termination is a 2 inch
or 3 inch pipe which terminates at the exterior wall and
utilizes a coupling to prevent the pipe from being pushed
back into the structure. The standard horizontal exhaust
outlet termination is a 2 inch or 3 inch pipe which termi­nates 12 inches from the outside wall (see figure 5). The
air inlet must be located with respect to the exhaust outlet
as shown in figure 5. To prevent potential condensate from
collecting in the venting system slope the vent at a down­ward pitch of 1/8” per 5ft. away from the water heater.

Install the correct size coupling at the outside wall on both
the inlet and exhaust to prevent the terminations from
being pushed inward.

NOTE: A rodent screen is available through the Parts
Department for installations where animals may be able to
access the vent system.

FIGURE 5
Standard Horizontal Termination

FIGURE 6
Vertical Vent Termination

Concentric Vent Terminations

Install 3” Concentric vent kit model KGAVT0601CVT, part
number 6910543. See Manufacturer’s instructions for
complete installation or call customer service at 1-800­456-9805 for assistance. To prevent potential condensate
from collecting in the venting system slope the vent at
a downward pitch of 1/8” per 5ft. away from the water
heater.

FIGURE 7
Concentric Vent Termination

Vertical Termination

The vertical inlet and exhaust outlet require a return bend
or two medium or long sweep radius 90° elbows to keep
the air inlet and exhaust outlet downward and prevent
entry of rain. Do not include these elbows when calculat­ing the maximum allowable vent pipe because they have
already been considered in the vent tables. Refer to figure
6 for the proper location of the air inlet with respect to
the exhaust outlet termination. The vertical exhaust outlet
termination is a 2 inch or 3 inch pipe which terminates at
least 12 inches above the inlet air termination.

The air inlet and exhaust outlet terminations must be at
least 12 inches above the roof line or anticipated snow
levels. See figure 6.

NOTE: A rodent screen is available through the Parts
Department for installations where animals may be able to
access the vent system.

10

WATER SYSTEM PIPING

Piping Installation

Piping, fittings, and valves should be installed according to
the installation drawing (Figure 8). If the indoor installation
area is subject to freezing temperatures, the water piping
must be protected by insulation.

Water supply pressure should not exceed 80 psi. If this
occurs a pressure limiting valve with a bypass may need
to be installed in the cold water inlet line. This should
be placed on the supply to the entire house in order to
maintain equal hot and cold water pressures.

IMPORTANT: Heat cannot be applied to the water fittings
on the heater as they may contain nonmetallic parts. If
solder connections are used, solder the pipe to the adapter
before attaching the adapter to the hot and cold water
fittings.

IMPORTANT: Always use a good grade of joint compound
and be certain that all fittings are drawn up tight.

1. Install the water piping and fittings as shown in Figure

8. Connect the cold water supply (3/4” NPT) to the
fitting marked “C”. Connect the hot water supply (3/4”
NPT) to the fitting marked “H”. IMPORTANT: Some
models may contain energy saving heat traps to
prevent the circulation of hot water within the pipes. Do
not remove the inserts within the heat traps.

2. The installation of unions in both the hot and cold
water supply lines is recommended for ease of
removing the water heater for service or replacement.

3. The manufacturer of this water heater recommends
installing a tempering valve or an anti-scald device
in the domestic hot water line as shown in Figure 9.
These valves reduce the point of use temperature of
the water by mixing cold and hot water and are readily
available for use. Point of use devices for reducing
scald hazards that attach to faucets and shower heads
are also available from plumbing supply houses.
Contact a licensed plumber or the local plumbing
authority.

4. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as
specified under “Closed System/Thermal Expansion”.

5. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve and
how to shut off the water to the heater.

6. A temperature and pressure relief valve must be
installed in the opening marked “Temperature and
Pressure (T & P) Relief Valve” on the water heater.
Add a discharge line to the opening of the T & P relief
valve. Follow the instructions under Temperature and
Pressure Relief Valve”.

FIGURE 8
Typical Water Piping Installation

FIGURE 9
Typical Tempering
Valve Installation

Tempering Valve
(set to 120°F
or lower)

Tempered Water
to fixtures

Cold

Water

Inlet

Please note the following:

• The system should be installed only with piping that is
suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. This water heater must not be
installed using iron piping or PVC water piping.

• Use only pumps, valves, or fittings that are compatible
with potable water.

• Use only full flow ball or gate valves. The use of valves
that may cause excessive restriction to water flow is
not recommended.

• Use only 95/5 tin-antimony or other equivalent solder.
Any lead based solder must not be used.

• Piping that has been treated with chromates, boiler
seal, or other chemicals must not be used.

• Chemicals that may contaminate the potable water
supply must not be added to the piping system.

11

Closed System/Thermal Expansion

CAUTION - PROPERTY DAMAGE HAZARD

Periodic discharge of the temperature and pressure
relief valve may be due to thermal expansion in a closed
water supply system. The water utility supply meter
may contain a check valve, backfl ow preventer or water
pressure reducing valve. This will create a closed water
system. During the heating cycle of the water heater, the
water expands causing pressure inside the water heater
to increase. This may cause the temperature and pressure
relief valve to discharge small quantities of hot water. This
is an unacceptable condition and must be corrected. To
prevent this, it is recommended that a diaphragm-type
expansion tank (suitable for potable water) be installed
on the cold water supply line. The expansion tank must
have a minimum capacity of 1.5 U.S. gallons for every 50
gallons of stored water. Contact the local water supplier
or plumbing inspector for information on other methods to

control this situation.

Temperature and Pressure
Relief Valve

FIGURE 10A
Temperature and Pressure
Relief Valve Installation

Drain Pan

Temperature and
Pressure Relief Valve

Discharge line 3/4” min.
Do not cap or plug.

6” max.

Drain

WARNING

Explosion Hazard

If the temperature and pressure relief valve
is dripping or leaking, have a qualified
person replace it.

Examples of a qualified person include:
licensed plumbers, authorized gas company
personnel, and authorized service
personnel.

Do not plug valve.

Do not remove valve.

Failure to follow these instructions can
result in death, or explosion.

T&P Valve and Pipe Insulation (Some Models)

1. Locate the T&P Valve on the water heater.

2. Locate the slit running the length of the insulation.

3 Spread this slit open and slip it over the T&P Valve. See

Figure 10B. Apply gentle pressure to the insulation to
ensure it is fully seated on the T&P Valve. Once sealed
secure the insulation with a section of tape.
IMPORTANT: The insulation or tape should not block
or cover the T&P drain opening. Also the insulation or
tape should not block or hinder access to the T&P valve
manual relief lever.

4. Next locate the hot water (outlet) & cold water (inlet) pipes
to the water heater.

5. Select one of the sections of pipe insulation and locate the
slit that runs the length of the insulation.

6. Spread the slit open at the base of the insulation and slip
it over the cold water (inlet) pipe. Apply gentle
pressure along the length of the insulation to ensure it is
fully seated around the cold water pipe. Also ensure that
the base of insulation is flush with the water heater. Once
seated secure the insulation with a section of tape.

7. Repeat steps 5 through 6 for the hot water (outlet) pipe.

Figure 10B
T&P Valve Insulation

For protection against excessive pressures and
temperatures, a temperature and pressure relief valve must
be installed in the opening marked “T & P RELIEF VALVE”
(see Figure 10A.) This valve must be design certifi ed by
a nationally recognized testing laboratory that maintains
periodic inspection of the production of listed equipment
or materials as meeting the requirements for Relief
Valves for Hot Water Supply Systems, ANSI Z21.22. The
function of the temperature and pressure relief valve is to
discharge water in large quantities in the event of excessive
temperature or pressure developing in the water heater.
The valve’s relief pressure must not exceed the working
pressure of the water heater as stated on the data plate.

IMPORTANT: Only a new temperature and pressure relief
valve should be used with your water heater. Do not use an
old or existing valve as it may be damaged or not adequate
for the working pressure of the new water heater. Do not

place any valve between the relief valve and the tank.
12

T&P Insulation

Manual Relief Lever

T&P Valve

T&P Valve
Drain Line

The Temperature and Pressure Relief Valve:

• Must not be in contact with any electrical part.

• Must be connected to an adequate discharge line.

• Must not be rated higher than the working pressure
shown on the data plate of the water heater.

The Discharge Line:

• Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in the
discharge line.

• Must not be capped, blocked, plugged or contain any

valve between the relief valve and the end of the
discharge line.

• Must terminate a maximum of six inches above a

fl oor drain or external to the building.

• Must be capable of withstanding 250°F (121°C)

without distortion.

• Must be installed to allow complete drainage of both

the valve and discharge line.

ELECTRICAL CONNECTIONS

IMPORTANT: Do not use an extension cord to connect the

WARNING

Electric Shock Hazard

Disconnect power before
servicing.

Replace all parts and panels
before operating.

Failure to do so can result in
death or electrical shock.

Before plugging in the water heater, always make sure:

• The voltage and frequency correspond to that specified
on the water heater wiring diagram.

• The electrical outlet has the proper overload fuse or
breaker protection.

water heater to an electrical outlet.

• The water heater and the outlet are properly grounded.

• Installed in accordance with prevailing provisions of
local codes, or in the absence of such, National Electric

Code, ANSI/NFPA 70.

NOTE: Always reference the wiring diagram for the correct
electrical connections.

After making all electrical connections, completely fill the
tank with water and check all connections for leaks. Open
the nearest hot water faucet and let it run for 3 minutes to
purge the water lines of air and sediment and to ensure
complete filling of the tank. The electrical power may then
be turned on. Verify proper operation after servicing.

WIRING DIAGRAM

120V 60Hz.

WHITE

GREEN

BLACK

GREEN

GREEN

BLOWER GROUND

TEMP.

SWITCH

BLUE

BLACK

YELLOW

MOTOR

120V 60Hz.

WHITE

WHITE/BLACK TRACER

YELLOW/BLACK TRACER

GAS VALVE CONNECTOR

WHITE

YELLOW

PRESSURE

SWITCH

13

INSTALLATION CHECKLIST

Water Heater Location

• Centrally located with the water piping system.
Located as close to the gas piping and vent pipe
system as possible.

• Located indoors and in a vertical position. Protected
from freezing temperatures.

• Proper clearances from combustible surfaces
maintained and not installed directly on a carpeted
fl oor.

• Provisions made to protect the area from water
damage. Drain pan installed and piped to an
adequate drain.

• Installation area free of corrosive elements and
fl ammable materials.

• Suffi cient room to service the water heater.

Gas Supply and Piping

• Gas supply is the same type as listed on the water
heater data plate.

• Gas line equipped with shut-off valve, union, and
drip leg.

• Approved pipe joint compound used.

• Adequate pipe size and of approved material.

• Chloride-free soap and water solution or other
approved means used to check all connections and
fi ttings for possible gas leaks.

Vent Pipe System

• Vent pipe and fittings of approved material.

• Acceptable size, length, and number of elbows on
air inlet pipe.

• Acceptable size, length, and number of elbows on
exhaust outlet pipe.

• Installed in accordance with prevailing provisions of
local codes, or in the absence of such, National Fuel
Gas Code, NFPA 54, ANSI Z223.1-Current Edition.

• Slope 2” & 3” horizontal piping at a downward pitch
of 1/8” per 5ft. away from the water heater.

• Not obstructed in any way.

Vent Termination

Concentric

• 12” Min. above grade/snow level.

• Slope exhaust outlet/air inlet piping at a downward
pitch of 1/8” per 5ft. away from the water heater.

Horizontal

• Correct relationship - outlet to inlet.

• 12” Min. above grade/snow level.

• Slope 2” & 3” horizontal piping at a downward pitch
of 1/8” per 5ft. away from the water heater.

• Away from corners, other vents, windows, etc.

Vertical

• Inlet - 12” Min. above roof/snow level.

• Correct relationship - outlet to inlet.

Water System Piping

• Temperature and pressure relief valve properly
installed with a discharge line run to an open drain and
protected from freezing.

• All piping properly installed and free of leaks.

• Heater completely fi lled with water.

• Closed system pressure build-up precautions
installed.

• Tempering valve installed per manufacturer’s
instructions, when applicable. (See page 16.)

Electrical Connections

• Unit connected to a dedicated power supply.

• Unit connected to a 120V electrical supply.

• Proper polarity.

• Water heater properly grounded.

• Installed in accordance with prevailing provisions of
local codes, or in the absence of such, the current
edition of the National Electric Code, ANSI/NFPA 70.

14

OPERATING YOUR WATER HEATER

Lighting Instructions

Read and understand these directions thoroughly before
attempting to operate the water heater. Make sure the
tank is completely filled with water before operating the
water heater. Check the data plate near the gas control
valve/thermostat for the correct gas. Do not use this
water heater with any gas other than the one listed on
the data plate. If you have any questions or doubts,
consult your gas supplier or gas utility company.

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING:

may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with

an ignition device which automatically lights the burner.
Do not try to light the burner by hand.

B. BEFORE LIGHTING 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 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 do not follow these instructions exactly, a fire or explosion

WARNING

Explosion Hazard

Replace viewport if glass is
missing or damaged.

Failure to do so can result in
death, explosion or fire.

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

C. Do not use this appliance if any part has been

under water. Immediately call a qualified service
technician to inspect the appliance. Water heaters
subjected to flood conditions or anytime the gas
controls, main burner or pilot have been
submerged in water require replacement of the
entire water heater.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information
above on this label.

2. Connect to a grounded 110/120 volt power
supply.

3. Set the thermostat to the lowest setting by first
pressing the COOLER and HOTTER
buttons together and holding for 1 second. Then
press the COOLER button until the WARM
indicator light appears.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting by first
pressing the COOLER and HOTTER
buttons together and holding for 1 second. Then
press the COOLER button until the WARM
indicator light appears.

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 minutes to clear out any gas. If you then
smell gas. STOP! Follow the “B” in the safety
information above on this label. If you don’t smell
gas, go to the next step.

6. Set the thermostat to the desired setting by first
pressing the COOLER and HOTTER
buttons together and holding for 1 second. Then
press the HOTTER button.

7. WATER TEMPERATURE ADJUSTMENT
is approximately 120°F.

CAUTION: Hotter water increases the risk of scald
injury. Consult the instruction manual before
changing the temperature.

8. If the appliance will not operate, follow the
instructions “TO TURN OFF GAS APPLIANCE”
and call a qualified person or gas supplier.

WARNING: TURN OFF ALL ELECTRIC POWER
BEFORE SERVICING.

2. Unplug electrical service to the appliance if
service is to be performed.

15

L.P.G. (Bottled Propane) Models

Liquefi ed petroleum gas is over 50% heavier than air
and in the occurrence of a leak in the system, the gas
will settle at fl oor level. Basements, crawl spaces, skirted
areas under mobile homes (even when ventilated), closets
and areas below ground level will serve as pockets for
the accumulation of gas. Before lighting an L.P. gas water
heater, smell all around the appliance at fl oor level. If you
smell gas, follow the instructions as given in the warning on
the front page.

When your L.P. tank runs out of fuel, turn off the gas at
all gas appliances including pilot lights. After the tank is
refi lled, all appliances must be re-lit according to their
manufacturer’s instructions.

Water Heater Operation

Figure 11 below shows the water heater’s sequence of
operation when a call for heat is initiated. The ignition
control module will attempt to light the burner three times.
If the ignition control does not detect ignition it will enter

lock-out mode, indicated by a three flash error code.

Figure 11
Sequence of Operation

CALL FOR

HEAT INDICATED

BY FAST FLASH

OF LED

FLAME SENSE ROD DETECTS

CONTROL CHECKS TO ENSURE
PRESSURE SWITCH IS OPEN

DRAFT INDUCER IS ENERGIZED

CONTROL CHECKS TO ENSURE
PRESSURE SWITCH CLOSES,
INDICATING BLOWER OPERATING
AND THERE ARE NO VENTING
BLOCKAGES (INLET OR OUTLET)

CONTROL ENERGIZES HOT
SURFACE IGNITER (HSI)

CONTROL ENERGIZES MAIN
GAS VALVE ALLOWING THE
BURNER TO BE LIT BY HSI

FLAME OF MAIN BURNER

WATER IN TANK IS HEATED BY
MAIN BURNER AND
TEMPERATURE REACHES
THERMOSTAT SETTING

MAIN VALVE DE-ENERGIZES
AND BLOWER CONTINUES FOR
A POST PURGE TIME OF
APPROX. 30 SECONDS

MAIN VALVE DE-ENERGIZES
AND BLOWER CONTINUES FOR
A POST PURGE TIME OF
APPROX. 5 SECONDS

HEATER RETURNS TO
STANDBY MODE

Burner Flames

Inspect the burner flames through the viewport and com­pare them to the drawings in Figure 16. A properly operat­ing burner should produce
a soft blue flame. Blue tips
with yellow inner cones
are satisfactory. The tips
of the flame may have a
slight yellow tint. The flame
should not be all yellow or

Figure 12
Flame Characteristics

Correct flame

soft blue

Tips may have
a yellow tint

Yellow inner
cones are
satisfactory

have a sharp blue-orange
color. Contaminated air
may cause an orange colored flame. Contact a qualified

person if the flame is not satisfactory.

Water Temperature Regulation

Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30°F (16.7
°C) higher or lower at the point of use such as, bathtubs,
showers, sink, etc.

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 infi rm, or physically/mentally handicapped. If
anyone using hot water in your home fi ts into one of these
groups or if there is a local code or state law requiring a certain

16

WARNING

Water temperature over 125°F can cause
severe burns instantly or death from scalds.

Children, disabled and elderly are at highest
risk of being scalded.

Feel water before bathing or showering.

Temperature limiting valves are available.

temperature water at the hot water tap, then you must take
special precautions. In addition to using the lowest possible
temperature setting that satisfi es 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.
Mixing valves are available at plumbing supply or hardware stores,
see Figure 9. Follow manufacturer’s instructions for installation of
the valves. Before changing the factory setting on the thermostat
see Figure 13 and the table below. Using the lowest hot water
temperature that meets your needs will also provide the most
energy effi cient operation of the water heater.

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.

Temperature

Settings

160°F (71°C)
150°F (66°C) About 1-1/2 seconds
140°F (60°C) Less than 5 seconds
130°F (54°C) About 30 seconds
120°F (49°C) More than 5 minutes

80°F (27°C) - - - - - - - - - - - - - - - -

NOTE: A water temperature range of 120°F-140°F (49°C-60°C)
is recommended by most dishwasher manufacturers.

The thermostat of this water heater has been factory set at its
lowest position, to reduce the risk of scald injury. It is adjustable
and must be reset to the desired temperature setting.

The mark (

) (on temperature setting of gas control valve/
thermostat) indicative of approximately 120°F is preferred
starting point. Some states have a requirement for a lower
setting. If you need hotter water, follow directions for
temperature adjustment, but beware of the warnings in this
section.

Pressing the “COOLER” button decreases temperature and
pressing the “HOTTER” button increases the temperature.

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 13). One or two of the temperature indicators
will light up. These indicators will only remain on for

Time to Produce 2nd & 3rd

Degree Burns on Adult Skin

About 1/2 second

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.
NOTE: During low demand periods when hot water is not
being used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs. If hot
water use is expected to be more than normal, a higher
thermostat setting may be required to meet the increased
demand. When leaving your home for extended periods
(vacations, etc.) turn the temperature dial to its lowest
setting. This will maintain the water at low temperatures
with minimum energy losses and prevent the tank from
freezing during cold weather.

Figure 13
Gas Valve/

Thermostat Settings

Temperature Setting

C - Flashing = approx. 160°F

C = approx. 150°F

B = approx. 140°F

A = approx. 130°F

= approx. 120°F

WARM = approx. 80°F

Display

A B C

Operational Conditions

Condensation

Moisture from the products of combustion condenses on
the tank surface and the outside jacket of the water heater
and forms drops of water which may fall onto the burner or
other hot surfaces. This will produce a “sizzling” or “frying”
noise. This condensation is normal and should not be
confused with a leaking tank. Condensation may increase
or decrease at different times of the year.
High effi cient energy saver water heaters will produce
larger amounts of condensation on initial start-up or
when a large amount of hot water is being used. Do not
confuse this with a “tank leak”. Once the water reaches
a temperature of 120°F (49°C) and the tank warms up
(usually 1-2 hours), the condensation will stop.

CAUTION - PROPERTY DAMAGE HAZARD

IMPORTANT: It is always recommended that a suitable
metal drain pan be installed under the water heater
to protect the area from water damage resulting from
normal condensation production, a leaking tank or piping
connections. Refer to “Location Requirements” section

Water Heater Sounds

During the normal operation of the water heater, sounds or
noises may be heard. These noises are common and may
result from the following:

1. Normal expansion and contraction of metal parts

during periods of heat-up and cool-down.

2. Condensation causes sizzling and popping within the

burner area and should be considered normal.

3. Sediment buildup in the tank bottom will create

varying amounts of noise and may cause premature

tank failure. Drain and fl ush the tank as directed

under “Draining and Flushing”.

Smoke/Odor

The water heater may give off a small amount of smoke
and odor during the initial start-up of the unit. This is due to
the burning off of oil from metal parts of a new unit and will

disappear after a few minutes of operation.

Safety Shut-off

This water heater is designed to automatically shut-off in
the event of the following:

1. The water temperature exceeds 180°F (83°C.)

2. A blockage occurs in the combustion chamber air inlet,
the fl ue gas exhaust outlet, or both the inlet and outlet.

3. The blower fails to operate or operates improperly.
A high temperature limit switch or ECO (Energy Cut Off) in
the tank is used to shut off the unit if the water temperature
exceeds 180°F (83°C.) The ECO is a single use switch and
requires complete replacement of the entire thermostat.
If the ECO should actuate, the water heater cannot be
used until the thermostat is replaced by a qualifi ed person.
Contact your local dealer for service information.

Anode Rod/Water Odor

Each water heater contains at least one anode rod, which
will slowly deplete while protecting the glass-lined tank
from corrosion and prolonging the life of the water heater.
Once the anode is depleted, the tank will start to corrode,
eventually developing a leak. Certain water conditions will
cause a reaction between this rod and the water. The most
common complaint associated with the anode rod is a “rotten
egg smell” produced from the presence of hydrogen sulfide
gas dissolved in the water. IMPORTANT: Do not remove this
rod permanently as it will void any warranties. The parts list
includes a special anode that can be ordered if water odor
or discoloration occurs. NOTE: This rod may reduce but not
eliminate water odor problems. The water supply system
may require special aeration or chlorination equipment from
a water conditioning company to successfully eliminate all
water odor problems.
The use of a water softener may decrease the life of the
water heater tank.
The anode rod should be removed from the water heater
tank every 3 years for inspection. The following are typical
(but not all) signs of a depleted anode rod:

• The majority of the rods diameter is less than 3/8”.

• Signifi cant sections of the support wire (approx. 1/3 or
more of the anode rod’s length) are visible.

If the anode rod show signs of either or both it should be
replaced. NOTE: Whether re-installing or replacing the
anode rod, check for any leaks and immediately correct if
found.
In replacing the anode:

1. Turn off gas supply to the water

heater.

2. Shut off the water supply and

open a nearby hot water faucet to
depressurize the water tank.

3. Drain approximately 5 gallons

of water from tank (Refer to the
“Draining and Flushing” section for
proper procedures). Close drain
valve.

4. Remove old anode rod.

5. Use Tefl on® tape or approved pipe

sealant on threads and install new
anode rod.

6. Turn on water supply and open

nearby hot water faucet to purge air
from water system. Check for any
leaks and immediately correct any if found.

7. Restart the water heater as directed under the

“Operating Your Water Heater” section. See the “Repair
Parts Illustration” section for anode rod location.

TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.

17

MAINTENANCE OF YOUR WATER HEATER

Draining and Flushing

It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up
during operation. The water heater should be drained if
being shut down during freezing temperatures. To drain
the tank, perform the following steps:

1. Turn off the gas to the water heater at the manual
gas shut-off valve.

2. Turn off the electrical supply to the water heater.

3. Close the cold water inlet valve.

4. Open a nearby hot water faucet.

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

NOTE:: The drain hose should be rated for at least
200°F (93°C). If the drain hose does not have this rating,
open the cold water inlet valve and a nearby hot faucet
until the water is no longer hot.

6. Open the water heater drain valve and allow all the
water to drain from the tank. Flush the tank with
water as needed to remove sediment.

7. Close the drain valve, refill the tank, and restart the
heater as directed under “Operating Your Water
Heater”.

If the water heater is going to be shut down for an
extended period, the drain valve should be left open.

IMPORTANT: Condensation may occur when refilling
the tank and should not be confused with a tank leak.

Routine Preventive
Maintenance

At least annually, a visual inspection should be made of
the venting and air supply system, piping systems, main
burner, and pilot burner. Check the water heater for the
following:

• Obstructions, damage, or deterioration in the venting
system. Make sure the ventilation and combustion
air supplies are not obstructed.

• Build up of soot and carbon on the main burner and
pilot burner. Check for a soft blue flame.

• Leaking or damaged water and gas piping.

• Presence of flammable or corrosive materials in the
installation area.

• Presence of combustible materials near the water
heater.

• Verify proper operation after servicing this water
heater.

IMPORTANT: If you lack the necessary skills required
to properly perform this visual inspection, you should not
proceed, but get help from a qualified person.

Temperature and Pressure
Relief Valve

WARNING

Explosion Hazard

If the temperature and pressure relief valve
is dripping or leaking, have a qualified
person replace it.

Examples of a qualified person include:
licensed plumbers, authorized gas company
personnel, and authorized service
personnel.

Do not plug valve.

Do not remove valve.

Failure to follow these instructions can
result in death, or explosion.

Manually operate the temperature and pressure relief valve
at least once a year to make sure it is working properly
(see Figure 15.) To prevent water damage, the valve must
be properly connected
to a discharge line
which terminates at an
adequate drain. Standing
clear of the outlet
(discharged water may
be hot), slowly lift and
release the lever handle
on the temperature and
pressure relief valve to
allow the valve to operate
freely and return to its
closed position. If the valve fails to completely reset and
continues to release water, immediately shut off the manual
gas shut-off valve and the cold water inlet valve and call a
qualifi ed person.

FIGURE 15
Temperature & Pressure Relief Valve

18

Replacement Parts

Removing the Burner from the

Replacement parts may be ordered through your
plumber or the local distributor. Parts will be shipped at
prevailing prices and billed accordingly. When ordering
replacement parts, always have the following information
ready:

1. model, serial, and product number

2. type of gas

3. item number

4. parts description

See “Repair Parts” section.

Removing the Burner/Manifold Assembly

1. Turn off the gas to the water heater at the manual
gas shut-off valve (See
figure 2), and disconnect
power to the water heater.

2. Remove the outer
door.

4. Remove the 2 screws
securing the manifold
door assembly to the skirt.

5. Disconnect the hot
surface igniter/flame
sense wire and manifold
tube at the thermostat.
(Figure 16) NOTE: L.P.
gas systems use reverse
(left-hand) threads on the
manifold tube.

6. Grasp the manifold tube
and push down slightly to
free the manifold from the gas control valve/
thermostat.

7. Carefully remove the manifold assembly from the
burner compartment. Be sure not to damage internal
parts.

8. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water.

FIGURE 16
Gas Valve/Thermostat

Manifold

Tube

Hot Surface

Igniter/Flame

Sense Connector

Manifold Assembly

1. Take off the burner by removing the two (2) screws
located underneath the burner.

2. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water.
See Figure 17.

FIGURE 17
Natural & L.P. Gas Burner Assembly

Burner

Manifold Door Gasket

Two Piece Wire

Connector

Flame Sense

Hot Surface
Igniter

Manifold Door Assembly

Burner

Manifold Door Assembly

Flame Sense/Hot
Surface Igniter Wire

Manifold

Tub e

Flame Sense/Hot
Surface Igniter Wire

Manifold Tube

Viewport

19

WARNING

Explosion Hazard

Tighten both manifold door screws
securely.

Remove any fiberglass between gasket
and combustion chamber.

6. Reconnect the manifold tubing to the thermostat. Do
not cross-thread or apply any thread sealant to the
manifold tubing.

NOTE: L.P. gas systems use reverse (left-hand) threads
on the manifold tube.

7. Reconnect the Flame Sense/Hot Surface Igniter wire
to the thermostat.

8. Turn gas supply on and refer to the Lighting
Instructions.

9. Check for leaks by brushing on an approved
noncorrosive leak detection solution. Bubbles will show
a leak. Correct any leak found.

10. Replace the outer door.

Removing and Replacing the Gas

Replace viewport if glass is missing or
damaged.

Replace two piece wire connector if missing
or removed.

Replace door gasket if damaged.

Failure to follow these instructions can
result in death, explosion, or fire.

Replacing the Manifold Assembly

1. Check the door gasket for damage or embedded
debris prior to installation.

2. Inspect the viewport for damage and replace as
required.

3. Insert the manifold assembly into the burner
compartment making sure that the manifold tab
engages the slot inside the combustion chamber.
See Figure 18.

FIGURE 18
Manifold Tab

Door Gasket

Viewport

4. Inspect the door gasket and make sure there is no
fiberglass insulation between the door gasket and the
combustion chamber.

5. Replace the two screws, which secure the manifold
assembly door to the combustion chamber and
tighten securely. Once the manifold assembly door is
tightened, visually inspect the door gasket between
the manifold assembly door and the combustion
chamber for spaces or gaps that would prevent a
seal. IMPORTANT: Do not operate the water heater if
the door gasket does not create a seal between the
manifold door and the combustion chamber.

20

Manifold Tab

Burner

Slot

Control Valve/Thermostat

IMPORTANT: Use only factory authorized replacement parts.
Removing the Gas Control Valve/Thermostat:

1. Set the gas control valve/thermostat to its lowest
setting by first depressing the COOLER

HOTTER
Then press the COOLER

indicator light appears.

2. Unplug the water heater from the wall outlet.

3. Turn off the gas at the manual shut-off valve on the
gas supply pipe (Figure 2).

4. Drain the water heater. Refer to the “Draining and
Flushing” section and follow the procedure.

5. Disconnect the flame sense/hot surface igniter wire
from the thermostat. Disconnect the manifold tube at
the thermostat (Figure 16). NOTE: L.P. gas systems
use reverse (left-hand) threads on the manifold tube.

6. Refer to “Gas Piping” (Figure 2) and disconnect the
ground joint union in the gas piping. Disconnect the
remaining pipe from the gas control valve/thermostat.

7. To remove the gas control valve/thermostat, thread a
correctly sized pipe into the inlet and use it to turn the
gas control valve/thermostat (counterclockwise.) Do not
use pipe wrench or equivalent to grip body. Damage
may result, causing leaks. Do not insert any sharp
objects into the inlet or outlet connections. Damage to
the gas control valve/thermostat may result.

Replacing the Gas Control Valve/Thermostat:

To replace the gas control valve/thermostat,
reassemble in reverse order. Use only factory
authorized replacement parts.

• Be sure to use approved Teflon® tape or pipe joint
compound on the gas piping connections and fitting
on the back of the gas control valve/thermostat that
screws into tank.

• Turn gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles forming
indicate a leak) or other approved method.

• Be sure tank is completely filled with water before
lighting and activating the water heater. Follow the
Lighting Instructions.

• If additional information is required, contact the Service
Department at: 1-800-456-9805.

TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.

buttons together and hold for 1 second.

button until the WARM

(Figure 13).

and

TROUBLESHOOTING

LED STATUS PROBLEM SOLUTION

An open earth ground circuit to the ignition
system.

Wiring error or a high resistance to earth
ground.

Pressure switch remained closed longer than 5
seconds after the call for heat began.

Pressure switch remained open longer than
5 seconds after the combustion blower was
energized.

Error in the hot surface igniter circuit. 1. Check that all wiring is correct and secure.

System in lockout. 1. Gas supply is off or too low to operate.

Problem in the gas valve driver circuit. 1. Turn power to the water heater off for 10 seconds

Problem with the internal circuit. 1. Turn power to the water heater off for 10 seconds

Problem with the internal circuit. 1. Turn power to the water heater off for 10 seconds

Flame signal sensed out of proper sequence. 1. Replace gas control valve.

1. Check that the earth ground connection is
properly connected.

2. Check that the earth ground conductor on the
water heater is properly connected.

1. Check for proper connection of line neutral and

hot wires.

2. Check that the water heater is securely

connected to earth ground.

1. Pressure switch wiring is incorrect.

2. Replace pressure switch.

1. Pressure switch wiring is incorrect.

2. Pressure Switch tubing is not connected correctly.

3. Air intake or exhaust obstructed.

2. Replace hot surface igniter.

2 Hot surface igniter not positioned correctly.

3. Low voltage to the water heater.

4. Electric polarity to unit is incorrect - test and cor­rect.

and then back on.

2. Replace gas control valve.

and then back on.

2. Replace gas control valve.

and then back on.

2. Replace gas control valve.

ECO activated. 1. Replace gas control valve.

One of the temperature adjust buttons stuck
closed.

Water temperature sensor is either open or
short circuited.

1. Press and release each of the buttons once.

2. Replace gas control valve.

1. Check that all wiring is correct and secure.

2. Replace gas control valve.

21

TROUBLESHOOTING cont.

PROBLEM CAUSE SOLUTION

Blower will not run.

A) Blower unplugged. Plug blower back into 115 VAC. outlet.
B) No power at outlet. Repair service to outlet.

NO HOT WATER

NOT ENOUGH

HOT WATER

VENT PIPE TOO HOT

(ABOVE 170°F)

YELLOW FLAME

CONDENSATION

WATER LEAKS

LEAKING T&P

HOT WATER ODORS

(See ANODE ROD/WATER

ODOR, Section)

WATER TOO HOT

WATER HEATER SOUNDS

SIZZLING-RUMBLING

SOOTING

HEATER LIGHTS BUT

GOES OUT IN 4-5

SECONDS

C) Thermostat defective. Replace thermostat.
D) High limit control circuit open. Replace ECO.
E) Blower motor defective. Replace Blower Assembly.
F) Pressure switch defective. Replace Pressure Switch/Blower Assembly.

Thermostat problems.

A) Thermostat set too low. Set temperature control higher.
B) Thermostat or ECO defective. Replace thermostat or ECO as required.

Others

A) Heater undersized. Reduce hot water use.
B) Low gas pressure. Contact dealer.
C) Incoming water is unusually cold. Allow more time for heater to reheat.
D) Leaking hot water pipes or fixtures. Have plumber check and repair leaks.
A) Defective air flow restrictor Take unit out of service immediately, call a qualified

B) Not enough dilution air to mix with flue

gases in inlet elbow.

C) Dilution air too hot for mixing with flue

gases.
D) Wrong burner orifice. Install correct orifice.
A) Dirt in burner ports. Turn off heater and gas, clean burner head.
B) Combustion air path restricted. Check intake venting arrangements for obstructions.
C) Not enough dilution air for proper

combustion.
A) Water on the floor under heater. See “OPERATIONAL CONDITIONS”, section.
B) Water dripping from blower assembly. Provide drip “TEE” to catch condensation from

A) Improperly sealed, hot or cold supply

connections, relief valve, drain valve or

thermostat threads.
B) Leakage from other appliances or water

lines.
C) Condensation of flue products. See “OPERATIONAL CONDITIONS”, section.
A) Thermal expansion in closed water

system.
B) Improperly seated valve. Check relief valve for proper operation (DO NOT

A) High sulfate or mineral content in water

supply.
B) Bacteria in water supply. Chlorinate water supply.

A) Thermostat set too high. See “WATER TEMPERATURE REGULATION”,

A) Condensation dripping on burner. See “OPERATIONAL CONDITIONS”, section.

B) Sediment at bottom of heater tank. See “MAINTENANCE OF YOUR WATER HEATER”,

A) Improper combustion. See “Combustion Air Supply/Vent Pipe System”,

A) Outlet polarity is reversed. Test polarity and correct.

person to service the unit.
Proper dilution air must be provided for combustion
and dilution of flue temp. See “Combustion Air
Supply/Vent Pipe System”, section.
Supply air is too hot. Check for heat sources around
intake terminal and blockage of dilution air leg.

Check intake venting arrangements for obstructions.

horizontal section of exhaust vent close to blower
assembly.
Tighten threaded connections.

Inspect other appliances near water heater.

Install thermal expansion tank (DO NOT plug T&P
valve).

plug T&P valve).
Drain and flush heater thoroughly then refill.

section.

section.

section.

22

REPAIR PARTS ILLUSTRATION

When ordering repair parts always give the following
information:

1. Model, serial and product number

2. Type of gas

3. Item number

4. Parts description

Repair Parts List

Item

No.

1 Blower

2 Pressure Switch (Not Pictured)

3 Flue Baffle

4 Heat Trap (Cold)

5 Heat Trap (Hot)

6 Cold Water Dip Tube

7 Anode Rod*

8 Temperature and Pressure Valve

9 Drain Valve

10 Gas Control Valve/Thermostat

11 Hot Surface Igniter (HSI)**

12 Natural Gas Burner

13 L.P. Gas Burner**

14 Manifold Door Assembly - Natural Gas

15 Manifold Door Assembly - L.P. Gas**

16 Two Piece Wire Connector w/Retainer Clip**

17 Manifold Door Gasket**

18 Viewport Assembly**

19 Outer Door

* Special anode rod available, see “Anode Rod/Water Odor” section.
** Pictured on next page.

Parts Description

7

10

14

19

1

5

4

3

8

6

9

12

23

Listed Parts Kits and Illustrations

Item 11: Flame Sense/Hot Surface Igniter Assembly.
Item 12: Burner (Natural Gas)
Item 13: Burner (L.P. Gas)
Item 14: Manifold door assembly which contains the manifold tube, gasket, manifold door, two piece wire connector

with retainer clip, and flame sense/hot surface igniter assembly. (Natural Gas)

Item 15: Manifold door assembly which contains the manifold tube, gasket, manifold door, two piece wire connector

with retainer clip, and flame sense/hot surface igniter assembly. (L.P. Gas)
Item 16: Contains two piece wire connector with retainer clip.
Item 17: Contains manifold door gasket.
Item 18: Contains viewport.

ITEM 14

ITEM 11

ITEM 12

ITEM 13

ITEM 15

ITEM 16

© 2007 American Water Heater Company, All Rights Reserved. Printed in the U.S.

ITEM 17

24

ITEM 18