A.O. Smith BPD-80 Installation Manual

Installation and Operating Manual

COMMERCIAL GAS WATER HEATERS

POWER DIRECT VENT GAS MODELS

WITH HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

MODELS BPD-80 SERIES 210, 211

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.

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

1502 331603-000

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE . . . . . . . . . . .3

GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Qualifi ed Installer Or Service Agency . . . . . . . . . . . . 6

Preparing For The Installation. . . . . . . . . . . . . . . . . . 6

INSTALLATION REQUIREMENTS FOR THE

COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7

TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 9

Get To Know Your Water Heater - Gas Models

(List Referencing Figures 1-5). . . . . . . . . . . . . . . . . . 9

Replacement Parts And Deliming Products . . . . . . 10

Combo Heating Inlet And Outlet Side Taps . . . . . . . 10

Water Piping - Mixing Valve Usage . . . . . . . . . . . . . .11

Mixing Valves

Water Heater Operation . . . . . . . . . . . . . . . . . . . . . 12

Electrical Requirements & Wiring Diagram . . . . . . . 13

SAFETY LOCKOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

High Limit Controls (Energy Cut Off). . . . . . . . . . . . 14

Thermostat/Water Temperature
Blower High Limit Switch

Blower Air Pressure Switches . . . . . . . . . . . . . . . . . 14

LOCATING THE NEW WATER HEATER. . . . . . . . . . . . . 15

Facts To Consider About The Location . . . . . . . . . . 15

Clearances To Combustibles
Floors With Carpeting
Clearances For Servicing
Important Notes and Warnings

Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . . 17

Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 17

INSTALLING THE NEW WATER HEATER . . . . . . . . . . . 18

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Space Heating And Potable Water Systems . . . . . . 18

Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Requirements
Installation

Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 20

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 20

Temperature-Pressure Relief Valve. . . . . . . . . . . . . 20

T&P Valve Discharge Pipe Requirements:
Temperature-Pressure Relief Valve And

Pipe Insulation

High Altitude Installation . . . . . . . . . . . . . . . . . . . . . 22

Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Sediment Traps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 24

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Termination Clearances (Sidewall) . . . . . . . . . . . . . 26

Side Wall Vent Terminal Installation
Roof Vent Terminal Installation
Concentric Vent Termination Kit Installation
Multiple Concentric Vent Installations
Vent Pipe Length
Vent Pipe Termination
Venting Terminations And Sizing
Vent Screen Installation
Vent Pipe Material

Vent Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . 30

Vent Pipe Installation
Vent Pipe Runs
Vent Terminal Installations

Blower Assembly Installation. . . . . . . . . . . . . . . . . . 33

Vent/Intake Pipe Connections To Blower/Air Duct
Coupling Installations According To Vent Sizes

Sound Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . 35

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 36

LIGHTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 37

OPERATING THE TEMPERATURE

CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Gas Control Valve/Thermostat . . . . . . . . . . . . . . . . 39

FOR YOUR INFORMATION. . . . . . . . . . . . . . . . . . . . . . . 40

Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 40

Condensate
Smoke/Odor
Strange Sounds

Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 40

Smelly Water

“Air” In Hot-Water Faucets . . . . . . . . . . . . . . . . . . . 40

PERIODIC MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 41

General Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Venting System Inspection . . . . . . . . . . . . . . . . . . . 41

Burner Operation And Inspection . . . . . . . . . . . . . . 41

Combustion Chamber And Burner Cleaning. . . . . . 42

Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Temperature-Pressure Relief Valve Test . . . . . . . . . 42

Draining And Flushing. . . . . . . . . . . . . . . . . . . . . . . 43

To Drain The Water Heater Storage Tank:
To Flush The Water Heater Storage Tank:

Anode Rod Maintenance. . . . . . . . . . . . . . . . . . . . . 44

LEAKAGE CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . 45

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

REFERENCE PARTS LISTING . . . . . . . . . . . . . . . . . . . . 46

TROUBLESHOOTING GUIDELINES. . . . . . . . . . . . . . . . 48

Resetting The Heater Control . . . . . . . . . . . . . . . . . 48

Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Soft Lockout
Hard Lockout

Ignition State And Timing . . . . . . . . . . . . . . . . . . . . 48

System Status And Error Codes . . . . . . . . . . . . . . . 49

Reading The LED Flash Sequence. . . . . . . . . . . . . 49

Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Other Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you
and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very

important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

This is the safety alert symbol. 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

DANGER

WARNING

CAUTION

CAUTION

hazardous situation which, if not avoided,
will 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,
could 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

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

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

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

This product is certifi ed to comply with a maximum weighted average of 0.25% lead content as required in some areas.

IMPORTANT DEFINITIONS

Qualifi ed Installer: A qualifi ed installer must have ability equivalent to a licensed tradesman in the fi elds of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the “National Fuel Gas
Code”, ANSI Z223.1/NFPA 54 as it relates to the installation of gas fi red water heaters. The qualifi ed installer must also
be familiar with the design features and use of fl ammable vapor ignition resistant water heaters and have a thorough
understanding of this Installation and Operating manual.

Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fi elds of plumbing, air
supply, venting and gas supply, including a thorough understanding of the requirements of the “National Fuel Gas Code”,
ANSI Z223.1/NFPA 54 as it relates to the installation of gas fi red water heaters. The service agency must also have a
thorough understanding of this Installation and Operating manual, and be able to perform repairs strictly in accordance
with the service guidelines provided by the manufacturer.

Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances
within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping
up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service
and inspection of appliances within the building.

3

DANGER

GENERAL SAFETY

Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.

HOT

HOT

BURN

Children, the elderly and the
disabled and are at highest
risk of scald injury.

Feel water before bathing or
showering.

Temperature limiting valves
are available.

Read instruction manual for
safe temperature setting.

WARNING

Fire or Explosion Hazard

• Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other
appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive

gas pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after

extended period of non-use.

Read instruction manual before

installing, using or servicing

4

water heater.

GENERAL SAFETY

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Install vent system in accordance with codes.

• Do not operate water heater if flood damaged.

• For operation above 10,100’, a high altitude
orifice must be installed.

• Do not operate if soot buildup is present.

• Do not obstruct water heater air intake with
insulating jacket.

• Do not obstruct blower air intake.

• Do not place chemical vapor emitting products
near water heater.

• Gas and carbon monoxide detectors are
available.

• No vent damper installation is compatible with
this power vented water heater.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

DANGER

FLAMMBLE

Vapors from flammable
liquids may explode and
catch fire causing death or
severe burns.

Do not use or store
flammable products such as
gasoline, solvents or adhe­sives in the same room or
area near the water heater.

Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

Installation: Do not install the water heater where flammable
products will be stored or used.

Flammable Vapors

Water heater has a main
burner and hot surface igniter.
The hot surface igniter:

1. can be triggered at any
time and

2. the hot surface will ignite
flammable vapors.

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor
and

4. can be carried from other
rooms to the the
electodes by air currents.

5

INTRODUCTION

Thank You for purchasing this water heater. Properly

installed and maintained, it should give you years of trouble
free service.

Abbreviations found in this Installation and Operating
manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• UL - Underwriters Laboratories Inc.

• AHRI - Air Conditioning, Heating and Refrigeration

Institute.

This gas-fi red water heater is design certifi ed by CSA
International, under Water Heater Standard ANSI

Z21.10.3 • CSA 4.3 (current edition), as applicable.

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation and service of this water heater requires ability
equivalent to that of a Qualifi ed Agency (as defi ned by
ANSI below) in the fi eld involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical
supply are required in addition to electrical testing skills
when performing service.

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

If you are not qualifi ed (as defi ned by ANSI above) and
licensed or certified as required by authority having
jurisdiction to perform a given task, do not attempt to
perform any of the procedures described in this manual.
If you do not understand the instructions given in this
manual do not attempt to perform any procedures outlined
in this manual.

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section of this manual
fi rst and then entire manual carefully. If you don’t
follow safety rules, the water heater will not operate
properly. It could cause DEATH, SERIOUS BODILY
INJURY AND/OR PROPERTY DAMAGE. This manual
contains instructions for installation, operation,
and maintenance of the gas-fi red water heater. It
also contains warnings throughout the manual that
you must read and be aware of. All warnings and
instructions are essential to proper operation of the
water heater and your safety. Since we cannot put

everything on the fi rst few pages, READ ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER. The installation
must conform with these instructions and local code
authority having jurisdiction. In absence of local codes,
installation must comply with current editions of the

“National Fuel Gas Code”, ANSI Z223.1/NFPA
54 and “National Electrical Code”, NFPA 70. All

documents are available from:

CSA International,
8501 East Pleasant Valley Road,
Cleveland, Ohio, United States
44131-5575.

NFPA documents are also available from:
National Fire Protection Association,
1 Batterymarch Park,
Quincy, MA 02269.

2. The water heater, when installed, must be electrically
grounded in accordance with the local codes or in
the absence of local codes: current edition of the
“National Electrical Code”, NFPA 70.

3. If after reading this manual you have any questions or
do not understand any portion of the instructions, call
the local gas utility or the manufacturer whose name
appears on the rating plate.

4. Carefully plan the place where you are going to put
the water heater. Correct combustion, vent action,
and vent pipe installation are very important in
preventing death from possible carbon monoxide
poisoning and fi res (see Figure 12). Examine the
location to ensure the water heater complies with
the “Locating The New Water Heater” section in this
manual.

5. For installation in areas subject to earthquakes, this
water heater must be braced, anchored, or strapped
to avoid falling or moving during an earthquake.
See instructions for correct installation procedures.
Instructions may be obtained from:

California Offi ce of the State Architect,
400 P Street,
Sacramento, CA 95814.

6. Massachusetts Code requires this water heater to be
installed In accordance with Massachusetts 248-CMR

2.00: State Plumbing Code and 248-CMR 5.00.

7. Complies with California Health and Safety code
116875 (known as AB-1953) and with weighted
average maximum of 0.25% lead.

6

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

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

INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfi tter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the fl oor level where
the gas equipment is to be installed. In addition, the installing plumber or gasfi tter shall observe that a battery operated
or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or
structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner
to secure the services of qualifi ed licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent fl oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.

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

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

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

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

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

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

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

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

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

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

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

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

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

7

INSTALLATION GRAPHIC: GAS-FIRED POTABLE
WATER HEATING/SPACE HEATING SYSTEM

• If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following

graphic during installation and during modifications to the water supply system.

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

TEMPERED WATER
TO FIXTURES
(MUST MEET TEMPS LISTED
IN MASS. CODE 248 CMR

MUST BE VERTICAL TO
REMOVE A

MIXING VALVE
(MUST BE INSTALLED BELOW
TOP OF WATER HEATER
AS PER MANUFACTURER’S
RECOMMENDATIONS)

WATER HEATER ACCEPTED
BY THE BOARD FOR
INSTALLATION IN
MASSACHUSETTS.

MASSACHUSETTS INSTALLATION REQUIREMENTS:

*

1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS

2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR

3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.

† REQUIRED FOR MASSACHUSETTS.

‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.

IR BUBBLES

FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.

& 780 CMR).

†

)

†

TYPICAL MIXING VALVE INSTALLATION

EXPANSION TANK

CHECK

VALVE

UNION

HOT

WATER

OUT

VACUUM

†

RELIEF
VALVE

UNION

TEMP/
PRESSURE
RELIEF
VALV E

SEE
NOTE ‡

100’-0” MAXIMUM DISTANCE
FROM WATER HEATER TO FAN
COIL AND BACK. (DEVELOPED
LENGTH) NOT INCLUDING COIL

CHECK VALVE

(1/8” HOLE

DRILLED IN CLAPPER)

PUMP

TO

AIR

HANDLER

SHUT-OFF

VALV E

*

IN HEATING UNIT

COLD WATER INLET

†

FLOW CONTROL

VA

LV

E

*

OUT

COIL

AIR

HANDLER

†

SHUT-OFF

VALVE

IN

8

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5)

1 Termination Elbow with Rodent

Screen
2 *Vent Pipe
3 *Coupling (if required)
4 CPVC Vent Pipe ( 5 ft. supplied)
5 *Vent Pipe Elbow (long radius)
6 *CPVC Vent Pipe Elbow
7 *Union (Di-electric water connection)
8 Cold-Water Inlet Nipple/Diptube
9 **Combo Heating System Supply

Outlet (Optional)
10 T&P Valve
11 * Discharge Pipe
12 **Combo Heating System Return

Inlet (Optional)
13 Gas Control Valve/Thermostat

(Honeywell)
14 Gas Valve Electronic Control Module

And Cover (Honeywell)
15 Drain Valve
16 Outer Gas Door
17 Manifold Door Assembly (behind

outer door) (see Figure 3)

2

1

3 4

5

18 *Metal Drain Pan
19 *Floor Drain
20 Flexible Manifold Tube (see

Figure 3)
21 ***Control Harness
22 *Sediment Trap
23 *Ground Joint Union (gas

connection)
24 *Main Manual Gas Shut-off Valve
25 *Gas Supply*
26 Anode (under cap)
27 Baffl e Assembly
28 Hot-Water Outlet Nipple/Anode
29 Sound Suppressor (Tee fi tting)
30 *Inlet Water Shut-off Valve
31 ****Rubber Coupling (see Figure 4)
32 Gear Clamp (see Figure 4)
33 ***Blower with Power Cord (see

Figure 4)
34 Air Duct Adapter
35 Air Inlet Snorkel
36 Air Duct
37 *Thermal Expansion Tank (see

“Closed Water Systems” and

“Thermal Expansion” sections)
38 Flame Sensor Rod (see Figure 3)
39 Sheet Metal Burner (see Figure 3)

40 Gas Orifi ce (see Figure 3)
41 Gas Manifold (see Figure 3)
42 Hot-Surface Igniter (see Figure 3)
43 Manifold Door Gasket (see

Figure 3)
44 Manifold Door (see Figure 3)
45 Two Piece Grommet With Clip (see

Figure 3)
46 Viewport (see Figure 3)
47 Air Tubing (Intake) (see Figure 4)
48 Blower High Limit Switch (see

Figure 4)
49 Intake Air Pressure Switch (NC)

(inside box) (see Figure 4)
50 Capacitor (see Figure 4)
51 Air Tubing (Exhaust) (see Figure 4)
52 Exhaust Air Pressure Switch (NO)

(inside box) (see Figure 4)
*, **, ***, **** see notes on following

page

29

7

28

27

26

25

24

23

6

2

7

8

9

10

11

30

37

AIR INLET
PIPING

7

36

EXHAUST OUTLET

PIPING

31

32

33

34

8

12

35

13 14

15

22

16 17

18

21

Front View

Figure 1 Figure 2

9

1920

Rear View

Natural gas and Propane
(LP) main burner with
igniter assembly. NG burner
shown. LP burner similar
but with drain hole (item 17
in Figure 1).

39

Flare
Nut

20

††

46

45

Figure 3

38

44

40

41

42

43

REPLACEMENT PARTS AND DELIMING PRODUCTS

Replacement parts and recommended delimer may be
ordered through authorized servicers or distributors. When
ordering parts, provide complete model and serial numbers
(see rating plate), quantity and name of part desired.
Standard hardware items may be purchased locally.

COMBO HEATING INLET AND OUTLET SIDE TAPS

Models equipped with Combo Heating capabilities are
shipped with the two side plumbing taps OPEN (item 9 and
item 12 in Figure 1 and see also Figure 6 & Figure 19). If
the heater is to be operated without using the side taps
these openings must be plugged with the two pipe plugs
supplied with the heaters.

Shown with
Junction Box Cover
removed for clarity.

32

33

52

51

50

Vacuum relief valve
install per local
codes (not supplied
with heater).

31

47

48

49

Figure 4

Figure 5

Notes:

* Items not supplied with the water heater.
** The side recirculation loop connections may not be

used as the primary water inlet and outlet connections.
See “Combo Heating Inlet And Outlet Side Taps”

below.
*** Caution harness has 120 VAC In operation.
**** See “Vent Pipe Installation” for more information.

10

WATER PIPING - MIXING VALVE USAGE

Mixing Valves

Water temperature over

DANGER

125°F can cause severe
burns instantly resulting in
severe injury or death.

Children, the elderly and the
disabled and are at highest
risk of scald injury.

Feel water before bathing or
showering.

Temperature limiting devices

HOT

HOT

such as mixing must be
installed when required by
codes and to ensure safe

BURN

temperatures at fixtures.

Water heated to a temperature which satisfi es space
heating, clothes washing, dish washing, and other
sanitizing needs can scald and cause permanent injury
upon contact. Short repeated heating cycles caused by
small hot-water uses can cause a temperature increase of
the hot water by 20F° higher than the heater’s temperature
settings.

TEMPERED
POTABLE WATER

MIXING

VALV E

TEMPERATURE­PRESSURE
RELIEF VALVE

SUGGESTED PIPING ARRANGEMENT

FOR TOP CONNECTIONS

SHUT-OFF

VALV E

COLD-WATER

INLET

This appliance has been design certifi ed as complying with
ANSI/CSA Standard for water heaters and is considered
suitable for combination Water (Potable) Heating and
Space Heating but not space heating only applications.

The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should 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.

TEMPERED

POTABLE WATER

NON-TEMPERED

WATER SUPPLY

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

TEMPERATURE­PRESSURE
RELIEF VALVE

DISCHARGE
PIPE (DO NOT
CAP OR PLUG)

* NOTE: THE

T&P VALVE

DISCHARGE PIPE

SHALL BE PIPED

DIRECTLY TO

THE DRAIN OR

EXTERNAL TO

THE BUILDING

SHUT-OFF

VALV E

COLD-WATER

INLET

NON-TEMPERED

WATER RETURN

MIXING VALVE

METAL DRAIN

PAN 1.75 in.

MAX. DEPTH.

AT LEAST 2

in. GREATER

THAN THE

DIAMETER OF

THE WATER

HEATER.

DISCHARGE
PIPE (DO NOT
CAP OR PLUG)

* NOTE: THE

T&P VALVE

DISCHARGE

PIPE SHALL

BE PIPED

DIRECTLY TO

THE DRAIN

OR EXTERNAL

TO THE

BUILDING

DRAIN
VALV E

MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE
PER SECTION 19 MGL 142.

CERTAIN MODELS

ARE EQUIPPED WITH

SIDE PLUMBING

CONNECTIONS FOR

SPACE HEATING.

METAL DRAIN PAN

1.75 in. MAX. DEPTH.
AT LEAST 2 in.

GREATER THAN THE

DIAMETER OF THE

WATER HEATER.

6 in.
MAX. AIR
GAP*

Figure 6

DRAIN
VALV E

6 in.
MAX. AIR
GAP*

MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE
PER SECTION 19 MGL 142.

Figure 7

TEMPERED

POTABLE

WATER

NON-

TEMPERED

WATER

SUPPLY

TO HOT

OUTLET

SHUT-OFF

MIXING

VALV E

VALV E

NON-

TEMPERED

WATER

RETURN

TO COLD

Figure 8

COLD-

WATER

SUPPLY

INLET

11

Some people are more likely to be permanently injured
by hot water than others. These include the elderly,
children, the infi rm and the physically/mentally disabled.
Table 1 (published by U.S. Government Memorandum,

1978) shows the approximate time-to-burn relationship
for normal adult skin. If anyone using hot water provided
by the water heater being installed fi ts into one of these
groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special
precautions must be taken.

Water

Temperature

°F

Time for 1st

Degree Burns

(Less Severe Burns)

110 (normal shower temp.)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seconds 25 seconds

140 2 seconds 5 seconds

149 1 second 2 seconds

154 instantaneous 1 seconds

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)

Time for Permanent

Burns 2nd & 3rd

Degree (Most

Severe Burns)

Table 1

In addition to using lowest possible temperature setting
that satisfi es demand of application, a mixing valve should
be installed at water heater (see Figure 6 & Figure 7) or at
hot-water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult
a Qualifi ed Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat,
read the “Operating The Temperature Control System”
section in this manual.

WATER HEATER OPERATION

Figure 9 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 lockout mode
and fl ash the corresponding error code.

HEATER

THERMOSTAT

CALLS FOR

HEAT

HEATER CONTROL

CHECKS TO ENSURE

BLOWER EXHAUST

PRESSURE SWITCH IS

OPEN

BLOWER IS

ENERGIZED

CONTROL CHECKS

TO ENSURE:
EXHAUST PRESSURE
SWITCH CLOSES AND

INTAKE PRESSURE

SWITCH REMAINS

CLOSED INDICATING

BLOWER IS

OPERATING AND

THERE ARE NO

BLOCKAGES (INTAKE

OR EXHAUST)

TEMPERATURE

SWITCH REMAINS
CLOSED INDICATING
VENT TEMPERATURE

IS NOT ABOVE THE

ALLOWABLE LIMIT

IGNITER IS ENERGIZED

AND GAS VALVE IS

OPENED

BURNER COMES ON

AND THE FLAME IS

SENSED BY CONTROL

BURNER CONTINUES

UNTILL THE WATER IN

THE TANK REACHES

THERMOSTAT SETTING

GAS VALVE IS CLOSED

AND BURNER SHUTS

OFF

BLOWER CONTINUES

FOR A POST PURGE

TIME

HEATER

REMAINS ON
STANDBY UNTIL
NEXT CALL FOR

HEAT

Figure 9

12

ELECTRICAL REQUIREMENTS & WIRING DIAGRAM

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

specifi ed on the water heater wiring diagram.

• The electrical outlet has the proper overload fuse or

breaker protection.

1. The unit must be connected to a 120VAC power
supply. A dedicated power circuit is preferred.

2. The water heater must be properly grounded.

3. This water heater is a polarity sensitive appliance and
will not operate if the power supply polarity is reversed.

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

After making all electrical connections, completely fi ll 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 fi lling of the tank. The electrical power may then
be turned on. Verify proper operation after servicing. See
also “Installation Checklist”.

CAUTION:

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

NOTE: REFER TO THE “Installation Checklist”
BEFORE OPERATING THIS HEATER.

N

1

L1

1

EARTH GND

CAPACITOR

3

6

BLOWER

2

5

P1

4

1

4

3

P2

2

1

2

4

P3

1

3

P4

3

FLAME SENSOR

6

5

HOT SURFACE IGNITER

4

PRESSURE SWITCH (CLOSED)

PRESSURE SWITCH (OPEN)

2

PRESSURE SWITCH (CLOSED)

4

HIGH LIMIT SWITCH (CLOSED)

4

Circled numbers indicate
sequence of operation.

Figure 11

IF WIRING HAS TO BE REPLACED IN THE FIELD, USE ONLY TYPE TEW 105°C WIRE.

ELECTRICAL RATING 120V, 5A, 60 HZ.

3

1

4

2

1

2

3

4

1

4

2

5

3

6

HONEYWELL GAS VALVE

YELLOW

YELLOW

WHITE

WHITE

WHITE

BLUE

BLUE

BLACK

GREEN

IGNITER - FLAME ROD
ASSEMBLY

PRESSURE

SWITCH

YELLOW

BLUE

JP

1

1

2

2

3

3

4

4

5

5

6

6

(NO)

BLACK SMOOTH - LINE

BLACK RIBBED - NEUTRAL

BLACK MIDDLE - GND

JUNCTION BOX

PRESSURE

SWITCH

(NC)

CAPACITOR

HIGH LIMIT

BLACK

BLACK

BLACK
WHITE

GREEN

120Vac/60Hz Wall Plug

SWITCH

BLOWER

Figure 10

13

SAFETY LOCKOUTS

This water heater has several lockout features designed
to prevent the heater from operating in unsafe conditions.

HIGH LIMIT CONTROLS (ENERGY CUT OFF)

Thermostat/Water Temperature

This feature is a part of the gas control valve/thermostat
(see Figure 1, item 12) and limits the maximum water
temperature. In the event of the water overheating, this
safety feature shuts off the fuel supply to the burner.

Blower High Limit Switch

This device is located on the blower (see Figure 4, item

48) and limits the maximum temperature of the blower.
If the blower temperature rises above the temperature
setting, the switch opens causing the heater to shut down.
The switch will auto reset once the temperature drops
suffi ciently.

BLOWER AIR PRESSURE SWITCHES

The blower/heater is equipped with two air pressure
switches located in the junction box (see Figure 4, item
49 and item 52). These devices are connected in series
and monitor the air pressure produced by the blower. In
the event that the exhaust venting becomes blocked or
suffi ciently restricted, the normally open (NO) air pressure
switch will shut down the heater. In the event that the
intake pipe becomes suffi ciently blocked or restricted, the
normally closed (NC) air pressure switch will shut down
the heater.

14

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

Carefully choose an indoor location for the new water
heater because the placement is a very important
consideration for the safety of the occupants in the building
and for the most economical use of the appliance. This
water heater is not for use in manufactured (mobile) homes
or outdoor installation.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must
be observed:

1. Select a location indoors as close as practical to
the vent termination or location to which the water
heater vent piping is going to be connected, and as
centralized with the water piping system as possible.

2. Selected location must provide adequate clearances
for servicing and proper operation of the water heater.

3. Avoid locations that could cause the water heater to
freeze from outside air.

4. Selected location must provide access to a properly
grounded electrical branch circuit. A dedicated circuit
is preferred. Do not use a GFI outlet.

5. Avoid locations that expose the water heater to direct
sunlight.

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

Important: Do not use an extension cord to connect the
water heater to an electrical outlet.

CAUTION

• Sensors mounted in the metal drain pan that trigger an

alarm or turn off the incoming water to the water heater
when leakage is detected.

• Sensors mounted in the metal drain pan that turn off

the water supply to the entire building when water is
detected in the metal drain pan.

• Water supply shut-off devices that activate based on

the water pressure differential between the cold-water
and hot-water pipes connected to the water heater.

• Devices that will turn off the gas supply to a gas water

heater while at the same time shutting off its water
supply.

WARNING

Fire or Explosion Hazard

• Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Property Damage Hazard

• All water heaters eventually leak.

• Do not install without adequate drainage.

Installation of the water heater must be accomplished in
such a manner that if the tank or any connections should
leak, the fl ow of water will not cause damage to the
structure. For this reason it is not advisable to install the
water heater in an attic or upper fl oor. In all cases, a metal
drain pan should be installed under the water heater. Metal
drain pans are available at your local hardware store. Such
a metal drain pan must have a clearance of at least 1 in.
greater than any point on the water heater’s outer jacket
and must be piped to an adequate drain. The pan must
have a maximum depth of 1.75 in. .
Water heater life depends upon water quality, water
pressure and the environment in which the water heater
is installed. Water heaters are sometimes installed in
locations where leakage may result in property damage,
even with the use of a metal drain pan piped to a drain.
However, unanticipated damage can be reduced or
prevented by a leak detector or water shut-off device used
in conjunction with a piped metal drain pan. These devices
are available from some plumbing supply wholesalers and
retailers, and detect and react to leakage in various ways:

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 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.

Flammable Vapors

WARNING

Fire Hazard

For continued protection against
risk of fire:

• Do not install water heater on
carpeted floor.

• Do not operate water heater if
flood damaged.

15

Clearances To Combustibles

Minimum clearances between water heater and
combustibles are 0 in. at the sides and rear, 5.5 in. from the
front and 12 in. from top (standard clearance.) If clearances
stated on the heater differ from standard clearances, install
water heater according to clearances stated on the heater
(see Figure 12).

Floors With Carpeting

This water heater must not be installed directly on
carpeting. Carpeting must be protected by a metal or
wood panel beneath the appliance extending beyond the
full width and depth of the appliance by at least 3 in. in
every direction, or if the appliance is installed in an alcove
or closet, the entire fl oor must be covered by the panel.
Failure to heed this warning may result in a fi re hazard.

Clearances For Servicing

When installing the heater, consideration must be given to
proper location. Location selected should be as close to
the wall as practicable and as centralized with the water
piping system as possible.

Servicing this appliance, such as changing the anodes,
etc. requires clearances for accessibility and replacement
of parts. The anode could be as long as 35 in. .

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Flue gases may escape if
vent pipe is deformed,
broken, or not properly
connected.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

Refer to the current edition of the “National Fuel Gas
Code”, ANSI Z223.1/NFPA 54 for detailed requirements.

0in. MIN.

TOP VIEW

OF CLOSET

WITHOUT DOOR

0 in.

MIN.

5.5 in. MIN.

TOP VIEW OF

CLOSET WITH

DOOR

0 in.
MIN.

Figure 12

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Install water heater in accordance with the
instruction manual and NFPA 54.

• To avoid injury, combustion and ventilation air
must be taken from outdoors.

• Do not place chemical vapor emitting products
near water heater.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

16

Important Notes and Warnings

• This heater is certifi ed to be installed using Schedule

40 PVC or CPVC or polypropylene plastic vent material.
Only use approved material. All venting material and
components must be joined with the approved primer/
cleaner and solvent cement or mechanical seals. To join
PVC and CPVC materials, use ATSM F-493 compliant
cement.

• Do not common vent this heater with any other

appliance.

• During operation the plastic piping will expand as it

heats up and contract as it cools down. This is normal
for this type of venting. Rigidly fastening the vent piping
can cause undue stress that may result in the cracking
or fracturing the vent piping material. A fracture of the
venting pipe may pose a serious safety hazard. To
prevent stressing of the vent system, all hangers and
supports must allow the vent piping freedom to move.

• Use long sweep elbows wherever possible. Closely

coupled elbows and short radius elbows can reduce
the venting capacity.

• All power vented water heaters generate a certain

amount of operational noise. In order to minimize
noise transmission to the support structure, it is
recommended to use isolation pads between the pipe
hangers and the vent pipe.

• Most power vent installations develop some

condensation in the vent piping. When using long runs
of venting or when the venting passes through cold or
unheated areas, considerable amounts of condensate
from the fl ue gases can develop. Provision must be
made for the condensate to drain freely from the
system or to be collected in a condensate trap(s) that
can be drained. Damage or fracture of the vent piping
may occur if the condensate is allowed to collect and
freeze. Pooling of condensate can restrict airfl ow and
can cause nuisance failures of the system.

Keep it on the side of the water heater or nearby for
future reference.

• Do obtain new warning and instruction labels from the

manufacturer for placement on the blanket directly over
the existing labels.

• Do inspect the insulation blanket frequently to make

certain it does not sag, thereby obstructing combustion
air fl ow.

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Do not obstruct water heater air intake(s) with
insulating jacket.

• Gas and carbcn monoxide detectors are available.

• Install water heater in accordance with the
instruction manual and NFPA54.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

AIR REQUIREMENTS

For safe operation an adequate supply of fresh,
uncontaminated air for combustion, dilution and ventilation
must be provided.
Note: Contaminated or dusty air may cause build-up on
the blower wheel resulting in nuisance shut downs.

INSULATION BLANKETS

Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary
with these products. The purpose of an insulation blanket is
to reduce standby heat loss encountered with storage tank
heaters. Your water heater meets or exceeds the current
standards with respect to insulation and standby loss
requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to
this heater, you should follow these instructions (For
identification of components mentioned below, see
Figure 1 thru Figure 5). Failure to follow these instructions
will restrict the air fl ow required for proper combustion and
dilution, potentially resulting in fi re, asphyxiation, serious
personal injury or death.

• Do not apply insulation to the top of the water heater,

as this will interfere with safe operation of the blower
assembly.

• Do not cover the outer door, thermostat or T&P relief

valve.

• Do not cover the “Installation And Operating manual”.

17