John Wood Envirosense Power Direct Vent User Manual

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RESIDENTIAL GAS WATER HEATERS

CANADIAN MANUAL

Instruction Manual

POWER VENT/POWER DIRECT VENT GAS MODELS

WITH HOT SURFACE IGNITION

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

PRINTED 0609 316312-000

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

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.

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.

IMPORTANT DEFINITIONS

• Qualied Installer: A qualied installer must have ability equivalent to a licensed tradesman in the elds of plumbing,

air supply, venting and gas supply, including a thorough understanding of the requirements of the Natural Gas and Propane Installation Code as it relates to the installation of gas red water heaters. The qualied installer must also be familiar with the design features of water heaters, and have a thorough understanding of this instruction manual.

• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the elds of plumbing,

air supply, venting and gas supply, including a thorough understanding of the requirements of the Natural Gas and Propane Installation Code as it relates to the installation of gas red water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer.

• Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning

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

GENERAL SAFETY

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE............................2

GENERAL SAFETY..................................................................3

TABLE OF CONTENTS ............................................................5

INTRODUCTION ......................................................................5

Preparing for the Installation .............................................5

Get to Know Your Water Heater ........................................6

INSTALLATION CONSIDERATIONS .......................................7

Rough In Dimensions........................................................7

Water Piping - Mixing Valve Usage ...................................8

Facts to Consider About Location .....................................9

Insulation Blankets ..........................................................10

Combustion Air and Ventilation .......................................10

Appliances in Unconned Spaces ...........................10

Appliances in Conned Spaces ..............................10

INSTALLING THE WATER HEATER ..................................... 12

Chemical Vapor Corrosion ..............................................12

Water Piping ...................................................................12

Temperature-Pressure Relief Valve ................................13

Gas Piping ......................................................................14

Sediment Traps ...............................................................15

Filling the Water Heater ..................................................15

Venting ............................................................................15

Vent Pipe Termination ............................................... 15-16

Planning the Vent System ...............................................18

Condensate.....................................................................18

Installation of Vent System..............................................19

Vent Terminal Installation, Sidewall .................................19

Sequence of Installations, Figure 18A ............................19

Direct Venting..................................................................19

Direct Vent Terminal Installation ......................................19

Installation Sequence......................................................20

Vertical Vent Terminal Installation ...................................20

Installation of Vent System, Sidewall ..............................21

Installation of Vertical Vent System .................................21

Vent Pipe Preparation .....................................................25

Controls and Switches ....................................................27

Power Vent Wiring Schematic.........................................28

LIGHTING & OPERATING LABEL .........................................29

TEMPERATURE REGULATION ............................................30

USING THE ELECTRONIC CONTROLLER ..........................31

FOR YOUR INFORMATION ...................................................35

Start Up Conditions

Smoke/Odor ............................................................35

Thermal Expansion .................................................35

Strange Sounds ......................................................35

Operational Conditions ...................................................35

Smelly Water ...........................................................35

“Air” in Hot Water Faucets .......................................35

PERIODIC MAINTENANCE ...................................................36

Venting System Inspection..............................................36

Burner Operation and Inspection ....................................36

Burner Cleaning ..............................................................36

Housekeeping .................................................................36

Anode Rod Inspection.....................................................37

Temperature-Pressure Relief Valve Operation ...............37

Draining...........................................................................37

Service ............................................................................38

LEAKAGE CHECKPOINTS ....................................................38

TROUBLESHOOTING ...........................................................39

NOTES ...................................................................................40

WARRANTY ...........................................................................41

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and

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

Abbreviations Found In This Instruction Manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturer’s Association

• UL - Underwriters Laboratories Inc.

This gas-red water heater is design certied by Underwriters Laboratories Inc. under American National Standard/CSA Standard for Gas Water Heaters ANSI Z21.10.3 • CSA 4.3 (current edition).

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section, page 3 and 4 of this manual rst and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY

DAMAGE.

This manual contains instructions for the installation, operation,

and maintenance of the gas-red water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the rst few pages, READ THE ENTIRE

MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

2. The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the Natural Gas and Propane Installation Code CAN/CSA B149.1 and the Canadian Electrical Code CAN/CSA C22.1. These publications are available from the Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

3. The water heater when installed must be grounded in accordance with the local codes, or in the absence of local codes: the Canadian Electrical Code (C22.1).

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

5. Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and res, see Figures 1 and 2.

Examine the location to ensure the water heater complies with

the “Facts to Consider About Location” section in this manual.

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Control Assembly B Blocked Inlet Switch C Blocked Outlet Switch D Fan Prover Switch E Blower Assembly F Burner Assembly G Flame Sensor H Hot Surface Igniter I Junction Box J Gas Valve Assembly K Display Board L Top Plastic Enclosure

M Display Enclosure ** N Exhaust Elbow Assembly ** O Condensate Tubing P Off/On Switch Q Display Label R Hot Water Outlet *S Electrical Outlet (120VAC) T Gas Supply U Main Manual Gas Shutoff Valve V Union W Inlet Water Shutoff Valve X Cold Water Inlet

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.

Y Inlet Dip Tube Z T/P Relief Valve AA Rating Plate BB Labels CC Drain Valve ** DD Vent Terminal EE Metal Drain Pan FF Anode GG Insulation HH Upper Temperature Probe II Access Door

VACUUM RELIEF

VALVE

*INSTALL PER

LOCAL CODES

ACCESS PANEL

Caution:

This access panel covers a 2” NPT plug that was required during the manufacturing of this water heater. This 2” NPT ange is not a cleanout tting, removing the 2” NPT plug and using this tting as a cleanout could void your warranty.

* CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See “Planning the Vent System,” “Installation of Vent System” and “Condensate” for more information.

FIGURE 1.

INSTALLATION CONSIDERATIONS

ROUGH IN DIMENSIONS

FIGURE 1A.

Rough-In-Dimensions

Model Units A B C D E F

Inches 68.50 49.25 22.00 15.75 3.00 8.00

100

Top/Side Inlet and Outlet: 3/4” NPT Gas Inlet: 1/2” NPT

Capacity, Gas and Electrical Characteristics

Model

All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa) Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa) Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa) Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.

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

Model

Recovery capacity based on 96% thermal efciency

cm 174 125.09 55.88 40.00 7.62 20.32

Approximate Capacity Manifold Pressure Electrical Characteristics

U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes

100 50 189 Nat./LP 0” 0” 120/60 <5

Input Recovery Capacities

Rating

(Btu/hr)

100 100,000 29.3

Rating

(kW)

Temp.

Rise

F 30 40 50 60 70 80 90 100 110 120 130 140

C 17 22 28 33 39 44 50 56 61 67 72 78

GPH 387 291 233 194 166 145 129 116 106 97 90 83

LPH 1465 1102 882 734 628 549 488 439 401 367 341 314

WATER PIPING - MIXING VALVE USAGE

* The side recirculation loop connections may not be used as the primary water inlet and outlet connections. For your convenience, plugs are installed

in these ttings at the factory. Remove these plugs if needed for your specic installation. Otherwise (as with all connections) check for leaks while lling the tank with water and after completing the installation.

FIGURE 2.

This appliance has been design certified as complying with American National Standard/CSA Standard for water heaters and is considered suitable for:

Water (Potable) Heating and Space Heating: All models are considered suitable for water (potable) heating and space heating.

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, and the physically or developmentally disabled. If anyone using hot water from this heater fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a Mixing Valve should be used at the hot water taps used by these people or at the water heater, see Figure 2. Mixing valves are available at plumbing supply or hardware stores. Consult a Qualified Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

FACTS TO CONSIDER ABOUT THE LOCATION

Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured

(mobile) homes or outdoor installation.

Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed:

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

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper oor. When such locations cannot be avoided, a suitable drain pan should be installed under the water heater. Drain pans are available at your local hardware store. Such a metal drain pan must have a clearance of at least 1.0” (2.5cm) greater than any point on the water heater’s outer jacket and must be piped to an adequate drain. The pan must not restrict combustion air ow. For example, if a circular pan is used, it must be a minimum of 27” (69cm) in diameter. See Figure 1.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a 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 drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the 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 drain pan.

• Water supply shut-off devices that activate based on the water

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

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

at the same time shutting off its water supply.

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VA PORS) ARE LIK ELY TO BE PRESENT OR STORE D (GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as gasoline, solvents, propane (LP or butane, etc.) and other substances (such as adhesives, etc.) emit ammable vapors which can be ignited by a gas water heater’s hot surface igniter or main burner. The resulting ashback and re can cause death or serious burns to anyone in the area.

Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3” (7.6 cm) in any direction, or if the appliance is installed

in an alcove or closet, the entire oor must be covered by the panel. Failure to heed this warning may result in a re hazard.

Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from the front and 12” (30.5 cm) from the top. (Standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater.

Adequate clearance 24” (61.0 cm) for servicing this appliance should be considered before installation, such as changing the anodes, etc.

A minimum clearance of 5.5” (14.0 cm) must be allowed for access to replaceable parts such as the thermostats, drain valve and relief valve.

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

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 ow.

COMBUSTION AIR AND VENTILATION

A gas water heater cannot operate properly without the correct amount of air for combustion. Do not install in a conned area such as a closet, unless you provide air as shown in the “Facts to Consider About Location” section. Never obstruct the ow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a re or explosion and cause death, serious bodily injury, or property damage.

FIGURE 3. FIGURE 4.

INSULATION BLANKETS

Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the Energy Policy Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identication of components mentioned below, see Figure 1). Failure to follow these instructions can restrict the air ow required for proper combustion, potentially resulting in 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 temperature & pressure relief valve.

• Do not allow insulation to come within 2” (5.1 cm) of the oor to prevent blockage of combustion air ow to the burner.

• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

• Do obtain new warning and instruction labels from the manufacturer

FIGURE 5.

If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater (s) be installed direct vent so that all air for combustion and ventilation is taken from outdoors.

Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly ammable in many cases, will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater. The results can be hazardous, and also cause product failure.

APPLIANCES IN UNCONFINED SPACES

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 cubic meters per kW) of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconned space.

In unconned spaces in buildings, inltration may be adequate to provide air for combustion, ventilation and dilution of ue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in “Appliances in Conned Space” that follows.”

APPLIANCES IN CONFINED SPACES

CONFINED SPACE is a space whose volume is less than 50 cubic

feet per 1,000 Btu per hour (4.8 cm per kW) of the aggregate input rating of all appliances installed in that space.

When drawing combustion air from inside a conventionally constructed building to a confined space, such a space shall be provided with

two permanent openings. ONE WITHIN 12 INCHES (30 cm) OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES (30 cm) OF THE ENCLOSURE BOTTOM. Each opening shall have

a free area of one square inch per 1000 Btu/hr (22 cm2/kW) of the total input of all appliances in the enclosure, but not less than 100 square inches (645 cm

If the conned space is within a building of tight construction, air for combustion and ventilation must be obtained from outdoors. When directly communicating with the outdoors or communicating through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btu/hr (5.5 cm

/kW) of total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btu/ hr (11cm

/kW) of the total input of all appliances in the enclosure.

A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 5 and 6) The conned space shall be provided with two permanent openings

communicating directly with an additional room(s) of sufcient volume so that the combined volume of all spaces meets the criteria for an unconned space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of one square inch per 1,000 Btu per hour (22 cm utilization

inches (645 cm

equipment in the conned space, but not less than 100 square

). One opening shall commence within 12 inches

/kW) of the total input rating of all gas

(30 cm) of the top and one commencing within 12 inches (30 cm) of the bottom of the enclosures.

Btu per hour (11 cm2/kW)) of total input rating of all equipment in the enclosure, see Figure 9.

FIGURE 8.

4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum short side dimension of rectangular air ducts shall not be less than 3 inches (7.6 cm), see Figure 9.

FIGURE 6.

B. ALL AIR FROM OUTDOORS: (See Figures 7, 8 and 9)

The conned space shall be provided with two permanent openings,

one commencing within 12 inches (30 cm) of the top and one commencing within 12 inches (30 cm) from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. Wh en di re ct ly co mm un ic ati ng wi th th e o utdo or s, eac h o pe ni ng s ha ll ha ve a minimum free area of 1 square inch per 4,000 Btu per hour (5.5 cm2/kW) of total input rating of all equipment in the enclosure, see Figure 7.

FIGURE 7.

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 Btu per hour (5.5 cm2/kW) of total input rating of all equipment in the enclosure, see Figure 8.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000

FIGURE 9.

5. Alternatively a single permanent opening may be used when communicating directly with the outdoors, or with spaces that freely communicate with the outdoors. The opening shall have a minimum free area of 1 square inch per 3,000 BTU per hour (8.3 cm2/kW) of total input rating of all equipment in enclosure. See Figure 9A.

FIGURE 9A.

6. Louvers and Grilles: In calculating free area, consideration shall be given to

the blocking effect of louvers, grilles or s protecting openings. Screens used shall not be smaller than 1/4 inch (6.4 mm) mesh. If the free area through a design of louver or grille is known, it should be used in calculating the size opening required to provide the free area specied. If the design and free area is not known, it may be assumed that wood louvers will be 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be xed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

7. Special Conditions Created by Mechanical Exhausting or Fireplaces: operation of exhaust fans, ventilation systems, clothes dryers or replaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.

INSTALLING THE NEW WATER HEATER

CHEMICAL VAPOR CORROSION

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH

CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION. Spray can propellants, cleaning solvents, refrigerator and air

conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.

Do not store products of this sort near the heater. Also, air which is brought in contact with the heater should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (See limited warranty for complete terms and conditions).

WATER PIPING

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure reducing valves, check valves, and back ow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system the volume of water will grow when it is heated. As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperaturepressure relief valve operation: water discharged from the valve due to excessive pressure build up. This condition is not covered under the limited warranty. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion.

A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion..

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the physically or developmentally disabled. If anyone using hot water ts into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satis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, see Figure 2. Valves for reducing point of use temperature by mixing cold and hot water are also available:

Consult a Qualied Installer or Service Agency. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance.

All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to Figure 2 for suggested piping arrangement.

FIGURE 10.

NOTE: To protect against untimely corrosion of hot and cold

water ttings, it is strongly recommended that di-electric unions

or couplings be installed on this water heater when connected to copper pipe, see Figure 2 also.

Figures 2 and 10 show the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 inch NPT water connections.

If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certied as indicated in the above paragraph.

NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water heater connections. Do not solder the water lines directly to the water heater connections. It will harm the dip tube and damage the tank.

T & P Valve and Pipe Insulation (if supplied)

Remove insulation for T & P valve and pipe connections from carton.

FIGURE 11.

Fit pipe insulation over the incoming cold water line and the hot water line. Make sure that the insulation is against the top cover of the heater.Fit T & P valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T & P valve.

The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater model rating plate.

For safe operation of the water heater, the relief valve must not be removed from its designated opening nor plugged.

The temperature-pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only within 6 inches (15.2 cm) above, or at any distance below the structural floor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve, see Figures 10.

No valve or other obstruction is to be placed between the relief valve and the tank. Do not connect tubing directly to discharge drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.

Btu/hr input rate as shown on the water heater’s

Secure all insulation using tape.

TEMPERATURE-PRESSURE RELIEF VALVE

This heater is provided with a properly certified combination temperature - pressure relief valve by the manufacturer.

The Discharge Pipe:

• Should not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

• Should not be plugged or blocked.

• Should be of material listed for hot water distribution.

• Should be installed so as to allow complete drainage of both the temperature-pressure relief valve, and the discharge pipe.

• Must terminate a maximum of six inches above a oor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

• Should not have any valve between the relief valve and tank.

The valve is certied by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.

The temperature-pressure relief valve must be manually operated periodically, see Figure 28. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot.

If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions, and replace the temperature-pressure relief valve with a new one.

GAS PIPING

Make sure gas supplied is same type listed on model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5 kPa) for natural and propane gas (L.P.). The minimum inlet gas pressure shown on rating plate is that which will permit ring at rated input.

All gas piping must comply with local codes and ordinances or with the Natural Gas and Propane Installation Code (CAN/CSA B149.1). Copper or brass tubing and ttings (except tin lined copper tubing) shall not be used.

HIGH ALTITUDE INSTALLATIONS

Rated inputs are suitable up to 10,100 feet (3,079m) elevation. Consult the factory for installation at altitudes over 10,100 feet (3,079m).

WARNING:

FOR USE WITHOUT MODIFICATION FOR AN ALTITUDE OF 10,100

FEET (3,079 METERS). INSTALLATIONS ABOVE THESE ALTITUDES MAY REQUIRE REPLACEMENT OF BURNER ORIFICE. CALL THE TECHNICAL CENTER AT (800) 527-1953 FOR

Some gas utility companies derate their gas for altitude, making it unnecessary to install high altitude orices. Call the local gas or utility company to verify BTU content.

Due to the input ration reduction at high altitudes, the output rating of the appliance is also reduced and should be compensated for in the sizing of the equipment for applications.

THIS HIGH EFFICIENCY WATER HEATER IS CERTIFIED

REQUIREMENTS.

If the gas control valve is subjected to pressures exceeding 1/2 psi (3.5 kPa), the damage to the gas control valve could result in a re or explosion from leaking gas.

If the main gas line Shut-off serving all gas appliances is used, also turn “off” the gas at each appliance. Leave all gas appliances shut “off” until the water heater installation is complete.

A gas line of sufcient size must be run to the water heater. Consult the current edition of the Natural Gas and Propane Installation Code (CAN/CSA B149.1) and your gas supplier concerning pipe size.

There must be:

• A readily accessible manual shut off valve in the gas supply line serving the water heater, and

• A drip leg (sediment trap) ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve.

• A exible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open ame. Rinse off soapy solution and wipe dry.

Use pipe joint compound or teon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases.

The appliance and its gas connection must be leak tested before placing the appliance in operation.

The appliance and its individual Shut-off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch (3.5 kPa). It shall be isolated from the gas supply piping system by closing its individual manual Shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 pound per square inch (3.5 kPa).

IMPORTANT: MAKE SURE THE GAS LINE IS PIPED IN WITH HARD PIPE. AVOID FLEX LINE CONSTRUCTION FOR GAS DUE TO POSSIBLE GAS FLOW PROBLEMS.

SEDIMENT TRAPS

A sediment trap shall be installed as close to the gas inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee tting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap.

Contaminants in the gas lines may cause improper operation of the gas control valve that may result in re or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a drip leg (sometimes called a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible. Install in accordance with the “Gas Piping” section. Refer to the current edition of the Natural Gas and Propane Installation Code (CAN/CSA B149.1).

FILLING THE WATER HEATER

VENTING

VENT PIPE TERMINATION

Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be lled with water. Water must ow from the hot water faucet before turning “ON” gas to the water heater.

To ll the water heater with water:

1. Close the water heater drain valve by turning the handle to the right (clockwise). The drain valve is on the lower front of the water heater.

2. Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open when the water heater is in use.

3. To insure complete lling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant ow is obtained. This will let air out of the water heater and the piping.

4. Check all water piping and connections for leaks. Repair as needed.

The first step is to determine where the vent pipe will terminate. See Figures 19, 20, and 21. The vent may terminate through a sidewall as shown in Figure 19 or through the roof as shown in Figures 20 and 21.

The vent system must terminate so that proper clearances are m aintaine d as ci t e d in l ocal co d es or the cu r r e nt edition of the Natural Gas and Propane Installation Code (CAN/ CSA-B149.1).

Instructions on proper installation through a sidewall are provided in Figures 15A and 15B.

Plan the vent system layout so that proper clearances are maintained from plumbing and wiring.

Vent pipes serving power vented appliances are classified by building codes as “vent connectors”. Required clearances from combustible materials must be provided in accordance with information in this manual under FACTS TO CONSIDER ABOUT LOCATION and INSTALLING THE WATER HEATER, and with the National Fuel Gas Code and local codes.

CAUTION

TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN

WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO

TERMINALS IS RECOMMENDED.

CANADIAN POWER VENT

VENT HOOD(S) MAY BE

WARNING

EXTREMELY HOT

DURING OPERATION.

FIGURE 12.

CAUTION

TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN

WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO

TERMINALS IS RECOMMENDED.

CANADIAN DIRECT VENT

VENT HOOD(S) MAY BE

WARNING

EXTREMELY HOT

DURING OPERATION.

FIGURE 13.

PLANNING THE VENT SYSTEM

Plan the route of the vent system from the exhaust elbow to the planned location of the vent terminal.

1. Layout total vent system to use a minimum of vent pipe and elbows.

2. This water heater is capable of venting ue gases equivalent to 25’ (7.6 m) of 2” pipe, 65’ (19.8 m) of 3” pipe, or 128’ (39.0 m) of 4” pipe as listed in Table 1.

TABLE 1

Number of 2” Maximum 3” Maximum 4” Maximum 90° Elbows Pipe - ft. (m) Pipe - ft. (m) Pipe - ft. (m)

1 20 (6.1) 60 (18.3) 120 (36.6) 2 15 (4.6) 55 (16.8) 112 (34.1) 3 10 (3.0) 50 (15.2) 104 (31.7) 4 -- 45 (13.7) 96 (29.3) 5 -- 40 (12.2) 88 (26.8) 6 -- 35 (10.7) 80 (24.3)

The minimum vent lengths for each of the pipe sizes is one 90° plus 2’ (61 cm) of straight pipe and the appropriate termination.

NOTE: The equivalent feet (m) of pipe listed above are exclusive

of the termination. That is, the termination, with an installed screen, is assumed to be in the system and the remainder of the system must not exceed the lengths discussed above.

3. The exhaust elbow assembly is designed to accept only straight

sections of 2” pipe. To start, a minimum of 2” (5.1cm) of 2” pipe must be inserted and glued to the exhaust elbow assembly if utilizing 3” or 4” vent pipe. Use the same method with the blower inlet if a direct vent conguration is utilized.

joints between elbows and other ttings and straight runs of vent pipe. Check system for signs of sagging or other stresses in joints as a result of misalignment of any components in the system. If any of these conditions are found, they must be corrected in accordance with the venting instructions in this manual before completing installation and putting the water heater into service.

NOTE: A. For water heaters in locations with high ambient

temperatures (above 100°F) it is recommended that CPVC pipe and ttings be used. B. A 22.5 degree elbow (2” vent pipe) or a 45 degree elbow (3” and 4” vent pipe) with an installed screen

VENT TERMINAL must be used in all cases.

4. There will be some installations where condensate will be formed

in the horizontal runs of the vent system. This condensate will run into the condensate elbow. The water heater is shipped with a condensate hose that attaches to the condensate elbow. No other tee or tting is required.

CONDENSATE

This water heater is a condensing unit and requires a drain to be located in close proximity to allow the condensate to drain safely. The condensate drains from the unit at the exhaust tee located at the bottom of the unit (see gure 16). Condensate from this water heater is mildly acidic. Please note that some local codes require that condensate is treated by using a pH neutralizing lter prior to disposal.

Caution must be used to ensure that the drain is free and clear of debris and will not allow backow through the condensate hose. Consideration must be given to avoid freezing of the condensate lines which could result in excessive build up of condensate inside the water heater. Waterproof heat tape may be required to prevent freezing of the condensate lines. Please ensure that the outlet of the condensate drain does not create a slippery condition which could lead to personal injury.

If using 2” inch vent pipe:

A minimum of 2” (5.1cm) diameter vent pipe must be attached

to the exhaust elbow assembly. The total system cannot exceed the lengths discussed above, where each elbow is equal to 5 equivalent feet (1.5m) of straight pipe.

If using 3” or 4” inch vent pipe:

Two inches (5.1cm) of 2” pipe must be attached to the exhaust

elbow assembly before adding a reducer to acquire the desired pipe diameter. An appropriately sized 45 degree elbow (supplied locally-a schedule 40 DWV) vent terminal must be obtained with an equivalent screen (supplied in vent kit). The total system cannot exceed the equivalent pipe lengths discussed above where each elbow is equal to 5 feet (1.5m) of straight pipe (3” vent pipe) or 8 feet (2.4m) of straight pipe (4” vent pipe).

Installation of this water heater must comply with CAN/CSA B149.1 - Natural Gas and Propane Installation Code which

requires the vent system components be certied to ULC

S636.

This water heater has been design certied to be vented with PVC

pipe certied and marked as complying with ULC S636. This water heater is supplied with a 2 inch 22.5 degree termination elbow that is a special tting that must be used with the appliance. Any outlet piping, ttings and glue used to vent this appliance that is not supplied by the manufacturer must comply with the ULC S636 requirements.

CONDENSATION WARNING: THIS WATER HEATER IS A CONDENSING UNIT AND REQUIRES A DRAIN TO BE LOCATED IN CLOSE PROXIMITY TO ALLOW CONDENSATE TO DRAIN SAFELY. THE CONDENSATE DRAINS FROM UNIT AT THE EXHAUST ELBOW LOCATED AT BOTTOM OF UNIT. NOTE: IT IS IMPORTANT THAT THE CONDENSATE HOSE NOT BE ELEVATED ABOVE THE EXHAUST ELBOW, SEE FIGURE 16. CONDENSATE BUILD-UP WILL BLOCK THE EXHAUST OUTLET, WHICH WILL CAUSE IMPROPER OPERATION.

If the water heater is being installed as a replacement for an existing

power vented heater in pre-existing venting, a thorough inspection of existing venting system must be performed prior to any installation work. Verify that correct material as detailed above has been used, and that the minimum or maximum vent lengths and terminal location as detailed in this manual have been met. Carefully inspect the entire venting system for any signs of cracks or fractures, particularly at

FIGURE 14.

INSTALLATION OF VENT SYSTEM

DIRECT VENTING

Before beginning installation of piping system thoroughly read the section of this manual VENT PIPE PREPARATION.

If you are installing your system so that it vents through roof, please refer to section titled INSTALLATION OF VERTICAL

VENT SYSTEM.

VENT TERMINAL INSTALLATION, SIDEWALL

1. Install the vent terminal by using the cover plate as a template to mark the hole for the vent pipe to pass through the wall.

BEWARE OF CONCEALED WIRING AND PIPING INSIDE THE WALL.

2. If the Vent Terminal is being installed on the outside of a finished wall, it may be easier to mark both the inside and outside wall. Align the holes by drilling a hole through the center of the template from the inside through to the outside. The template can now be positioned on the outside wall using the drilled hole as a centering point for the template.

3. A) MASONRY SIDE WALLS

Chisel an opening approximately one half inch (1.3 cm) larger

than the marked circle.

B) WOODEN SIDE WALLS Drill a pilot hole approximately one quarter inch (0.64 cm) outside

of the marked circle. This pilot hole is used as a starting point for a saws-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch (0.64 cm) outside of the line. (This will allow the vent to easily slide through the opening. The resulting gap will be covered up by the Vent Terminal cover plate.) Repeat this step on inside wall if necessary.

SEQUENCE OF INSTALLATIONS, FIGURE 18A

The air intake provided on the unit contains a mesh screen to prevent large particles from entering the unit.

FIGURE 16.

WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH SCREEN MUST BE REMOVED. THE INLET VENT PIPE

MAY THEN BE GLUED TO THE AIR INTAKE (See Figure 18B)

PROVIDED ON THE UNIT. THE SCREEN REMOVED FROM THE

INTAKE NEEDS TO BE INSERTED INTO THE 2” - 22.5 DEGREE VENT TERMINAL SUPPLIED IN THE VENT TERMINAL KIT.

DIRECT VENT TERMINAL INSTALLATION IMPORTANT

THIS UNIT CONSISTS OF TWO VENT TERMINALS - AN INTAKE VENT TERMINAL AND AN EXHAUST VENT TERMINAL. THE INTAKE VENT TERMINAL IS A 2” 22.5° PVC ELBOW(-) WITH A MESH SCREEN AND THE EXHAUST VENT TERMINAL IS A 2” 22.5° PVC

ELBOW WITH A MESH SCREEN.

NOTE: TO PREVENT EXHAUSTING PRODUCTS FROM CIRCULATING TO THE AIR INTAKE IN WINDY/COLD AREAS, THE MAXIMUM PRACTICAL DISTANCE BETWEEN THESE TWO

TERMINALS IS RECOMMENDED.

Cut a length of PVC pipe about 3.5 inches (8.9 cm) longer than the wall thickness at the opening. Glue the vent terminal to this section of pipe. Slide the wall plate over the pipe to stop against the vent terminal. Place a bead of caulking (not supplied) around the gap between the pipe and cover plate. Apply enough to fill some of the gap between the pipe and wall. Place some of the caulking on the back of the plate to hold it against the wall after installation. If the vent pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the vent terminal can be prepared for gluing before inserting through the wall. Slide the pipe through the wall and insert into the coupling on the other side of the wall, making sure that the vent terminal ends up pointed in the correct position, see Figure 15.

VENT TERMINATION - FIGURE 15.

FIGURE 17.

WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.

1. The intake air terminal and the exhaust vent terminal must terminate on the same exterior wall and must be separated by a minimum of 24” (61cm) on vertical centerline (see Figure 18C). In colder climates increasing the 24” (61cm) minimum will reduce possibility of frost over from side winds blowing exhaust vapors to the air intake of the direct vent.

2. The horizontal centerline of the intake air terminal may not be located lower than the horizontal centerline of the exhaust vent terminal (see Figure 17).

INSTALLATION SEQUENCE

VERTICAL VENT TERMINAL INSTALLATION

VENT TERMINALS SUPPLIED WITH HEATER MUST BE USED.

NOTE: BEFORE BEGINNING INSTALLATION OF ANY VENT PIPE READ THE VE NT PIPE MANUFACTURER’S

INSTALLATION INSTRUCTIONS.

1. After the points of termination have been determined, use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall. BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL. If the vent terminals are being installed on the outside of a nished wall, it may be easier to mark both the inside and outside wall. Align the holesby drilling a hole through the center of the template from the inside through to the outside. The template can now be positioned on the outside wall using the drilled holes as a centering point for the template.

A.) MASONRY SIDE WALLS Chisel an opening approximately

1/2” (1.3 cm) larger than the marked circle. B.) WOODEN SIDE WALLS Drill a pilot hole approximately one quarter inch outside of the marked circle. This pilot hole is used as a starting point for a saws-all or sabre saw blade. Cut around the marked circle staying approximately one quarter inch outside of the line. (This will allow the vent pipe to easily slide through the opening. The resulting gap will be covered by the vent terminal cover plates.) Repeat this step on the inside wall if necessary.

2. Cut a length of 3” PVC pipe about 3.5” (8.9 cm) longer than the wall thickness at the opening.

3. Glue the intake vent terminal to the section of the pipe.

4. Slide the wall plate over pipe to stop against intake vent terminal.

5. Place a bead of caulking (not supplied) around the gap between the pipe and the wall. Place some of the caulking on the back of the plate to hold it against the wall after installation.

6. If the vent pipe is installed up to the wall, with a coupling on the end against the wall opening, the pipe with the vent terminal can be prepared for gluing before inserting through the wall. Slide the pipe through the wall and insert into coupling on the other side of the wall, making sure that the vent terminal ends up pointed in the correct position (Figure 18 and 19).

CAUTION

IMPORTANT

WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.

1. Proper support must be provided for all pipe protruding through the roof.

2. The vertical roof terminals should be sealed with a plumbing roof boot or equivalent ashing.

3. The intake vent terminals and the exhaust vent terminals must penetrate the same side of roof.

4. The center line of the intake vent terminal and the center line of the exhaust vent terminal must be no closer than 24” (61cm).

5. The intake vent terminal and the exhaust vent terminal must be oriented facing downward and the same direction.

The specications are displayed in Figures 20 & 21.

NOTE: Exhaust vent terminal is installed using the same procedure.

FIGURE 18.

FIGURE 19.

FIGURE 20.

FIGURE 21.

INSTALLATION OF VENT SYSTEM, SIDEWALL

Item Description Qty.

Rain Cap 3 in. 1 SDR-26 pipe 4 in. dia. 1 SDR-26 pipe 2½ in. dia. 1 Y Concentric Fitting 3 in. 1 Installation Instructions 194504 1

With the route of the venting system and selection of materials completed, as discussed in the section of this manual titled PLANNING THE VENT SYSTEM, the through the wall vent terminal in place and the rst section of piping, up to rst elbow, installed at the blower it is time to complete the installation of the venting system for the sidewall installation.

FIGURE 22.

Before completing the installation of the venting system be sure to read the sections of this manual discussing the proper method of cutting and cementing PVC pipe and ttings: VENT PIPE PREPARATION.

It is recommended that the completion of the venting system start at the blower assembly and run to the coupling on the inside wall of the vent terminal, Figure 18A.

The vent system piping should be supported every 5 feet (1.5 m) of vertical run and every 3 feet (91 cm) of horizontal run. All piping and ttings must be joined by the proper procedures as described under: VENT PIPE PREPARATION.

INSTALLATION OF VERTICAL VENT SYSTEM

A proper ashing or “BOOT” should be used to seal the pipe where it exits the roof. The total vent system should not exceed the equivalent feet of pipe as listed in Table 1.

Provide support for all pipe protruding through the roof. All piping should be properly secured. The vent system piping should be supported every 5 feet (1.5 m) of vertical run and every 3 feet (91 cm) of horizontal run. All piping and ttings must be joined by the proper procedures as described under: VENT PIPE PREPARATION.

FIGURE 23.

IMPORTANT

The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the Natural Gas and Propane Installation Code (CAN/CSA-B149.1) and as listed below:

1. Vent Termination must extend a minimum of 12 inches (30.5 cm) above roof or above the anticipated snow level to prevent blockage of the vent termination, as shown in Figures 20 and 21.

CONCENTRIC VENT INSTALLATION

This appliance is certied for concentric venting with concentric vent kit #9006328005. Follow instructions below for proper installations.

KIT COMPONENTS

Each kit is comprised of the following:

Field supplied pipe and fittings are required to complete the installation.

This concentric vent termination kit may be used with 3 or 4 inch diameter pipe systems. When connecting to a 4 in. diameter pipe system a 3 x 4 inch eld supplied reducer is to be installed at the intake and exhaust connection of the concentric vent termination kit.

1. Determine best location for termination kit.

NOTE: Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and less visible vent vapors.

SAFETY CONSIDERATIONS

Installing and servicing water heating equipment can be hazardous due to gas and electrical components. Installation and service of the concentric vent termination requires ability equivalent to that of a qualied installer or service agent, see page 2. All precautions in the literature, on tags, and labels attached to the unit must be observed.

Follow all safety codes. Wear safety glasses and work gloves.

FIGURE 24.

2. Cut 1 hole (5 in. diameter)

3. Partially assemble concentric vent termination kit. a) Cement Y co ncentri c fitti ng to larger diameter kit

pipe, see Figure A.

b) Cement rain cap to smaller diameter kit pipe, see Figure A.

FIGURE 27.

NOTE: Instead of cementing the smaller pipe to the rain cap, a

eld-supplied stainless steel screw may be used to secure the 2 components together when eld disassembly is desired for

cleaning, see Figure 27.

WARNING

When using alternate screw method, drill clearance hole in rain cap and pilot hole in vent pipe for screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

FIGURE 25.

* Dimension 21 1/8 in. may be lengthened to 60 in. maximum. Dimension 21 1/8 in. may also be shortened by cutting the pipes, provided in the kit, to 12 in. minimum.

** Dimension 39 will change accordingly as dimension 21 1/8 in. is lengthened or shortened.

WARNING

Do not operate the heater with rain cap removed or recirculation of combustion products may occur. Water may also collect inside

larger combustion-air pipe and ow to the burner enclosure.

Failure to follow this warning could result in product damage or improper operation, personal injury or death.

4. Install Y concentric fitting and pipe assembly through structure’s hole and eld supplied roof boot/ashing.

FIGURE 26.

INSTALLATION PROCEDURE 1 ROOF TERMINATION, see Figure 26.

FIGURE 28.

NOTE: Do not allow insulation or other materials to accumulate inside pipe assembly when installing through hole.

5. Secure assembly to roof structure as shown in Figure E using field supplied metal strapping or equivalent support material.

NOTE: See the venting information (pages 16-20) in this

manual for additional vent location requirements.

NOTE: Ensure termination height is above the roof surface or anticipated snow level as shown in Figure C.

6. Install rain cap and small diameter pipe assembly in roof penetr a t ion as s e mbly, En s u re sm a l l dia m e ter pi p e is cemented and bottomed in Y concentric fitting.

7. Cement water heater combustion air intake and vent pipes to con centr ic ve nt te rmina tion asse m bly. See Fi gure E for proper pipe attachment.

8. Operate heater through 1 heat cycle to ensure combustion air and vent pipes are properly connected to concentric vent termination connections.

NOTE: All vent terminations must be the same height when installing multiple unit venting. If assembly is too short to meet height requirement, the 2 pipes supplied in the kit may be replaced

by using same diameter, eld supplied ULC S636 approved pipe.

Do not extend the 21-1/8” dimension outer pipe to be more than 60 inches, see Figure 25.

CAUTION

Do not use eld-supplied couplings to extend pipes. Airow

restriction will occur and the heater pressure switch may cause intermittent operation.

PROCEDURE 2 SIDE WALL TERMINATION, see Figure 29.

2. Cut 1 hole (5 in. diameter)

3. Pa r t i a l l y assemble c o n c e n t r i c v e n t termination k i t .

a) Ceme nt the Y con centric fi tting to larg er diam eter

kit pipe, see Figure 24.

b) C e ment th e r ain cap t o t he small e r diamet e r kit

pipe, see Figure 24.

NOTE: Instead of cementing the smaller pipe to the rain cap, a

eld-supplied stainless steel screw may be used to secure the 2 components together when eld disassembly is desired for

cleaning, see Figure 27.

WARNING

When using alternate screw assembly method, drill clearance hole in rain cap and pilot hole in vent pipe for screw being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

WARNING

Do not operat e the hea t er wi th ra in ca p re moved or recirculation of combustion products may occur. Water may also collect inside larger combustion-air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury or death.

FIGURE 29.

1. Determine best location for termination kit.

NOTE: Consideration for the following should be used when determining an appropriate location for the termination kit:

• Termination kit positioned where the vent vapors will n ot d am age pl a n ts/ s hr u bs o r ai r c on d it ion i ng equipment.

• Termination kit positioned so it will not be affected by wind eddy that may allow recirculation of combustion products, or airborne leaves, or light snow.

• Termination kit positioned where it will not get damaged or be subjecte d to foreign obj ects, such as st ones , balls, etc.

• Termination kit positioned where the vent vapors will not be objectionable.

4. Inst all Y concent ric fitting and pipe assem bly thr ough structure’s hole.

NOTE: Do not allow insulation or other materials to accumulate inside pipe assembly when installing through hole.

5. Insta ll rain cap and smal l di amet er pipe asse mbly in Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in Y concentric tting.

6. Secure assembly to structure as shown in Figure G using eldsupplied metal strapping or equivalent support material.

NOTE: Ensure termination location clearance dimensions are as shown in the diagrams found in Figure 12 and Figure 13. When extending the length of the 4” pipe, the added length beyond 21-1/8” must be deducted from the maximum equivalent feet of vent pipe.

NOTE: If assembly needs to be extended to allow side wall thickness requirement, the 2 pipes supplied in the kit may be replaced by using same diameter, field-supplied ULC S636 approved pipe. Do not extend 21 1/8” dimension more than 60 in. (See Figure 25.)

CAUTION

Do not use eld-supplied couplings to extend pipes. Airow

restriction will occur and the heater pressure switch may cause intermittent operation.

7. Cement heater combustion-air and vent pipes to concentric vent termination assembly. See Figure 30 for proper pipe attachment.

8. Operate heater through 1 heat cycle to ensure combustion-air and vent pipes are properly connected to concentric vent termination connections.

FIGURE 30.

MULTI-CONCENTRIC VENT TERMINATIONS

When two or more appliances are directed vented with concentric vent terminations near each other, each appliance must be individually vented. NEVER common vent this appliance. When two or more appliances are direct vented using concentric vent terminations, the appliances may be vented as shown in Figure H and Figure 32.

Concentric Vent Terminations

FIGURE 31.

for Horizontal Direct Venting.

FIGURE 32.

Concentric Vent Terminations for Vertical

Direct Venting through a roof.

VENT PIPE PREPARATION

PRIMER

1. INITIAL PREPARATION.

A.) Make sure the solvent cement you are planning to use

is designed for the specic application you are attempting.

B.) Know the physical and chemical characteristics and limitations of the PVC and CPVC piping materials that you are about to use.

C.) Know the reputation of your manufacturer and their products.

D.) Know your own qualications or those of your contractor. The solvent welding technique of joining PVC and CPVC pipe is a specialized skill just as any other pipe tting technique.

E.) Closely supervise the installation and inspect the nished job before start-up.

F.) Contact the manufacturer, supplier, or competent consulting agency if you have any questions about the application or installation of PVC and CPVC pipe.

G.) Take the time and effort to do a professional job. Shortcuts will only

cause you problems and delays in start-up. By far, the majority of failures in PVC and CPVC systems are the result of shortcuts and/or improper joining techniques.

2. SELECTION OF MATERIALS.

Cutting Device - Saw or Pipe Cutter.

•

Deburring Tool, Knife, File, or Beveling Machine (2” and above).

•

Brush - Pure Bristle.

•

Rag - Cotton (Not Synthetic).

•

Primer and Cleaner.

•

Solvent Cement - PVC for PVC Components and CPVC for CPVC

•

Components.

Containers - Metal or Glass to hold Primer and Cement. Select the

•

type of PVC or CPVC materials to be used on the basis of their application with respect to chemical resistance, pressure rating, temperature characteristics, etc.

Insertion Tool - Helpful for larger diameter pipe and ttings 6 inches

•

(15.2cm) and above.

It is recommended that Tetrahydrofuran (THF) be used to prepare the surfaces of pipe and ttings for solvent welding. Do not use water, rags, gasoline or any other substitutes for cleaning PVC or CPVC surfaces. A chemical cleaner such as MEK may be used.

CEMENT

The cement should be a bodied cement of approximately 500 to 1600 centipoise viscosity containing 10-20% (by weight) virgin PVC material solvated with tetrahydrofuran (THF). Small quantities of dimethyl formamide (DMF) may be included to act as a retarding agent to extend curing time. Select the proper cement; Schedule 40 cement should be used for Schedule 40 pipe. Never use all-purpose cements, commercial glues and adhesives or ABS cement to join PVC or CPVC pipe and ttings.

APPLICATORS

Select a suitable pure bristle type paint brush. Use a proper width brush or roller to apply the primer and cement (see Table 2). Speedy application of cement is important due to its fast drying characteristics. IMPORTANT NOTE: A dauber type applicator should only be used on pipe sizes 2” and below. For larger diameter pipe, a brush or roller must be used.

TABLE 2.

RECOMMENDED BRUSH* SIZE FOR PRIMER

AND CEMENT APPLICATIONS

Nominal Pipe (IPS) Size Brush Width

2 1.5” (3.8cm) 3 1.5”-2.5” (3.8cm - 6.4cm)

*USE ONLY NATURAL BRISTLE

3. MAKING THE JOINT.

A.) Cutting Pipe must be squarely cut to allow for the proper

interfacing of the pipe end and the tting socket bottom. This can be accomplished with a miter box saw or wheel type cutter Wheel type cutters are not generally recommended for larger diameters since they tend to are the corner of the pipe end. If this type of cutter is used, the are on the end must be completely removed.

NOTE: Power saws should be specically designed to cut plastic pipe.

STEP A

B. Deburring

Use a knife, plastic pipe deburring tool, or file to remove burrs from

the end of small diameter pipe. Be sure to remove all burrs from around the inside as well as the outside of the pipe. A slight chamfer (bevel) of about 10°-15° should be added to the end to permit easier insertion of the pipe into the end of the fitting. Failure to chamfer the edge of the pipe may remove cement from the fitting socket, causing the joint to leak.

STEP B

C. Test dry t of the joint

Tapered tting sockets are designed so that an interfaced t should

occur when the pipe is inserted about 1/3 to 2/3 of the way into the socket. Occasionally, when pipe tting dimensions are at the tolerance extremes, it will be possible to fully insert dry pipe to the bottom of the tting socket. When this happens, a sufcient quantity of cement must be applied to the joint to ll the gap between the pipe and tting. The gap must be lled to obtain a strong, leak-free joint.

D. Inspection, cleaning, priming

Visually inspect the inside of the pipe and tting sockets and

remove all dirt, grease or moisture with a clean dry rag. If wiping fails to clean the surfaces, a chemical cleaner must be used. Check for possible damage such as splits or cracks and replace if necessary.

Depth-of-entry

Marking the depth of entry is a way to check if the pipe has

reached the bottom of the fitting socket in Step F. Measure the fitting depth and mark this distance on the pipe O.D. You may want to add several inches to the distance and make a second mark as the primer and cement will most likely destroy your first one.

Apply primer to the surface of the pipe and tting socket with

a natural bristle brush. This process softens and prepares the PVC or CPVC for the solvent cementing step. Move quickly and without hesitation to the cementing procedure while the surfaces are still wet with primer.

STEP E

F. Joint assembly

Working quickly, insert the pipe into the tting socket bottom and

give the pipe or tting a 1/4 turn to evenly distribute the cement. Do not continue to rotate the pipe after it has hit the bottom of the tting socket. A good joint will have sufcient cement to make a bead all the way around the outside of the tting hub. The tting will have a tendency to slide back while the cement is still wet so hold the joint together for about 15 seconds.

STEP F

G. Cleanup and joint movement

Remove all excess cement from around the pipe and tting with a

dry cotton rag. This must be done while the cement is still soft.

The joint should not be disturbed immediately after the cementing

procedure, and sufcient time should be allowed for proper curing of the joint. Exact drying time is difcult to predict because it depends on variables such as temperature, humidity and cement integrity. For more specic information, you should contact your solvent cement manufacturer.

E. Application of solvent cement

• Apply the solvent cement evenly and quickly around the

outside of the pipe at a width a little greater than the depth of the tting socket.

• Apply a light coat of cement evenly around the inside of the

tting socket. Avoid puddling.

• Apply a second coat of cement to the pipe end.

STEP G

CONTROLS AND SWITCHES

This model is provided with three pressure switches. These switches are essential to the safe and proper operation of the unit. All switches are wired in series. The controller is set up to shut the unit down whenever there is a failure of any of the switches. It is important to understand the purpose of each switch.

FIGURE 33.

BLOWER PROVER SWITCH

(SEE FIGURE 12)

The Blower Prover Switch is provided on the heater to verify that the fan is operating. It is a positive pressure switch whose electrical contacts are normally open. When the fan increases the pressure in the burner, the pressure switch will allow the electrical contacts to close. The pressure switch is connected to the burner tap by a piece of tygon tubing. This tubing must be connected in order for the switch to change the electrical contacts. The controller requires that the electrical contacts on this air ow switch be open before it will allow the blower to come on.

BLOCKED EXHAUST SWITCH

(SEE FIGURE 12)

The Blocked Exhaust Switch is set up to shut the unit off when a build-up of positive pressure in the exhaust vent pipe occurs. This switch is a positive pressure switch that requires an increase in pressure to change the electrical contacts from normally closed to

open. When this switch prevents the unit from igniting, most likely the exhaust is blocked by some means. Check to see if the condensate is allowed to ow freely from the exhaust elbow and for obstructions in the exhaust venting and exhaust vent terminal. Also verify that the vent length does not exceed the maximum allowed as shown in the Vent Section of this manual.

BLOCKED INTAKE SWITCH

(SEE FIGURE 12)

The Blocked Intake Switch is set up to shut the unit off when a build-up of negative pressure in the intake air pipe occurs. This switch is a negative pressure switch that requires an increase in negative pressure to change the electrical contacts from normally closed to open. The switch is connected to the pressure tap on the PVC pipe connected to the inlet of the blower. When this switch prevents the unit from igniting, most likely the intake is blocked. Verify that the screen on the intake air connection (conventional vent), the intake air pipe and termination (direct vent installations) are free of obstructions that may prevent air from entering the unit. Insure the screen on intake air connection has been removed on direct vent installations, see Figure 18B. Also verify the intake air pipe length does not exceed the maximum allowed as shown in the Vent Section of this manual.

ON/OFF SWITCH

The ON/OFF Switch is a single-pole, single-throw rocker switch. This switch provides 120V from the line source to the heater.

CAUTION

THE WATER HEATER IS POLARITY SENSITIVE. BEFORE APPLYING ELECTRICITY TO THIS HEATER BE CERTAIN THAT SUPPLY NEUTRAL WIRE TO GROUND CHECK INDICATES ZERO VOLTAGE.

HOT SURFACE IGNITER

The Hot Surface Igniter is a device that ignites the main burner by high temperature (>1800°F or >982°C). When 120VAC is applied to the igniter, sufcient heat is generated to ignite the main burner. Although improvements have been made to strengthen the igniter, it is still fragile and care must be taken when handling the igniter to prevent breakage.

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 - FIGURE 34.

THIS WATER HE ATER IS POLAR ITY SENSIT VE. BE FOR E A PPLY IN G ELECTRICITY TO THIS HEATER B E CE RTAIN THAT SUPPLY NEUTRAL WIRE TO GROU ND

CHECK INDICATES ZERO

VOLTAGE.

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire

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

BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.

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 OPERATING smell all around the appliance

area for gas. Be sure to smell next to the oor because some gas is heavier than air and will settle on the oor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric switch; Do not use any phone in your building.

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

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

C. Use only your hand to push in the gas control buttons.

Never use tools. If the control buttons will not push in, don’t try to repair them, call a qualied service technician. Force or attempted repair may result in a re or explosion.

D. Do not use this appliance if any part has been under

water. Immediately contact a qualied installer or service agency to replace a ooded water heater. Do not attempt to repair the unit! It must be replaced!

OPERATING INSTRUCTIONS

5. This appliance is equipped with a device which automatically lights the burner.

DO NOT TRY TO LIGHT THE BURNER BY HAND.

Wait five (5) minutes to gas.

If you smell gas, in the safety information above on this label. If you don’t smell gas.

7. Turn on all electrical power to the appliance.

clear out any STOP! Follow “B”

OFF

O N

120 F

Operating Set Point

Status: Heating

GAS

Menu Help

ON/OFF SWITCH

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

2. Set the ON/OFF switch on the control panel to the “ON” position.

3. Set the thermostat to the lowest setting.

4. Set the ON/OFF switch on the control box to the “OFF” position.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

8. Set the ON/OFF switch on the control box to the “ON” position.

9. Set the thermostat to the desired setting.

10. I f the appliance will no t oper ate, foll ow the

POWER BEFORE SERVICING

2. Set the ON/OFF switch on the control panel to the

3. Turn off all electrical power to the appliance if service

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

instructions “TO TURN OFF GAS TO APPLIANCE” and call your technician or gas supplier.

WARNING: TURN OFF ALL ELECTRIC

“OFF” position.

is to be performed.

TEMPERATURE REGULATION

It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperatures be set for the lowest temperature which satises your hot water needs. This will also provide the most energy efcient operation of the water heater.

HOT 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 inrm, or physically/mentally handicapped. If anyone using hot water from this heater ts into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satis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 2. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower.

The water heater should be located in an area where the general public does not have access. If a suitable area is not available, a cover should be installed over the thermostat to prevent tampering. The water temperature setting was factory set at the lowest temperature; THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER TEMPERATURES REQUIRED

FOR AUTOMATIC DISHWASHER AND LAUNDRY USE CAN CAUSE SCALD BURNS RESULTING IN SERIOUS PERSONAL

INJURY AND/OR DEATH. THE TEMPERATURE AT WHICH INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME OF THE EXPOSURE. THE SLOWER RESPONSE TIME

OF CHILDREN, AGED OR DISABLED PERSONS INCREASES

THE HAZARDS TO THEM. NEVER ALLOW SMALL CHILDREN

TO USE A HOT WATER TAP, OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS TO SET TEMPERATURES.

SETTING THE WATER HEATER TEMPERATURE AT 120°F/49°C WILL REDUCE THE RISK OF SCALDS. Some states require settings at specific lower temperatures.

The water temperature is controlled using the Temperature Control on the Display at the front of the unit (See Figure 1). This control utilizes a temperature probe to determine the tank temperature. The primary temperature probe is located at the top of the tank.

The temperature may be adjusted from 90°F/32°C to 160°F/71°C. The thermostat was adjusted to 120°F/49°C before the heater was shipped from the factory. It is recommended that lower water temperature be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature which satisfies your hot water needs. This will also provide the most energy efficient operation of the water heater and minimize scale formation.

Valves for reducing the point-of-use temperature by mixing cold and hot water are available, see Figure 2. Also available are inexpensive devices that attach to faucets to limit hot water temperatures. Contact a licensed plumber or the local plumbing authority.

Table 3 shows the approximate time-to-burn relationship for normal adult skin. Short repeated heating cycles caused by small hot water uses can cause temperatures at the point of use to exceed the thermostat setting by up to 20°F/11°C. If you experience this type of use, you should consider using lower temperature settings to reduce scald hazards.

TABLE 3.

Time to Produce 2nd & 3rd Degree Temperature Setting Burns on Adult Skin

160°F (71°C) About 1/2 Second 150°F (65°C) About 1 1/2 Seconds 140°F (60°C) Less than 5 Seconds 130°F (54°C) More than 30 Seconds 120°F (49°C) More than 5 minutes

HI LIMIT SWITCH (E.C.O.)

The top immersion well of the dual bulb controller also contains the high interrupts main burner approximately 202°F/94°C.

Should the high limit switch activate, the control system will automatically reset the unit once the water temperature in the tank falls below 140°F/60°C. If the unit is manually shut down and restarted, as long as the temperature in the tank is lower than 160°F/71°C, the unit will reset and initiate operation.

If you experience higher than usual water temperature along with frequent automatic resetting of the system, this is evidence of high limit switch operation. The following are possible reasons for high limit switch operation.

• A malfunction in the thermostatic controls would allow the gas valve to remain open causing water temperature to exceed the thermostat setting. The water temperature would continue to rise until high limit switch operation.

Contact your dealer or servicer if continued high limit switch operation occurs.

limit (energy cutoff) sensor. The high limit switch

gas flow should water temperature reach

USING THE ELECTRONIC CONTROLLER

1. Overview

Interaction with the water heater controller is done through an up, a down, and three operation buttons. These buttons are illustrated to the right. Operation of the three lower buttons is dened immediately above them on the screen. The [UP] and [DN] buttons are used to navigate through the menus and make adjustments to the water heater.

While the water heater is operating, the user interface will display the desktop screen (if there are no active fault or alert conditions). An example of this screen is shown to the right. The temperature on this screen is the Operating Set Point. The Operating Set Point is the temperature at which the water heater will maintain the water inside the tank. The second line on the screen is a text description of the Operational State of the water heater (please see Operating States for more details).

The following status icons describe graphically operational details of the heater. The legend of all the status icons is listed below.

2. Operating States

In the main desktop screen, there are some specic Operating States that are indicated on the status line. These are summarized below:

3. Adjusting the Operating Set Point

The Operating Set Point of this water heater determines the regulated temperature for the water in the tank. This parameter is adjusted in the Temperature menu. Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set

Point.

ACTION: From the desktop screen, press Menu.

DISPLAY:

ACTION: From the Main Menu, press Select to enter the "Temperatures" screen.

DISPLAY:

ACTION:

Press Change then use the UP and DOWN buttons to change the Set Point.

3. Changing the Display Units

The display interface to the heater has the option of selecting between degrees Fahrenheit and degrees Celsius for temperature displays. This can be found in the “Display Settings” menu. Also in this menu, you may adjust how the backlight operates and the contrast of the LCD screen.

ACTION:

From the Main Menu, press the Down button to highlight "Display Settings" then press Select.

DISPLAY:

ACTION:

Use the UP and DOWN buttons to highlight the desired setting. Then press Change. Again, use the UP and DOWN buttons to scroll through the options for that setting.

DISPLAY:

There are two types of conditions that can occur during operation. These are Alerts and Faults:

• Alerts: This is a non-safety related condition that the control has detected that may cause the water heater to operate in a less than optimal condition, but does not pose a safety concern.

NOTE: When these conditions occur, continued heating cycles will continue and the heater will attempt to regulate the water in the tank to the Operating Set Point.

Example of an Alert:

• Faults: This is a safety related condition that has been detected by the heater.

NOTE: When these conditions occur, the water heater will not continue any further heating cycles and the water will no longer be heated until the condition is corrected and, in most cases, power has been cycled.

Example of a Fault:

ACTION: Press Update to accept the change or Cancel to reject it.

DISPLAY:

4. Fault and Alert Conditions

This water heater is equipped with electronic controls that have the ability to monitor almost all aspects of the water heater operation. In the case that there is an undesirable or unsafe condition that occurs, the water heater controls will detect this condition and determine the appropriate action. Part of this is displaying the information on the LCD in plain text that accurately describes the condition and diagnostics information that can be used to correct the issue.

Advanced Diagnostics Information

When a fault or alert has been declared, advanced information can be found in the control. By pressing the Advanced button, detailed information can be found regarding diagnosing and resolving the problem.

WARNING: Usage of the Advanced information requires ability

equivalent to that of a licensed tradesmen in the eld involved.

5. Access to the Current Fault or Alert

When a fault or alert has been detected by the control, it will automatically be displayed on the screen and the back light will blink. If you choose to leave the current fault or alert by pressing the Back key, you can always return to the fault screen through the menu.

ACTION: To get to the current fault information screen, press Menu.

DISPLAY:

ACTION: Press the DOWN button to highlight "current Fault" and press Select.

DISPLAY:

6. Viewing the Fault History

The controller for this water heater will store a history of ten of the last Fault and Alert conditions that occurred. This is stored in the Fault History. Along with all the information about the fault, including a estimate time of when the fault occurred, information regarding the advanced diagnostics for that fault can be accessed at any time.

ACTION: Press the DOWN button for more information.

DISPLAY:

ACTION:

Press the DOWN key to scroll through the fault history. If you select a specic fault or alert, you may press the VIEW button to view details regarding this fault.

DISPLAY:

ACTION: Press the DOWN button for more information.

DISPLAY:

7. Viewing Information About the Heater

The electronic control for this water heater monitors many different aspects of the water to ensure safe and optimal operation. Much of the information monitored is available to view in two areas of the control. The rst is the "Heater Status" and; the second is "Heater Information." These items can be selected through the main menu in the same fashion as described above. In these menus, detailed information about the water heater and the current status of specic conditions can be found.

FOR YOUR INFORMATION

START UP CONDITIONS

SMOKE/ODOR

It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.

THERMAL EXPANSION

Water supply systems may, because of such events as high line pressure, frequent cut-offs, the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back flow preventers, etc. to control these types of problems. When these devices are not equipped with an internal by pass, and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water.

The water within the water tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater’s temperature-pressure relief valve is reached, the valve will release excess pressure. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This is an unacceptable condition and must be corrected. It is recommended that any devices installed which could create a closed system have a by-pass a n d/or t h e s ystem h a v e an e x p a n s i o n t a n k or device to relieve the pressure built by thermal expansion in the water system. Expansion tanks are available for ordering through a local plumbing contractor. Contact the local water heater supplier or qualified service agency for assistance in controlling these situations.

STRANGE SOUNDS

Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not necessarily represent harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. See “Condensate” in this section.

OPERATIONAL CONDITIONS

SMELLY WATER

In each water heater there is installed at least one anode rod (see parts section) for corrosion protection of the tank. Certain water conditions will cause a reaction between this rod and the water. The most common complaint associated with the anode rod is one of a “rotten egg smell” in the hot water. The smell is a result of four factors which must all be present for the odor to develop:

a. A concentration of sulfate in the supply water. b. Little or no dissolved oxygen in the water. c. A sulfate reducing bacteria which has accumulated within the

water heater (this harmless bacteria is nontoxic to humans).

d. An excess of active hydrogen in the tank. This is caused by the

corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater models by replacing the anode(s) with one of less active material, and then chlorinating the water heater tank and all water lines. Contact the local water heater supplier or a qualied service agency for further information concerning an Anode Replacement Kit and this chlorination treatment.

If the smelly water persists after the anode replacement and chlorination treatment, we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem.

Do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided.

“AIR” IN HOT WATER FAUCETS

HYDROGEN GAS: 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 ammable and explosive. To prevent the possibility of injury under these conditions, we recommend the hot water faucet, located farthest away, be opened for several minutes before any electrical appliances which are connected to the hot water system are used (such as a dishwasher or washing machine). If hydrogen gas is present, there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened. There must be no smoking or open ame near the faucet at the time it is open.

PERIODIC MAINTENANCE

VENTING SYSTEM INSPECTION

At least once a year a visual inspection should be made of the venting system. You should look for:

1. Obstructions which could cause improper venting. The combustion and ventilation air ow must not be obstructed.

Soot build-up indicates a problem that requires correction before further use. Turn “OFF” gas to water heater and leave off until repairs are made, because failure to correct the cause of the sooting can result in a re causing death, serious injury, or property damage.

BURNER CLEANING

In the event your burner or burner air openings require cleaning, turn the on/off switch to the “OFF” position and allow the unit to cool. Call a qualied service agency to remove and clean the burner and correct the problem that required the burner to be cleaned.

HOUSEKEEPING

Vacuum around base of water heater for dust, dirt, and lint on a regular basis.

2. Damage or deterioration which could cause improper venting or leakage of combustion products.

Be sure the vent piping is properly connected to prevent escape of dangerous ue gasses which could cause deadly asphyxiation.

Obstructions and deteriorated vent systems may present serious health risk or asphyxiation.

Chemical vapor corrosion of the ue and vent system may occur if air for combustion contains certain chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, bleach and process chemicals are typical compounds which are potentially corrosive.

If after inspection of the vent system you found sooting or deterioration, something is wrong. Call the local gas utility to correct the problem and clean or replace the ue and venting before resuming operation of the water heater.

BURNER OPERATION AND INSPECTION

Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a ooded water heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualified installer or service agency to replace a ooded water heater. Do not attempt to repair the unit! It must be replaced!

At least once a year a visual inspection should be made of the main burner and the hot surface igniter assembly for proper ame characteristics and ignition sequences. You should also check for sooting. Soot is not normal and will impair proper combustion. A visual inspection of the main burner and HSI igniter assembly should also be done at least once a year.

INSTALLED IN SUITABLE AREA: To insure sufcient ventilation and combustion air supply, proper clearances from the water heater must be maintained. See “Facts to Consider About Location” section. Combustible materials such as clothing, cleaning materials, or ammable liquids, etc. must not be placed against or adjacent to the water heater which can cause a re.

ANODE ROD INSPECTION

Each water heater contains at least one anode rod, which will slowly deplete (due to electrolysis) prolonging the life of the water heater by protecting the glass-lined tank from corrosion. Adverse water quality, hotter water temperatures, high hot water usage, and water softening methods can increase the rate of anode rod depletion. Once the anode rod is depleted, the tank will start to corrode, eventually developing a leak.

Certain water conditions will cause a reaction between the anode rod and the water. The most common complaint associated with the anode rod is a “rotten egg smell” produced from the presence of hydrogen sulde 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 rod 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 ltration equipment from a water conditioning company to successfully eliminate all water odor problems.

Articially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions. 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. NOTE: articially softened water requires the anode rod to be inspected annually.

The following are typical (but not all) signs of a depleted anode rod: * The majority of the rods diameter is less than 3/8”. * Signi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:

FIGURE 35.

When checking the temperature-pressure relief valve operation, make sure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot, see Figure 28.

If the temperature-pressure relief valve on the appliance weeps or discharges periodically, this may be due to thermal expansion. You may have a check valve installed in the water line or a water meter with a check valve. Consult your local water supplier or a qualied service agency for further information. Do not plug the temperaturepressure relief valve.

DRAINING and FLUSHING

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 “Draining and Flushing” for proper procedures). Close drain valve.

4. Remove old anode rod.

5. Use Te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.

Restart the water heater as directed under “Operating Your Water Heater.” See the Repair Parts Illustration for anode rod location.

FIGURE A. ANODE ROD DEPLETION

TEMPERATURE-PRESSURE RELIEF VALVE OPERATION

It is recommended that the tank be drained and ushed 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. Set the power switch to the “OFF” position.

2. Open a nearby hot water faucet until the water is no longer hot.

3. Close the cold water inlet valve.

4. Connect a hose to the drain valve and terminate to an adequate drain or external to the building.

5. OPEN the water heater drain valve and allow all of the water to drain from the tank. Flush the tank with water as needed to remove sediment.

6. CLOSE the drain valve, rell the tank, and restart the heater as directed in this manual.

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 relling the tank and should not be confused with a tank leak.

SERVICE

If a condition persists or you are uncertain about the operation of the water heater contact a qualied service agency.

If you are not thoroughly familiar with gas codes, your water heater, and safety practices, contact your gas supplier or qualied installer

to check the water heater.

Use this guide to check a “Leaking” water heater. Many suspected “Leakers” are not leaking tanks. Often the source of the water can

be found and corrected.

LEAKAGE CHECKPOINTS

Read this manual rst. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water.

Never use this water heater unless it is completely lled with water. To prevent damage to the tank, the tank must be lled with water. Water must ow from the hot water faucet before turning “ON” gas to the water heater.

A *Condensation may be seen on pipes in humid weather or pipe

connections may be leaking.

B. *The anode rod tting may be leaking.

C. Small amounts of water from temperature-pressure relief valve

may be due to thermal expansion or high water pressure in your area.

D. *The temperature-pressure relief valve may be leaking at the

tank tting.

E. Water from a drain valve may be due to the valve being slightly

opened.

F. *The drain valve may be leaking at the tank tting.

G. Combustion products contain water vapor which can condense

on the cooler surfaces of the tank. Droplets form and drip onto the burner or run on the oor. This is common at the time of start-up after installation and when incoming water is cold.

H. Water in the water heater bottom or on the oor may be from

condensation, loose connections, or the relief valve. DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken.

Leakage from other appliances, water lines, or ground seepage should also be checked.

* To check where threaded portion enters tank, insert cotton

swab between jacket opening and tting. If cotton is wet, follow “Draining” instructions in the “Periodic Maintenance” section and then remove tting. Put pipe dope or teon tape on the threads and replace. Then follow “Filling the Water Heater” instructions in the “Installing the New Water Heater” section.

TROUBLESHOOTING GUIDELINES

These guidelines should be utilized by a qualied service agent.

PROBLEMS

1.) Blower will not run.

a. “ON/OFF” control switch turned off. Turn switch to the “ON” position.

b. Blower unplugged. Plug blower back into 115 VAC outlet.

c. No power at outlet. Repair service to outlet.

d. Thermostat defective. Replace thermostat. e. Control harness defective. Replace control harness.

Reduce the water temperature below 140°F. Turn the power switch to the off position.

f. High limit control circuit open.

NOT ENOUGH HOT WATER

g. Blower motor defective. Replace blower assembly.

2.) Thermostat problems

a. Thermostat set too low. Adjust temperature control higher. b. Thermostat or ECO defective Replace thermostat.

3.) Others

a. Heater undersized.. Reduce hot water use. b. Low gas pressure Contact dealer. c. Incoming water is usually cold. Allow more time for heater to reheat. d. Leaking hot water pipes of fixtures. Have plumber check and repair leaks. e. Heater not lit or thermostat not on. Refer to LIGHTING INSTRUCTIONS.

VENT PIPE TOO HOT (ABOVE 170°F [77°C]) Wrong burner orice. Turn off heater and gas, clean burner head.

Dirt in burner ports. Turn off heater and gas, clean burner head.

YELLOW FLAME

CONDENSATION Water on the oor under heater. See CONDENSATION section.

WATER LEAKS

LEAKING T & P

HOT WATER ODORS

(refer to cathodic protection)

HOT WATER TOO HOT Thermostat set too high.

WATER HEATER SOUNDS Condensation dripping on burner. Refer to CONDENSATION above.

SIZZLING - RUMBLING Sediment at bottom of heater tank.

SOOTING Improper combustion. Refer to Air Requirements.

BURNER WILL NOT STAY LIT-GOES OUT

4-5 SECONDS

VENT GAS ODORS

Combustion air path restricted.

Impr operly se aled, hot or co ld supply connections, relief valve, drain valve or thermostat threads.

Leakage from other appliances or water lines. Condensation of ue products. Refer to CONDENSATION section.

Thermal expansion in closed water system.

Improperly sealed valve.

High sulfate or mineral content in water supply.

Bacteria in water supply. Chlorinate water supply.

Outlet polarity is reversed. Test polarity and correct.

High ambient room temperature.

Defective gas valve. Replace gas valve.

Lack of air supply.

Improperly installed vent piping. Downdraft Poor Combustion

Wait 10 seconds. Turn the power switch to the on position. Reduce the point to minimize likelihood of reoccurrence. this does not solve the problem, replace the thermostat.

Check exhaust venting and air openings in bottom base pan for obstructions or blockage.

Check for leaks. See Figure 1.

Inspect other appliances near water heater.

Install thermal expansion tank (Do not plug T&P valve).

Check relief valve for proper operation (Do not plug T&P valve).

Drain and ush heater thoroughly then rell.

Refer to TEMPERATURE REGULATION section.

Cle a n se d imen t fro m tan k . Ref e r to

DRAINING.

Cont act a quali fied servic e age ncy to determine cause.

Shut off water heater immediately and contact a qualied service agency to determine cause.

temperature set

NOTES

Limited Warranty

THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY. If the glass lined tank in this water heater shall prove upon examination by (the warrantor) to have leaked during the warranty period in normal residential use, due to natural corrosion from potable water therein, the warrantor will furnish the ORIGINAL OWNER a replacement water heater of equivalent size and current model, or a replacement part for any component part which fails in normal use, in accordance with the warranty terms and conditions specied below. THE WATER HEATER REPLACEMENT MODEL OR PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY. The warranty period will be determined by the original installation date of the water heater. PROOF-

OF-PURCHASE AND PROOF-OF-INSTALLATION ARE NECESSARY

TO VALIDATE THIS WARRANTY. This warranty is not transferable.

b. Shipping and delivery charges for forwarding the new water heater or

replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor except in the state of California where such charges are the manufacturer’s responsibility.

c. All cost necessary or incidental for handling and administrative

charges, and for any materials and/or permits required for installation of the replacement heater or part.

LIMITATION ON IMPLIED WARRANTIES

Implied warranties, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

Product Line TANK

WARRANTY PERIOD

PARTS

6G50100NVC02 6 YEARS 6 YEARS 6G50100PVC02 6 YEARS 6 YEARS

When the water heater has been used for other than single family residential application: 1. The Tank warranty shall be reduced to 3 years on 10 year models and 1 year on 6 and 8 year models. 2. The parts warranty shall be reduced to 1 year for all models. Returned parts which meet any of the following conditions are not covered by this warranty: 1) improper installation or removal; 2) damaged by other than normal wear; 3) replaced for cosmetic purposes; or 4) returned with defaced date codes.

CONDITIONS AND EXCEPTIONS

This warranty shall apply only when the water heater is installed and operated in accordance with: 1) all local re codes and plumbing codes, ordinances and regulations; 2) the printed instructions provided with it;

3) good industry practices; and 4) proper safety practices such as but not limited to a properly sized drain pan if installed in an area where leakage from connections of the tank would result in damage to the area adjacent to the heater. In addition, a new temperature and pressure relief valve, certied by the Canadian Standards Association must have been properly installed and piped to the nearest drain.

This warranty shall apply only when the heater is:

• owned by the original purchaser;

• used at temperatures not exceeding the maximum calibrated setting of its thermostat;

• not subjected to excessive water pressure uctuations and not subject to an operating pressure greater than 150 P.S.I.;

• lled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;

• used in a non-corrosive and non-contaminated atmosphere;

• used with factory approved anode(s) installed;

• in its original installation location;

• in the United States and its territories or possessions or Canada;

• sized in accordance with proper sizing techniques for residential water heaters;

• bearing a rating plate which has not been altered, defaced or removed except as required by the warrantor;

• used in an open system or in a closed system with a properly sized and installed thermal expansion tank;

• red at the factory rated input using the fuel stated in the face of the rating plate;

• operated with the inner and outer combustion chamber doors in place;

• maintained in accordance with the instructions printed in the manual included with the heater.

Any accident to the water heater or any part thereof (including freezing, re, oods, or lightning), any misuse, abuse or alteration of it, any operation of it in a modied form, or any attempt to repair tank leaks or parts, will void this warranty.

SERVICE AND LABOR RESPONSIBILITY

UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF. THE

OWNER IS RESPONSIBLE FOR ALL OTHER COSTS. Such costs may include but are not limited to: a. Labor charges for service, removal, or reinstallation of the water heater

or part thereof.

CLAIM PROCEDURE

Any claim under this warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products.

The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor.

Dealer replacements are made subject to in-warranty validation by warrantor.

PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION DATES

ARE REQUIRED TO SUPPORT WARRANTY FOR CLAIM FROM

ORIGINAL OWNER. THIS FORM DOES NOT CONSTITUTE PROOFOF-PURCHASE OR PROOF-OF-INSTALLATION.

DISCLAIMERS

NO EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF

OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER OR PARTS. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO

PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE.

THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.

Some states do not allow the limitation or exclusion of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights which vary from state to state. Should governmental regulations or industry standards prohibit the Manufacturer from furnishing a comparable model replacement under this warranty, the Owner will be furnished with the closest comparable water heater meeting the current governmental regulations and industry standards. A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards.

Fill out and keep with water heater.

IMPORTANT INFORMATION

Model Number ________________________________________

Serial Number ________________________________________

Installation Information:

Date Installed_________________________________________

Company’s Name _____________________________________

Street or P.O. Box _____________________________________

City, State, and Zip Code ________________________________

Phone Number ____________ Plumber’s Name _____________

GSW Water Heating 599 Hill Street West

Fergus, ON Canada N1M 2X1

Should you have any questions please

Email us at techsupport@gsw-wh.com or

Visit our websites: www.gsw-wh.com or

www.johnwoodwaterheaters.com or

Call our Technical Support line at

1-888-GSW-TECH (479-8324)

GSW Water Heating is a division of A.O.Smith Enterprises Ltd.

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