Lochinvar RPD-I, Power Direct Vent Gas Service Manual

INSTALLATION & SERVICE MANUAL

RPD-I&S

POWER DIRECT VENT GAS-FIRED WATER HEATER

WARNING

If the information in these instructions is not followed exactly,
a fire or explosion may result causing property damage,
personal injury or death.

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

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

For your family’s comfort, safety and convenience, we recommend
this water heater be installed and serviced by a plumbing
professional.

TABLE OF CONTENTS

GENERAL INFORMATION .......................................................... 1

INSTALLATION ..................................................................... 1

Locating The Water Heater .............................................. 1

Minimum Clearances ....................................................... 2

Venting ...................................................................... 2-6

Water Connections ......................................................... 7

Gas Connections............................................................. 8

Electrical Connections...................................................... 8

Wiring Diagram.............................................................. 9

GENERAL OPERATION .............................................................. 8

Lighting and Shutdown Instructions .............................. 10

Thermostat Adjustment ................................................. 10

Burner Flame Check ....................................................... 10

MAINTENANCE ...................................................................... 11

INSTALLATION INSTRUCTIONS FOR POTABLE WATER AND

SPACE HEATING .................................................................... 12

VENT PIPE PREPARATION AND JOINING .................................. 12

warranty for this water heater is in effect only when the water heater is
installed, adjusted, and operated in accordance with these Installation and
Operating Instructions. The manufacturer will not be held liable for any damage
resulting from alteration and/or failure to comply with these instructions.

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

CAUTION

Incorrect operation of this appliance may create a hazard to life
and property and will nullify the warranty.

Do not use this appliance if any part has been submerged in water. You should
contact a qualified service technician to inspect the appliance and to replace
any part of the control system including the combination gas control which has
been submerged in water.

DANGER

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

IMPORTANT

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

Make sure that you check the rating plate and combination gas control on the
water heater to be certain that the type of gas being supplied corresponds with
the marking on the rating plate and combination gas control.

A sacrificial anode is used to extend tank life. The removal of this anode, for
any reason, will nullify the warranty. In areas where water is unusually active,
an odor may occur at the hot water faucet due to a reaction between the
sacrificial anode and the impurities in the water. If this should happen, an
alternative anode may be purchased from the supplier that installed this water
heater. This will minimize the odor while protecting the tank. Additionally, the
water heater should be flushed with appropriate dissolvers to eliminate any
bacteria.

INSTALLATION

GENERAL INFORMATION

This gas-fired water heater’s design is certified by CSA International under the

American National Standard Z21.10.1 - (as indicated on the rating plate) and
CSA 4.1-M - (as indicated on the rating plate).

This water heater must be installed in accordance with local codes or, in the
absence of local codes, the National Fuel Gas Code, ANSI Z223.1-Latest Edition)
and/or in Canada CAN/CGA B149 Installation Codes (Latest Editions). The

Water heaters are heat producing appliances. To avoid damage or injury there

WARNING

shall be no materials stored against the water heater or vent-air intake system.
Use proper care to avoid unnecessary contact (especially by children) with
the water heater and vent-air intake components. UNDER NO

CIRCUMSTANCES SHALL FLAMMABLE MATERIALS, SUCH AS GASOLINE
OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS
WATER HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY LOCATION
FROM WHICH FUMES COULD REACH THE WATER HEATER OR
VENT-AIR INTAKE SYSTEM.

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Locating The Water Heater

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

CAUTION

The National Fuel Gas Code (ANSI Z233.1-or latest edition) and CAN/CGA
(B149.1-or latest edition), expressly prohibits the installation of a water
heater in a garage, unless the unit is installed so that the burner and ignition
devices are at least eighteen (18) inches (46 cm) above floor level and

protected to avoid damage by a moving vehicle.

The location of this water heater is of the utmost importance. Before installing
this water heater, read the installation section of these instructions. After
reading these installation and operating instructions, select a location for the
water heater where the floor is level and is easily accessible to gas and water
supply lines. DO NOT locate the water heater where water lines could

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

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

EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY THE
WARRANTY. DO NOT OPERATE THE WATER HEATER IF EXPOSURE
HAS OR WILL OCCUR. DO NOT STORE ANY POTENTIALLY
CORROSIVE COMPOUNDS IN THE VICINITY OF THE WATER HEATER.

WARNING

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

IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

DO NOT OPERATE APPLIANCE UNTIL LEAKAGE IS CORRECTED!

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT

WARNING

CERTAIN OF THE FOLLOWING:

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

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

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

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

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

The water heater must be located close enough to the outside wall to keep the
venting distance within the maximum distance described in the installation
instructions. Read the venting section in this installation instruction manual
before locating the water heater.

This water heater must be located in an area where leakage of the tank or
water line connections and the combination temperature and pressure relief
valve will not result in damage to the area adjacent to the water heater or to
lower floors of the structure. When such locations cannot be avoided, a suitable
drain pan adequately piped for proper drainage, must be installed under the
water heater. The drain pan must be no greater than 1-½ inches (3.8 cm)
deep and have a minimum length and width of at least four (4) inches (10.2
cm) measured from the jacket of the water heater. The drain pan, as described
above, can be purchased from your plumbing professional. The drain pan must
be piped to an adequate drain. The piping must be at least 3/4 inch (1.9 cm)
in diameter and pitched for proper drainage.

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

MINIMUM CLEARANCES

WARNING

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

This installation must allow access to the front of the water heater and adequate
clearance must be provided for servicing and operating this water heater. The
water heater may be installed on either a combustible or non-combustible floor.
If the water heater is to be installed directly on carpeting, it must be installed
on top of a metal or wood panel extending beyond the full width and depth of
the appliance by at least three (3) inches (7.6 cm) in any direction or, if the
appliance is to be installed in an alcove or closet, the entire floor must be
covered by the panel. The minimum clearances to combustibles for this water
heater is: zero (0) inches (0 cm) from the sides and rear, five (5) inches (12.7
cm) from the front of the jacket, zero (0) inches (0 cm) from the vent
connector and fifteen (15) inches (38.1 cm) from the jacket top.

VENTING

The Nation Fuel Gas Code ANSI Z223.1-(Latest Edition), CGA/CAN B149 Installation
Code, and local codes have specific requirements for the location of the vent
terminals on vertical walls. The guide lines listed below are from the National

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Fuel Gas Code. Consult the local codes, and/or National Fuel Gas Code ANSI
Z223.1-(Latest Edition), or CGA/CAN B149 Installation Code to determine if
there are any additions or changes to the following specifications.

(A) The vent terminals must terminate at least 3 feet (.91 m) above any

forced air inlet duct located within 10 feet (3 m). Exception: This
provision shall not apply to the combustion air intake of a direct vent
appliance.

(B) The vent terminals must terminate at least 1 foot (1.2m) below, 1

foot (1.2 m) horizontally from, or 1 foot (.31 m) above any door,
window, gravity air inlet into the building.

(C) The bottom of the vent terminals must be located at least 1 foot

(.31 m) above grade and above the anticipated snow level.

(D) The vent terminals must not terminate over a public walkway or over

an area where condensate or vapor could create a nuisance or hazard
or could be detrimental to the operation of regulators, relief valve, or
other equipment.

(E) The water heater location must provide easy access for the entire

length of the vent connector.

(F) The vent system must be inspected at least once a year to ensure

against leakage of exhaust products.

Exceptions For Installations in Canada:

(A) The vent terminals must be located at least 1 foot (.31 m) from any

window or door which can be opened in any building, any non-mechanical
air supply inlet to any building, or the combustion air inlet to any other
appliance.

(B) The vent terminals must be located at least 6 feet (1.8 m) from any

mechanical air supply inlet to the building.

(C) The vent terminals must not terminate above a meter/regulator

assembly or within 3 feet (.91 m) horizontally of the vertical center
line of the regulator and must be at least 6 feet (1.8 m) from any gas
service regulator vent outlet.

(D) The vent terminals must be at least 7 feet (2.1 m) above a paved

sidewalk or a paved driveway located on public property.

(E) The vent terminals must not terminate above a paved sidewalk or a

paved driveway which is located on adjacent private property.

7. After securing the Vertical Pipe to the Jacket Head with the Support
Bracket, tighten the clamps on the Rubber Intake Elbow.

8. Using the RTV sealant provided, place a bead of RTV around the
Vertical Pipe at the Metal Boot location, and at the Intake Tee
location. Smooth out the RTV to provide a seal at both locations.

9. Two 90° end terminal elbows are supplied. These must be installed
at the extreme ends of the intake and exhaust venting outside
the building. The end terminal with the external screen must be
installed on the intake vent as shown in Figure 7.

10.Proceed as necessary to complete the venting installation as
described in the venting section of this manual.

Figure 1

Vent Assembly Illustration

“This End up” Label

Intake Tee

Apply RTV Sealant Here

Support Bracket

Vertical Pipe

Apply RTV Sealant Here

Metal Boot

Curve Faces
Upward

Rubber Intake Elbow

Blower Intake Collar

Jacket Head

Gas Control

Venting Installation Instructions For Supplied Intake Venting:

1. Refer to Figure 1, “Vent Assembly Illustration” to install intake
venting as described below.

2. Insert one end of the Vertical Pipe into Metal Boot on the lower
backside of the water heater.

3. Slide the Support Bracket over the Vertical Pipe, but do not fasten
to the Jacket Head.

4. Position the Intake Tee on top of the Vertical Pipe so that the short
straight section of the tee faces the Blower Intake Collar, and the
curve of the tee faces upward. Proper orientation of the

curved section of the tee is critical. Be sure it is facing
upward. Refer to “This End Up” label on Intake Tee.

5. Slide the Rubber Intake Elbow over the Blower Intake Collar and
over the short straight section of the Intake Tee.

6. Using a level to ensure that the Vertical Pipe is straight up and
down, secure the Vertical Pipe to the Jacket Head using the
Support Bracket and three (3) self-drilling screws provided. NOTE:

Correct vertical positioning of the Vertical Pipe is
Important.

Venting System Condensation

Condensate formation does not occur in all installations of power vented
heaters, but should be protected against on installations where condensation
can form in the venting system.

Formation of condensation in the venting system of Power Vented water
heaters is dependent upon installation conditions including, but not limited to:

ambient temperature and humidity of installation location;

ambient temperature and humidity of venting space;

vent distance and slope;

and product usage.

In order to effectively control condensate from adversely affecting the mechanical
components of the water heater several methods may be employed:

1. For horizontal installations the vent pipe can be installed with a downward
slope (not less than 1/8" nor greater than ½” per foot maximum) and
away from the blower motor.

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2. In order to prevent condensate from draining back into the blower (vertical
or horizontal runs), a fitting and drain hose is available as a condensate
trap kit (see Table 1 for service part numbers). The all rubber fitting with
drain outlet mounts directly to the blower motor outlet and is secured with
two hose clamps (one to the blower motor outlet and the other to the vent
connector). The plastic tubing is provided to drain any accumulated
condensate away from the water heater and to a suitable drain. The kit
comes complete with instructions for proper installation of the fitting.

Table 1

Model Service Part

2” (5.1 cm) Blower Outlet (exhaust) DRV1200
3” (7.6 cm) Blower Outlet (exhaust) DRV1201

3. In order to prevent condensate from draining back into the blower (vertical
or horizontal runs), a drain tee and condensate trap can be installed in the
horizontal vent as close as practical to the blower vent connection (see
Figure 2). The condensate disposal tube should be installed to drain any
accumulated condensate away from the water heater and to a suitable
drain. The drain tee and condensate hose are available through your local
distributor.

CONDENSATE “T”

ELBOW

Figure 2

ELBOW

BLOWER

To calculate total equivalent feet

Add up the total number of 90° elbows on the intake and the exhaust, and
multiply by 5 feet (1.5 m) (each 90° elbow is equivalent to 5 feet (1.5 m) of
straight pipe). To this number add the total number of feet of straight pipe on
the intake and the exhaust. This sum (total of all 90° elbows at 5 feet (1.5 m)
each, plus total number of feet of straight pipe) must not exceed 80 feet (24.4
m). All elbows must be included in the calculation except those on the extreme
ends of the intake and exhaust. 45° elbows may also be used. When using
45° elbows, take the total number of 45° elbows on the intake and exhaust
and multiply by 2-1/2 feet (.76 m) (each 45° elbow is equivalent to 2-1/2 feet
(.76 m) of straight pipe).

Total equivalent feet=
(# of 90° elbows x 5) + (# of 45° elbows x 2-1/2) + (total feet of straight pipe)

Total equivalent meters=
(# of 90° elbows x 1.5) + (# of 45° elbows x .76) + (total meters of straight
pipe)

EXAMPLE: The exhaust has two 90° elbows and the intake has four 90° elbows.
The total feet of straight pipe on the exhaust is 15 ft. (4.6 m) and the total feet
of straight pipe on the intake is 20 ft (6.1 m).

six 90° elbows x 5 ft. each = 30 ft

Total straight pipe = 11 ft+3 ft+1 ft+3 ft+9 ft+6 ft+2 ft= 35 ft

Total equivalent feet = 65 ft

LOOP

DRAIN TUBE

TO DRAIN

This water heater is a power direct vented appliance and is designed to intake
and exhaust its products of combustion through 3" (7.6 cm) or 4" (10.2 cm)
diameter Schedule 40 PVC pipe to the outdoors. This water heater may intake
and exhaust either through the wall or vertically through the roof. Use a 3" (7.6

cm) to 4" (10.2 cm) reducer to connect to the intake and outlet when using 4"
(10.2 cm) PVC. Table 2 lists the maximum intake and exhaust lengths for this

water heater using 3" (7.6 cm) PVC. If possible, locate the water heater so that
the venting length and number of elbows are kept to the minimum distance
necessary to reach the outside. If the installation requires venting lengths that
exceed the lengths listed for 3" (7.6 cm) PVC in Table 2, then use 4" (10.2 cm)
PVC for the vent connector. Table 3 lists the venting distances allowed with 4"

(10.2 cm) diameter PVC pipe. When venting with 4" (10.2 cm) PVC, use a 4"
(10.2 cm) to 3" (7.6 cm) reducer to exit through the building wall with 3" (7.6
cm) PVC. Use the 3" (7.6 cm) vent terminal supplied with the water heater to

terminate on the outside of the building. If the length of the 3" (7.6 cm) PVC
needed to go through the wall is greater than 14" (35.5 cm), use 4" (10.2 cm)
PVC to go through the wall and reduce to 3" (7.6 cm) PVC immediately after
exiting the outside wall. Refer to the venting illustrations on the following
pages. Make sure the vent pipe terminal elbow fittings are at least 1" (2.5 cm)
away from the edge of the wall.

Total six 90° elbows x 1.5 m each = 9.0m
straight pipe=3.4m+.91m+.31m+.91m+2.7m+1.8m+.61m = 10.6m

Total equivalent meters = 19.6m

1 FT

(0.31 M)

EXHAUST

3 FT

(0.91 M)

BLOWER ASSEMBLY

9 FT

(2.7 M)

INTAKE

11 FT

(3.4 M)

6 FT

(1.8 M)

ELBOWS NOT INCLUDED

IN CALCULATION

WALL

2 FT

(0.6 M)

ELBOWS INCLUDED

3 FT

(0.91 M)

IN CALCUALTION

Figure 3

IMPORTANT

For 3" (7.6 cm) vent piping, the total equivalent feet of venting (intake plus
exhaust) must not exceed 80 feet (24.4 m) and the total equivalent feet of
venting (intake or exhaust) must not exceed 40 feet (12.2 m). The total
equivalent feet of intake must be within 20 feet (6.1 m) of the total
equivalent feet of exhaust. See Table 2 for common 3" (7.6 cm) vent
lengths.

For 4" (10.2 cm) vent piping, the total equivalent feet of venting (intake
plus exhaust) must not exceed 150 feet (45.7 m) and the total equivalent
feet of venting (intake or exhaust) must not exceed 75 feet (22.9 m). The
total equivalent feet of intake must be within 20 feet (6.1 m) of the total
equivalent feet of exhaust. See Table 3 common 4" (10. cm) vent lengths.

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TABLE - 2

VENT CONNECTOR LENGTHS

FOR 3” (7.6 CM) DIAMETER PVC

Total # of 90° elbows Max. # of feet

of straight pipe

(Intake + Exhaust) (Intake + Exhaust)

2 70 (21.3 m)
365 (19.8 m)
460 (18.3 m)
5 55 (16.8 m)
6 50 (15.2 m)
7 45 (13.7 m)
8 40 (12.2 m)

TABLE - 3

VENT CONNECTOR LENGTHS

FOR 4” (10.1 CM) DIAMETER PVC

Total # of 90° elbows Max. # of feet

of straight pipe

(Intake + Exhaust) (Intake + Exhaust)

2 140 (42.7 m)
3 135 (41.1 m)
4 130 (39.6 m)
5 125 (38.1 m)
6 120 (36.6 m)
7 115 (35.1 m)
8 110 (33.5 m)

NOTE: When using 4" (10.1 cm) PVC, use a 4" (10.1 cm) to 3" (7.6
cm) reducer on the intake of the “Tee” as shown in Figure 4. When

exiting the building wall, use another 4" (10.1 cm) to 3" (7.6 cm)
reducer, and exit the wall with 3" (7.6 cm) PVC. If the length of 3"

(7.6 cm) PVC needed to go the through wall is greater then 14"
(35.5 cm), use 4" (10.1 cm) PVC to go through the wall and reduce to

3" (7.6 cm) PVC immediately after exiting the outside wall. Terminate
the venting with the 3" (7.6 cm) vent terminals supplied, as shown
in Figure 7.

Figure 4

INTAKE

EXHAUST

NOTE: ABS or CPVC pipes may be substituted for PVC pipe. Do not
mix ABS and PVC pipe in the same installation.

THROUGH THE WALL VENTING:

Cut a 3-1/2 in. (8.9 cm) diameter hole in the wall at the point where the vent
connector is going to pass through the wall. Use the proper cement to secure
the 90° vent terminal provided with the water heater to the vent connector.
The distance between the edge of the 90° vent terminal and the exterior wall
(see Figure 5) must be at least 1 in. (2.5 cm). The exhaust and intake
terminals must not be less than 16 in. (40.6 cm) apart (see Figure 7). The
exhaust terminal must not be mounted below the intake terminal. Use the
proper cement and assembly procedures to secure the vent connector joints
between the terminal and the blower outlet. Provide support brackets for
every 3 feet (.91 m) of horizontal vent.

Figure 5

4” (10.2 cm) PVC

3” (7.6 cm) PVC

WALL

14” MAX

(35.6 cm)

3” (7.6 cm) PVC

GROUND LEVEL

1” (2.5 cm)

WALL

1” (2.5 cm)

90°
VENT TERMINAL

12”

(30.5 cm)

90°
VENT TERMINAL

12”

(30.5 cm)

GROUND LEVEL

THROUGH THE WALL VENTING WITH LOW GROUND CLEARANCE:

When venting cannot exit through the wall at a height greater than or equal to
12" (30.5 cm) above the ground or anticipated snow level, the installation must
be modified as shown (Figure 6). Refer to Table 4 for maximum venting
lengths using 3" (7.6 cm) PVC or Table 5 for maximum lengths using 4" (10.1
cm) PVC.

4” (10.2 cm) TO
3” (7.3 cm)
PVC REDUCER

BLOWER

IMPORTANT

All of the Venting connections must be leak checked with a soap and water
solution upon initial start up of the water heater. Any leaks must be repaired
before continuing operation of the water heater.

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Figure 6

4” (10.2 cm) PVC

3” (7.6 cm) PVC

WALL

14” MAX

(35.6 cm)

3” (7.6 cm) PVC

WALL

GROUND LEVEL

1” (2.5 cm)

1” (2.5 cm)

90° OR 45°
VENT TERMINAL

12”

(30.5 cm)

90° OR 45°
VENT TERMINAL

12”

(30.5 cm)

GROUND LEVEL

TABLE - 4

3” (7.6 cm) PVC VENT CONNECTOR LENGTHS FROM INSIDE WALL

FOR LOW GROUND CLEARANCE INSTALLATIONS

Terminating # of 90° Elbows Max. # of Feet

(2) 90° Elbows with (1) 90° Elbow 2 50 ft (15.2 m)

(2) 90° Elbows with (1) 90° Elbow 3 45 ft (13.7 m)

(2) 90° Elbows with (1) 90° Elbow 4 40 ft (12.2 m)

(2) 90° Elbows with (1) 90° Elbow 5 35 ft (10.7 m)

(2) 90° Elbows with (1) 90° Elbow 6 30 ft (9.1 m)

(2) 90° Elbows with (1) 90° Elbow 7 25 ft (7.6 m)

(2) 90° Elbows with (1) 90° Elbow 8 20 ft (6.1 m)

(Intake + Exhaust) of straight pipe

(Intake + Exhaust)

EXTERIOR WALL

EXHAUST TERMINAL

16” MIN

(40.6 cm)

Figure 7

INTAKE TERMINAL

THROUGH THE ROOF VENTING: (VERTICAL VENTING)

Cut the necessary holes through the roof and ceiling and install the vent
connector as shown in Figure 8. Make sure that the installation meets the local
codes and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or CGA/
CAN B149 Installation Code.

6” (15.2 cm) TO

8” (20.3 cm)

90° OR 45°
VENT TERMINAL

4” (10.2 CM)
TO 3” (7.6 CM)
REDUCER

24” MIN.

(61 cm)

FLASHING

ROOF

Figure 8

HIGH ALTITUDE INSTALLATIONS FOR ELEVATIONS OVER 2,000 FEET
(914.5 m) ABOVE SEA LEVEL

TABLE - 5

4” (10.1 cm) PVC VENT CONNECTOR LENGTHS FROM INSIDE WALL

FOR LOW GROUND CLEARANCE INSTALLATIONS

Terminating (Reduce 4” to 3”) # of Elbows Max. # of Feet

(Reduce 10.1 cm to 7.6 cm) (Intake + Exhaust) of straight pipe

(Intake + Exhaust)

(2) 90° Elbows with (1) 90° Elbow 2 120 ft (36.6 m)

(2) 90° Elbows with (1) 90° Elbow 3 115 ft (35.1 m)

(2) 90° Elbows with (1) 90° Elbow 4 110 ft (33.5 m)

(2) 90° Elbows with (1) 90° Elbow 5 105 ft (32.0 m)

(2) 90° Elbows with (1) 90° Elbow 6 100 ft (30.5 m)

(2) 90° Elbows with (1) 90° Elbow 7 95 ft (29.0 m)

(2) 90° Elbows with (1) 90° Elbow 8 90 ft (27.5 m)

When venting through the wall, the exhaust terminal must exit the structure at
a minimum of 16" (40.6 cm) from either side, or any location above the intake
terminal. The exhaust terminal must not be located below the intake terminal
for any reason (See Figure 7).

The capacity of the induced draft blower declines with increasing altitude due to
a reduction in the air density. In order to assure safe and reliable performance
of the water heater, the following guidelines must be followed. Refer to the
venting tables below for maximum distances for the altitudes in your location.

TABLE - 6

HIGH ALTITUDE LENGTHS

Altitude Max. venting Max. venting Modifications to
above length reduction length reduction water heater
sea level from tables from tables

2 & 4 3 & 5

0-2,000 ft

(0-609 m)

over 2,000­10,000 ft

(609-3048 m)

No reduction
in vent length
required

No reduction
in vent length
required

No reduction
in vent length
required

No reduction
in vent length
required

None

Requires high altitude
Kit. Call the supplier or
the manufacturer

6

WATER CONNECTIONS

Note:

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

After shutting off the main water supply, open a faucet to relieve the water line
pressure to prevent any water from leaking out of the pipes while making the
water connections to the water heater. After the pressure has been relieved,
close the faucet. The COLD water inlet and HOT water outlet are identified on
the top of the water heater. The fittings at the cold water inlet and hot water
outlet are dielectric waterway fittings with 3/4" (1.9 cm) NPT male thread.
Make the proper plumbing connections between the water heater and the
plumbing system to the house. Install a shut-off valve in the cold water supply
line.

CAUTION

If sweat fittings ar to be use, DO NOT apply heat to the nipples on top of the water
heater. Sweat the tubing to the adapter before fitting the adapter to the water
connections. It is imperative that heat is not applied to the nipples containing a
plastic liner.

RPD-I&S

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED ¾” X ¾”

WARNING

TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIM WHICH MIGHT RESULT FROM
EXCESSIVE TEMPERATURE AND PRESSURES.

If this water heater is installed in a closed water supply system, such as one
having a back-flow preventer in the cold water supply, provisions must be made
to control thermal expansion. DO NOT operate this water heater in a closed
system without provisions for controlling thermal expansion. Your water supplier
or local plumbing inspector should be contacted on how to control this situation.

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

FIRST BEING CERTAIN IT IS FILLED WITH WATER.

WARNING

Hydrogen gas can be produced in an operating water heater
that has not had water drawn from the tank for a long period
of time (generally two weeks or more). Hydrogen gas is
extremely flammable. To prevent the possibility of injury under
these conditions, we recommend the hot water faucet to be
open for several minutes at the kitchen sink before you use any
electrical appliance which is connected to the hot water system.
If hydrogen is present, there will be an unsual sound such as air
escaping through the pipes as hot water begins to flow. Do not
smoke or have open flame near the faucet at the time it is open.

This water heater can deliver scalding temperature water at any faucet in the
system. Be careful whenever using hot water to avoid scalding injury. Certain
appliances such as dishwashers and automatic clothes washers may require
increased temperature water. By setting the thermostat on this water heater to
obtain the increased temperature water required by these appliances, you may
create the potential for scald injury. To protect against injury, you should install
an anti-scald tempering valve in the water system. This valve will reduce point
of discharge temperature by mixing cold and hot water in branch supply lines.
Such valves are available from the local plumbing supplier. Please consult with
a plumbing professional.

WARNING

For protection against excessive temperatures and pressure, install
temperature and pressure protective equipment required by local codes,
but not less than a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory that maintains
periodic inspection of production of listed equipment or materials as
meeting the requirements of the Standard for Relief Valves and Automatic

Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22 or the
Standard CAN1-4.4. Temperature and Pressure and the Standard
CAN1-4.4, Temperature, Pressure, Temperature and Pressure Relief Valves
and Vacuum Relief Valves. The combination temperature and pressure

relief valve shall be marked with a maximum set pressure not to exceed
the maximum working pressure of the water heater. The combination
temperature and pressure relief valve shall also have an hourly rated
temperature steam BTU discharge capacity not less than the hourly
rating of the water heater.
Install the combination temperature and pressure relief valve into the
opening provided and marked for this purpose on the water heater.
NOTE: Some models may already be equipped or supplied with a
combination temperature and pressure relief valve. Verify that the
combination temperature and pressure relief valve complies with local
codes. If the combination temperature and pressure relief valve does
not comply with local codes, replace it with one that does. Follow the
installation instructions above on this page.
Install a discharge line so that water discharged from the combination
temperature and pressure relief valve will exit within six (6) inches
(15.2 cm) above, or any distance below the structural floor and cannot
contact any live electrical part. The discharge line is to be installed to
allow for complete drainage of both the combination temperature and
pressure relief valve and the discharge line. The discharge opening must
not be subjected to blockage or freezing. DO NOT thread, plug or cap
the discharge line. It is recommended that a minimum clearance of four
(4) inches (10.2 cm) be provided on the side of the water heater for
servicing and maintenance of the combination temperature and pressure
relief valve.
Do not place a valve between the combination temperature and pressure
relief valve and the tank.

7

RPD-I&S

GAS CONNECTIONS

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

The minimum permissible gas supply pressure for the purpose of input
adjustment is 1.5" water column (.37 kPa) above the operating manifold
pressure for natural gas and 1.0" (.25 kPa) water column for L.P. gas. See the
rating plate and combination gas control for the manifold pressure and gas
type. The maximum permissible gas supply pressure is 14.0" water column
(3.5 kPa) for natural gas and liquefied petroleum gases/propane gas.

1. Connect this water heater only to the type of gas (Natural or Propane

gas) as shown on the rating plate. Use clean 1/2 inch (1.3 cm) black
iron pipe. (Dirt and scale from the pipe can enter the combination
control and cause it to malfunction). The inlet gas line must have a
minimum length of 3" (7.6 cm) drip leg (sediment trap) installed as
close to the water heater’s combination gas control as possible. A
ground joint union must be installed in the gas supply line feeding the
water heater to permit servicing of the water heater. Compounds used
on the threaded joints of the gas piping must be resistant to the action
of liquefied petroleum gases/propane gas.

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

placing the water heater in operation. Check for gas leaks with a soap
and water solution and a brush or a commercial leak detector fluid.

NEVER USE A MATCH OR OPEN FLAME FOR TESTING!

power source. Connect the hot, neutral, and ground leads of the electrical
supply to the corresponding locations that were connected to the flexible line
cord.

CAUTION

Turn off or disconnect the electrical power supply to the water heater
before servicing. Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

GENERAL OPERATION

WARNING

Water heaters are heat producing appliances. To avoid damage or injury
there shall be no materials stored against the water heater or vent-air
intake system and proper care shall be taken to avoid unnecessary
contact (especially by children) with the water heater and vent-air intake
system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE USED
OR STORED IN THE VICINITY OF THIS WATER HEATER,
VENT-AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH
FUMES COULD REACH THE WATER HEATER OR VENT-AIR INTAKE
SYSTEM.

TO FILL THE WATER HEATER

1. Close the water heater drain valve using a standard screwdriver.

CAUTION

The water heater and individual shutoff valve must be disconnected from
the gas supply piping system during any pressure testing of the system at
test pressures in excess of ½ psi (3.5kPa). The water heater must be
isolated from the gas supply piping system by closing its manual shutoff
valve during any pressure testing of the gas supply system at test pressures
equal to or less than ½ psi (3.5kPa). The supply line must be capped when
not connected to the water heater.

3. While checking for leaks care must be taken to prevent solution from

contacting the electrical connections at the control. If electrical
connections at the control become wet, they must be thoroughly dried
before attempting to operate the water heater.

ELECTRICAL CONNECTIONS

All electrical wiring and connections must be in accordance with the National
Electric Code ANSI/NFPA No. 70 (latest edition), or the Canadian Electrical Code
C22.1 (latest edition) and any local codes which may apply. The water heater
must be electrically grounded.

If a flexible line cord and plug is permitted by local code, then provide a (3)
three wire grounding type receptacle within 6 feet (1.9 m) of the water heater
and use the flexible cord provided. Do not plug the line cord into a receptacle
that can have the power supply interrupted by a switch that is used to turn on
and off lights.

2. Open the cold water supply shut-off valve.

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

4. When a steady stream of water flows from the faucets, the water heater is
filled. Close the faucets and check for water leaks at the water heater
drain valve, combination temperature and pressure relief valve and the
hot and cold water connections.

TO DRAIN THE WATER HEATER

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

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

2. Turn off/disconnect all electric power to the water heater.

3. Close the cold water supply shut-off valve.

4. Open the drain valve on the water heater using a standard screwdriver.

The drain valve has threads on the end that will allow the connection of a
standard hose coupling.

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

If wiring in conduit is required, remove the flexible line cord from the jacket and
install a 1/2" (1.3 cm) electrical conduit connector and connect a 110/120 volt

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

8

Figure 9

RPD-I&S

9

RPD-I&S

LIGHTING AND SHUTDOWN INSTRUCTIONS

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.

A. This appliance is equipped with an ignition device which automatically

lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be

sure to smell next to the floor because some gas is heavier than air and
will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

C. Use only your hand to push in or turn the gas control knob. Never use

tools. If the knob will not push in or turn by hand, don’t try to repair it,
call a qualified service technician. Force or attempted repair may result
in a fire or explosion.

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

call a qualified service technician to inspect the appliance and to replace
any part of the control system and any gas control which has been
under water.

OPERATING INSTRUCTIONS

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

2. Turn off all electric power to appliance.

3. Set the thermostat to the lowest setting.

4. This appliance is equipped with on ignition device which automatically
lights the pilot. Do not try to light the pilot by hand.

5. Slide the switch on the left side of the gas valve to the “OFF” position.

6. Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas, STOP! Follow “B” in the
safety information above on this table. If you
don’t smell gas, go to the next step.

7. Slide the switch on the left side of the gas valve to the “ON” position.

8. Set thermostat to desired setting.

9. Turn on all electric power to the appliance.

10. If the appliance will not operate, follow the instructiolns “To Turn Off Gas
To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Turn off all electric power to the appliance.

2. Set the thermostat to lowest setting.

3. Slide the switch on the left side of the gas valve to the “OFF” position.

THERMOSTAT ADJUSTMENT

adjust the thermostat turn the dial clockwise with a screwdriver until the
minimum acceptable temperature is set. It is suggested that the starting point
setting not exceed the 120°F (49°C) or “HOT” setting on the thermostat.

Figure 10

DANGER

Hotter water increases the risk of scald injury. Scalding may occur within
five (5) seconds at a temperature setting of 135°F (57°C). To protect
against hot water injury, install an anti-scald tempering valve in the water
system. This valve will reduce point of discharge temperature by mixing
cold and hot water in branch water lines. A licensed plumbing professional
or local plumbing authority should be consulted.

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

BURNER FLAME CHECK

Cast Iron Burner: At the time of installation and at periodic intervals (not

more than 6 months), a visual check of the main burner and pilot flames
should be made to determine if they are burning properly. For ideal operation,
the gas and air must be properly proportioned. The proper air-gas mixture is
obtained by adjusting the air shutter on the mixer face of the main burner (See
Figure 11). To adjust for proper burning, loosen the air shutter nut (if provided),
rotate shutter to close the opening in the burner then slowly rotate the shutter
until the yellow tips disappear and the flame becomes blue. On 75 gallon
models fired on LPG or propane, adjust the air shutter as described above until
the yellow flame is minimized (note-the burner flame may contain a mixture of
yellow and blue). Tighten the air shutter nut (if provided). Too much air will
cause the flame to lift off the burner ports and create noisy operation. Too little
air will result in soot formation. The main burner flame should light smoothly
from the pilot.

CAUTION

Before adjusting thermostat(s), turn off power supply to the water heater.

The thermostat dial is adjusted to approximately 120°F when shipped from the
factory. When adjusting the thermostat, it should be remembered that lower
temperature settings are more energy efficient. The thermostat cover, to the
right of the gas valve, must be removed when the thermostat is adjusted. To

Steel Burner: These models are equipped with self adjusting air mixture and
do not have an adjustable air shutter (See Figure 11). At periodic intervals a

visual check of the main burner and pilot flames should be made to determine
if they are burning properly. The main burner flame should light smoothly from
the pilot.

10

RPD-I&S

Figure 11

MAINTENANCE

WARNING

Water heaters are heat producing appliances. To avoid damage or injury
there shall be no materials stored against the water heater or vent-air
intake system, and proper care shall be taken to avoid unnecessary
contact (especially by children) with the water heater and vent-air intake
system. UNDER NO CIRCUMSTANCES SHALL FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE
USED OR STORED IN THE VICINITY OF THIS WATER HEATER,
VENT-AIR INTAKE SYSTEM OR IN ANY LOCATION FROM WHICH
FUMES COULD REACH THE WATER HEATER OR VENT-AIR
INTAKE SYSTEM.

A qualified service technician should perform the following maintenance at the
minimum periodic intervals suggested below. In some installations, the
maintenance interval may be more frequent depending on the amount of use
and the operating conditions of the water heater. Regular inspection and
maintenance of the water heater and vent-air intake system will help to ensure
safe and reliable operation.

1. Annually check the operation of the thermostat.

2. The flow of combustion and ventilation air MUST NOT be restricted.
Clear the combustion air openings of any dirt, dust, or other restrictions.
WARNING! The ventilation air system may be HOT.

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

4. Bi-annually conduct a visual check of the main and pilot burner flames to
determine that they are burning properly. See Burner Flame Check
section on page 10. If sooting or other burner anomalies are evident, shut
down the water heater by turning off the gas per the instructions listed in
this manual or as listed on the water heater.

needed to remove scale deposits and debris. NOTE: It is imperative

for proper operation of the water heater that the inner door be
replaced in the original location.

WARNING

When lifting lever of the combination temperature and
pressure relief valve, hot water will be released under pressure.
Be careful that any released water does not result in bodily
injury or property damage.

6. At least once a year, check the combination temperature and pressure
relief valve to ensure that the valve has not become encrusted with lime.
Lift the lever at the top of the valve several times until the valve seats
properly without leaking and operates freely.

7. Monthly drain off a gallon of water to remove silt and sediment.

WARNING! THIS WATER MAY BE HOT.

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

temperature and pressure relief valve outlet.

9. A combination sacrificial anode rod/hot water outlet nipple has been
installed to extend tank life. The anode rod should be inspected periodically
(every 2 years) and replaced when necessary to prolong tank life. Water
conditions in your area will influence the time interval for inspection and
replacement of the anode rod. Contact the plumbing professional who
installed the water heater or the manufacturer listed on the rating plate
for anode replacement information. The use of a water softener may
increase the speed of anode consumption. More frequent inspection of
the anode is needed when using softened (or phosphate treated) water.

10. The induced draft blower has sealed motor bearings and does not require
adding oil.

CAUTION

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

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

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

5. Annually remove the inner door and main burner assembly to clean
orifices and related parts of any dirt or other foreign material. Inspect the
burner ports for obstructions or debris and clean with a wire brush as
needed. Wire brush and/or vacuum clean the combustion chamber as

11

RPD-I&S

VENT PIPE PREPARATION AND JOINING

Most failures in PVC, CPVC or ABS systems result from improper preparation and
joining of pipe and fittings. The guidelines below must be followed when
installing the venting system. If you have any question about the application
or installation of the PVC, CPVC or ABS venting system, contact the manufacturer,
supplier, or your plumbing professional.

1) Specific cleaners, solvents, primers and cements are available for PVC,
CPVC and ABS pipe. Be sure these materials match the type of pipe to be
installed. Never use all-purpose cements, commercial glues and adhesives
or ABS cement to join PVC or CPVC pipe and fittings.

a) CLEANERS, SOLVENTS, PRIMERS AND CEMENTS ARE

FLAMMABLE. Do not store or use these materials near
heat or open flame, or in the vicinity of other appliances.

2) Use proper cutting, deburring and applicator tools to ensure proper
preparation and joining of pipe and fittings.
a) Cutting Tools

i) A square cut must be achieved with a miter box saw or pipe

cutter to ensure a proper mating with the female. If a pipe
cutter is used, the burr created at the outer edge of the pipe
must be removed.

b) Deburring Tools

i) A file, knife or plastic deburring tool can be used to remove

burrs. Burrs must be removed from the inside and outside
edges of the pipe to ensure a proper seal.

c) Applicator Tools

i) A pure bristle paintbrush or roller may be used to apply

cement. Prompt application of the cement is important due
its fast drying properties.

3) Inspection, Cleaning, Priming and Cementing
a) Inspect the pipe inside and out for dirt, dust, moisture or grease

etc. Check pipe and fittings for splits or cracks and replace if
necessary.

b) Clean pipe and fittings are imperative for proper joining. Following

cutting and deburring, wipe away any foreign material with a clean
dry rag. If wiping fails to thoroughly clean surfaces, chemical
cleaning is necessary.

c) Primer must be applied to the pipe surface and fitting socket with

a natural bristle brush. This serves to soften and prepare the PVC
or CPVC for cementing.

d) Cementing must be done quickly to avoid over-drying before joining.

i) Apply one coat to the outside end of the pipe at a width

slightly greater than the depth of the socket.
ii) Apply a coat around the inside of the fitting socket.
iii) Apply a second coat around the end of the pipe.

4) Joining
a) Joints should be made immediately after cement is applied.
b) After fully inserting pipe into fitting socket, give pipe about ¼ turn

to help spread cement evenly. Hold joint together for about 15 to
20 seconds.

c) Remove excess cement from around pipe and fitting with a clean

rag.

d) Cement drying times may vary. Be sure to allow for the

recommended drying time before disturbing joints.

For more specific and detailed information about the above, contact the
manufacturer, supplier, or competent professional.

THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF:

GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING

AND SPACE HEATING

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

2. Toxic chemicals, such as those used for boiler treatment, must not be
introduced into potable water used for space heating.

3. This water heater must not be connected to an existing heating system
or component(s) previously used with a non-potable water heating
appliance.

4. When the system requires water for space heating at temperatures
higher than required for other means, a tempering valve must be
installed to temper the water for those uses in order to reduce the scald
hazard potential.

Please refer to the illustration for the suggested piping arrangement.

12

Printed in USA