PowerFlex POWER VENTED GAS Models Installation And Operating Manual

Installation and Operating Manual

RESIDENTIAL GAS WATER HEATERS

POWER VENTED GAS MODELS

WITH HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

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

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

1306 324083-003

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

TABLE OF CONTENTS

TABLE OF CONTENTS 2 SAFE INSTALLATION, USE AND SERVICE 3 GENERAL SAFETY 4 INTRODUCTION 6

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

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

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS 7 TYPICAL INSTALLATION 9

Get To Know Your Water Heater - Gas Models

(List Referencing Figures 1-7). . . . . . . . . . . . . . . . . . 9

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

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

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

Mixing Valves

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

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

SAFETY LOCKOUTS 14

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

Thermostat/Water Temperature Blower High Limit Switch

Blower Air Pressure Switch. . . . . . . . . . . . . . . . . . . 14

Flammable Vapor Sensor . . . . . . . . . . . . . . . . . . . . 14

LOCATING THE NEW WATER HEATER 15

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

Storage Of Flammable Liquids . . . . . . . . . . . . . . . . 15

Clearances to combustibles Floors with carpeting Clearance for servicing

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

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

Unconﬁ ned Space. . . . . . . . . . . . . . . . . . . . . . . . . . 17

Unusually Tight Construction . . . . . . . . . . . . . . . . . 17

Conﬁ ned Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Direct Vent Appliances . . . . . . . . . . . . . . . . . . . . . . 18

Exhaust Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fresh Air Openings For Conﬁ ned Spaces. . . . . . . . 18

Chemical Vapor Corrosion . . . . . . . . . . . . . . . . . . . 19

INSTALLING THE NEW WATER HEATER 20

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Space Heating And Potable Water Systems . . . . . . 20

Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System Requirements Installation

Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 22

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 22

Temperature-Pressure Relief Valve. . . . . . . . . . . . . 23

T&P valve discharge pipe requirements: Temperature-Pressure Relief Valve and

Pipe Insulation

High Altitude Installation . . . . . . . . . . . . . . . . . . . . . 24

Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Sediment Traps/Dirt Leg . . . . . . . . . . . . . . . . . . . . . 25

Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 26

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Termination Clearances Sidewall Power Vent. . . . . 27

Blower Assembly Installation. . . . . . . . . . . . . . . . . . 28

Installation Of Vent System. . . . . . . . . . . . . . . . . . . 28

Planning The Vent System . . . . . . . . . . . . . . . . . . . 28

High Ambient Temperature Installations . . . . . . . . . 28

Polypropylene Vent Systems . . . . . . . . . . . . . . . . . 29

Condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Important Notes and Warnings Venting terminations and sizing Vent screen installation Calculating Equivalent Feet Venting instructions Vent pipe connection to blower Different coupling installations according

to vent sizes

Blower Exhaust Direction . . . . . . . . . . . . . . . . . . . . 35

Vent Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . 35

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 38

LIGHTING INSTRUCTIONS 39 OPERATING THE TEMPERATURE CONTROL SYSTEM 40

Gas Control Valve/Thermostat . . . . . . . . . . . . . . . . 41

FOR YOUR INFORMATION 42

Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condensate Thermal expansion Closed water systems Smoke/odor Strange sounds

Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 42

Smelly water

“Air” In Hot-Water Faucets . . . . . . . . . . . . . . . . . . . 43

PERIODIC MAINTENANCE 44

General Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Venting System Inspection . . . . . . . . . . . . . . . . . . . 44

Blower Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 44

Cleaning The Blower. . . . . . . . . . . . . . . . . . . . . . . . 44

Burner Operation And Inspection . . . . . . . . . . . . . . 45

Combustion Chamber And Burner Cleaning. . . . . . 46

Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Anode Rod Inspection. . . . . . . . . . . . . . . . . . . . . . . 46

Anode Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Removing Anode Rod: Installing Anode Rod:

Temperature-Pressure Relief Valve Test . . . . . . . . . 47

Draining And Flushing. . . . . . . . . . . . . . . . . . . . . . . 48

To drain the water heater storage tank: To ﬂ ush the water heater storage tank: LEAKAGE CHECKPOINTS 49

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

REFERENCE PARTS LISTING 50 TROUBLESHOOTING GUIDELINES 52

Resetting The Heater Control . . . . . . . . . . . . . . . . . 54

Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Soft Lockout Hard Lockout

Ignition State And Timing . . . . . . . . . . . . . . . . . . . . 55

System Status And Error Codes . . . . . . . . . . . . . . . 55

LIMITED WARRANTY 58

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SAFE INSTALLATION, USE AND SERVICE

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

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

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

DANGER indicates an imminently

DANGER

WARNING

CAUTION

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

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

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

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

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

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

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

IMPORTANT DEFINITIONS

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

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

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

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GENERAL SAFETY

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GENERAL SAFETY

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Install vent system in accordance with codes.

• Do not operate water heater if flood damaged.

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

• Do not operate if soot buildup is present.

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

• Do not obstruct blower air intake.

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

• Gas and carbon monoxide detectors are available.

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

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

DANGER

FLAMMBLE

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

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

Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

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

Flammable Vapors

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

1. can be triggered at any time and

2. the hot surface will ignite flammable vapors.

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor and

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

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INTRODUCTION

Thank You for purchasing this water heater. Properly

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

Abbreviations found in this Installation and Operating manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• UL - Underwriters Laboratories Inc.

• AHRI - Air Conditioning, Heating and Refrigeration

Institute.

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

Z21.10.1 • CSA 4.1 (current edition).

QUALIFIED INSTALLER OR SERVICE AGENCY

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

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

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

READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

2. The installation must conform with these instructions and local code authority having jurisdiction. In absence of local codes, installation must comply with current editions of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and National Electrical Code, NFPA 70. All documents are available from:

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

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

3. The water heater, when installed, must be electrically grounded in accordance with the local codes or in the absence of local codes: the National Electrical Code (NFPA 70).

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 ﬁ res (see Figure 14 & Figure 15). Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.

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

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

PREPARING FOR THE INSTALLATION

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

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

2.00: State Plumbing Code and 248-CMR 5.00.

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

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

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

MUST BE VERTICAL TO REMOVE A

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

WATER HEATER ACCEPTED BY THE BOARD FOR INSTALLATION IN MASSACHUSETTS.

MASSACHUSETTS INSTALLATION REQUIREMENTS:

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

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

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

† REQUIRED FOR MASSACHUSETTS.

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

IR BUBBLES

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

& 780 CMR).

†

)

†

TYPICAL MIXING VALVE INSTALLATION

EXPANSION TANK

CHECK

VALVE

UNION

HOT

WATER

OUT

VACUUM

†

RELIEF VALVE

UNION

TEMP/ PRESSURE RELIEF VALV E

SEE NOTE ‡

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

CHECK VALVE

(1/8” HOLE

DRILLED IN CLAPPER)

PUMP

AIR

HANDLER

SHUT-OFF

VALV E

IN HEATING UNIT

COLD WATER INLET

†

FLOW CONTROL

OUT

COIL

AIR

HANDLER

†

SHUT-OFF

VALVE

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TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS (list referencing Figures 1-7)

1. Vent Termination Elbow with Rodent Screen

2. *Vent Pipe

3. *Vent Pipe Coupling (if required)

4. *Vent Pipe Elbow (long radius)

5. Blower High Limit Switch (see Figure 6)

6. T&P Valve

7. Cold-Water Inlet Nipple/Diptube

8. Bafﬂ e Assembly

9. * Discharge Pipe

10. Gas Control Valve/Thermostat (Honeywell)

11. Gas Valve Electronic Control Module And Cover (Honeywell)

12. Drain Valve

13. Outer Gas Door

14. Manifold Door Assembly (behind outer door) (see Figure 3 & Figure 4)

15. *Floor Drain

16. *Metal Drain Pan

17. Flammable Vapor Sensor (under cover) (see Figure 5)

18. **Combo Heating System Return Inlet (Optional)

19. Air Inlet Snorkel

20. **Combo Heating System Supply Outlet (Optional)

21. Blower with Power Cord (see also Figure 6)

22. Air Switch (inside box) (see Figure 6)

23. Junction Box (see Figure 6)

24. Junction Box Cover (see Figure 6)

25. Air Tubing (see Figure 6)

26. Rubber Coupling (see also Figure

27. Gear Clamp (see also Figure 6)

28. Flue Collector

29. Hot-Water Outlet Nipple

30. Anode (under cap)

31. ***Control Harness

32. Flexible Manifold Tube (see Figure 3 & Figure 4)

33. Viewport (see Figure 3 & Figure 4)

34. Flame Sensor Rod (see Figure 3 & Figure 4)

35. Gas Oriﬁ ce (see Figure 3 & Figure 4)

36. Sheet Metal Burner (see Figure 3 & Figure 4)

37. Gas Manifold (see Figure 3 & Figure 4)

38. Hot-Surface Igniter (see Figure 3 & Figure 4)

39. Manifold Door Gasket (see Figure 3 & Figure 4)

40. Manifold Door (see Figure 3 & Figure 4)

41. Two Piece Grommet With Clip (see Figure 3 & Figure 4)

42. *Inlet Water Shut-off Valve

43. *Gas Supply*

44. *Main Manual Gas Shut-off Valve

45. *Ground Joint Union (gas connection)

46. *Sediment Trap/Dirt Leg

47. *Union (water connection)

48. Rating Plate

49. *Thermal Expansion Tank (required for all closed systems)

*, **, ***, **** see notes on following

page

Blower

Dilution Air

Inlets

Combustion

Air Inlets

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Front View Rear View

Figure 1. Figure 2.

Natural gas and Propane main burner with igniter assembly for 40k to 50k Btu/hr models

Figure 3.

Natural gas and Propane main burner with igniter assembly for 60k to 75k Btu/hr models

4041

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

Figure 6.

32 34

Figure 4.

Figure 7.

Notes:

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

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

below. *** Caution harness has 120 VAC In operation. **** See “Planning The Vent System”, “Condensate” and

“Blower Assembly Installation” for more information.

REPLACEMENT PARTS AND DELIMING PRODUCTS

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

COMBO HEATING INLET AND OUTLET SIDE TAPS

Models equipped with Combo Heating capabilities are shipped with the two side plumbing taps OPEN (items 18 and 20 in Figure 1 and see also Figure 8 & Figure 25). If the heater is to be operated without using the side taps, these openings must be closed with the two pipe plugs supplied with the heaters.

Figure 5.

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WATER PIPING - MIXING VALVE USAGE

Mixing Valves

Water temperature over

DANGER

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

his appliance has been design certiﬁ ed as complying with American National Standard/CSA Standard for water heaters and certain models with side plumbing connections are considered suitable for Water (Potable) Heating and Space Heating. Note: Do not use in space heating only applications.

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

Feel water before bathing or showering.

Temperature limiting devices

HOT

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

BURN

temperatures at fixtures.

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

SUGGESTED PIPING ARRANGEMENT FOR

TOP CONNECTIONS

MIXING VALVE

TEMPERATUREPRESSURE RELIEF VALVE

* NOTE: THE

T&P VALVE

DISCHARGE

PIPE MUST

BE PIPED

DIRECTLY TO

THE DRAIN

OR EXTERNAL

TO THE

BUILDING

DISCHARGE PIPE (DO NOT CAP OR PLUG)

TEMPERED POTABLE WATER

HEATING. THE HOT AND COLD FITTING

SHUT-OFF

VALV E

COLD-WATER

INLET

CERTAIN

MODELS ARE EQUIPPED WITH SIDE PLUMBING

CONNECTIONS

FOR SPACE

ASSEMBLIES (PART #9001262)

CAN BE ORDERED

THROUGH THE

MANUFACTURER

METAL DRAIN

PAN 1.75”

MAX. DEPTH.

AT LEAST 2”

GREATER THAN

THE DIAMETER OF THE WATER

HEATER.

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

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

NON-TEMPERED

WATER SUPPLY

MIXING VALVE

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

142.

GAS

SUPPLY

DRAIN VALV E

METAL DRAIN

PAN 1.75” MAX.

DEPTH. AT

LEAST

2” GREATER

THAN THE

DIAMETER OF

THE WATER

HEATER.

TEMPERED

POTABLE WATER

SHUT-OFF

VALV E

COLD-WATER

INLET

NON-TEMPERED

WATER RETURN

TEMPERATUREPRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

* NOTE: THE

T&P VALVE

DISCHARGE PIPE

MUST BE PIPED

DIRECTLY TO

THE DRAIN OR

EXTERNAL TO

THE BUILDING

6” MAX. AIR GAP*

Figure 9.

GAS SUPPLY

6” MAX. AIR GAP*

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

Figure 8.

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DRAIN VALV E

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

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

Water

Temperature

°F

Time for 1st

Degree Burns

(Less Severe Burns)

110 (normal shower temp.)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seconds 25 seconds

140 2 seconds 5 seconds

149 1 second 2 seconds

154 instantaneous 1 seconds

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

Time for Permanent

Burns 2nd & 3rd

Degree (Most

Severe Burns)

Table 1.

In addition to using lowest possible temperature setting that satisﬁ es demand of application, a mixing valve should be installed at water heater (see Figure 8 & Figure 9) or at hot-water taps to further reduce system water temperature. Mixing valves are available at plumbing supply stores. Consult a Qualiﬁ ed Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Operating The Temperature Control System” section in this manual.

WATER HEATER OPERATION

Figure 10 shows the water heater’s sequence of operation when a call for heat is initiated. The ignition control module will attempt to light the burner three times. If the ignition control does not detect ignition it will enter lockout mode and ﬂ ash the corresponding error code.

HEATER

THERMOSTAT

CALLS FOR

HEAT

HEATER CONTROL CHECKS TO ENSURE BLOWER PRESSURE

SWITCH IS OPEN

BLOWER IS

ENERGIZED

CONTROL CHECKS TO ENSURE PRES-

SURE SWITCH CLOSES

INDICATING BLOWER

IS OPERATING AND

THERE ARE NO

VENTING BLOCKAGES

(INLET OR OUTLET)

IGNITER IS ENERGIZED

AND MAIN GAS VALVE

IS OPENED

MAIN BURNER COMES ON AND THE FLAME IS SENSED BY CONTROL

MAIN BURNER CONTIN-

UES TILL THE WATER IN THE TANK REACHES THERMOSTAT SETTING

MAIN BURNER SHUTS

OFF. BLOWER

CONTINUES FOR A

POST PURGE TIME

HEATER

REMAINS ON STANDBY UNTIL NEXT CALL FOR

HEAT

Figure 10.

12 www.americanwaterheater.com

ELECTRICAL REQUIREMENTS & WIRING DIAGRAM

WARNING

Electric Shock Hazard

Disconnect power before servicing.

Replace all parts and panels before operating.

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

Before plugging in the water heater, always make sure:

• The voltage and frequency correspond to that

speciﬁ ed on the water heater wiring diagram.

• The electrical outlet has the proper overload fuse or

breaker protection.

1. The unit must be connected to a dedicated power supply.

2. The unit must be connected to a 120VAC power supply.

3. The water heater must be properly grounded.

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

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

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

NOTE: REFER TO THE “INSTALLATION CHECKLIST” BEFORE OPERATING THIS HEATER.

EARTH GND

CAPACITOR

BLOWER

FLAME SENSOR

HOT SURFACE IGNITER

PRESSURE SWITCH

HIGH LIMIT SWITCH

FLAMMABLE VAPOUR SENSOR

After making all electrical connections, completely ﬁ ll the tank with water and check all connections for leaks. Open the nearest hot-water faucet and let it run for 3 minutes to purge the water lines of air and sediment and to ensure complete ﬁ lling of the tank. The electrical power may then be turned on. Verify proper operation after servicing. See also “Installation Checklist”. CAUTION

Circled numbers indicate sequence of operation.

Figure 11.

www.americanwaterheater.com 13

Figure 12.

SAFETY LOCKOUTS

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

HIGH LIMIT CONTROLS (Energy Cut Off)

Thermostat/Water Temperature

This feature is a part of the gas control valve/thermostat (see Figure 1, item 10) and limits the maximum water temperature. In the event of the water overheating, this safety feature shuts off the fuel supply to the burner.

Blower High Limit Switch

This device is located on the blower (see Figure 6, item

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

BLOWER AIR PRESSURE SWITCH

This device, located in the junction box, monitors the air pressure produced by the blower. In the event that the exhaust venting becomes blocked or sufﬁ ciently restricted, the switch will shut the heater down (see Figure 6, item 22).

If there is a problem with the wiring of the ﬂ ammable vapor sensor or the ﬂ ammable vapor interface, the LED will ﬂ ash the failure status code (see “System Status And Error Codes”).

* ROTATE LEFT (CCW) TO REMOVE

COVER*

MOUNTING

BRACKET

FLAMMABLE

VAPOR SENSOR

(PULL TO REMOVE)

Figure 13.

FLAMMABLE VAPOR SENSOR

When using a gas ﬁ red water heater there is a risk of ﬂ ammable vapors entering the combustion chamber, being

ignited by the burner ﬂ ame and causing a ﬂ ashback. In order to detect such ﬂ ammable vapors before they enter the combustion chamber, this water heater is equipped with a ﬂ ammable vapor sensor (FVS). It is a chemical- absorption based sensor that is connected to the gas control/thermostat (see Figure 13). When exposed to

ﬂ ammable vapors it will trigger the control to stop the ﬂ ow of gas and enter the FVS lockout state. While in the

FVS lockout state the LED on the control will ﬂ ash the gas lockout code. (Refer to the “System Status And Error Codes” section of this manual for an explanation of the codes applicable to the control installed on your water heater.) If this error occurs, check around the water heater for sources of chemical contamination such as: ﬂ ammable vapors including gas vapors, solvents, paint and thinners as well as sources of water and detergents.

Note: Resetting the heater will reset the FVIR circuit if all sources of contamination have been removed and the sensor clears. If all sources of contamination have been removed and the system will not reset, the sensor will need to be replaced (see “Resetting the Heater Control”).

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LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

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

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

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

3. Ensure the area has a continuous supply of air for combustion, dilution and ventilation.

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

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

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

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

Important: Do not use an extension cord to connect the water heater to an electrical outlet. Important: this heater has special venting requirements when installed in areas where the ambient temperatures exceed 110°F (see “High Ambient Temperature Installations”).

CAUTION

Property Damage Hazard

• All water heaters eventually leak.

• Do not install without adequate drainage.

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

prevented by a leak detector or water shut-off device used in conjunction with a piped metal drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the metal drain pan that trigger an

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

• Sensors mounted in the metal drain pan that turn off

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

• Water supply shut-off devices that activate based on

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

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

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

STORAGE OF FLAMMABLE LIQUIDS

Flammable liquids (such as gasoline, solvents, propane (LP or butane, etc.) and other substances (such as adhesives, paints, etc.) emit ﬂ ammable vapors which can be ignited by a gas water heater’s hot surface igniter (HSI) or main burner. The resulting ﬂ ashback and ﬁ re can cause death or serious burns to anyone in the area.

This water heater is equipped with a FV (Flammable Vapor) sensor for detecting the presence of ﬂ ammable vapors. When the sensor detects those vapors, the unit will shut down and not operate. Should this happen, please refer to the “Troubleshooting Guidelines” section of this manual. Even though this water heater is a ﬂ ammable vapors ignition resistant (FVIR) water heater and is designed to reduce the chances of ﬂ ammable vapors being ignited, gasoline and other ﬂ ammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open ﬂ ame or spark producing appliance. Examples of such locations are garages, storage and utility areas.

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

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WARNING

Fire or Explosion Hazard

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

liquids in the vicinity of this or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Clearance for servicing

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

A minimum clearance of 5.5” must be allowed for access to replaceable parts such as 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.

TOP VIEW

OF CLOSET

WITHOUT DOOR

AIR INTAKE*

TOP VIEW OF CLOSET WITH

DOOR

WARNING

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

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

Flammable Vapors

WARNING

Fire Hazard

For continued protection against risk of fire:

• Do not install water heater on carpeted floor.

• Do not operate water heater if flood damaged.

Clearances to combustibles

Minimum clearances between water heater and combustibles are 0” at the sides and rear, 5.5” from the front and 12” from top (standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater (see Figure 14).

0” MIN. 0” MIN.

0” MIN.

* DO NOT BLOCK THE AIR INTAKES AT THE BACK OF THE WATER HEATER.

5.5” MIN.

Figure 14.

A gas water heater cannot operate properly without the correct amount of air for combustion and ventilation. Do not install in a conﬁ ned area such as a closet unless you provide air as shown below and described in the “Air Requirements” section (see Figure 15). Never obstruct the ﬂ ow of ventilation air for dilution and combustion. 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 ﬁ re or explosion and cause death, serious bodily injury, or property damage.

WARNING

Breathing Hazard - Carbon Monoxide Gas

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

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

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

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

Floors with carpeting

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

16 www.americanwaterheater.com

Figure 15.

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 or water heaters be installed so that combustion and ventilation air be taken from outside these areas. Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly ﬂ 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.

INSULATION BLANKETS

Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the current standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identiﬁ cation of components mentioned below, see Figure 1 thru Figure 7). Failure to follow these instructions will restrict the air ﬂ ow required for proper combustion and dilution, potentially resulting in ﬁ re, asphyxiation, serious personal injury or death.

AIR REQUIREMENTS

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

An insufﬁ cient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a condition often will result in a yellow, luminous burner ﬂ ame, causing sooting of the combustion chamber, burners and ﬂ ue tubes and creates a risk of asphyxiation.

Do not install the water heater in a conﬁ ned space unless an adequate supply of air for combustion, dilution and ventilation is brought into that space using the methods described in the “Conﬁ ned Space” section that follows.

Never obstruct the ﬂ ow of dilution/ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amounts of air can result in a ﬁ re or explosion and cause property damage, serious bodily injury or death. The combustion and dilution air inlets are shown in Figure 2. Important: Power Vented water heaters require air for combustion and dilution air for the blower.

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

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

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

valve, FV sensor, or Air Intake Snorkel.

• Do not cover the “Installation And Operating 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 for placement on the blanket directly over the existing labels.

• Do inspect the insulation blanket frequently to make

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

WARNING

Breathing Hazard - Carbon Monoxide Gas

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

• Gas and carbcn monoxide detectors are available.

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

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

UNCONFINED SPACE

An Unconﬁ ned Space is one whose volume is not less than 50 cubic feet per 1,000 Btu/hr of the total input rating of all appliances installed in the 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 unconﬁ ned space.

Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers and ﬁ replaces should also be considered in determining the adequacy of a space to provide combustion, ventilation and dilution air.

UNUSUALLY TIGHT CONSTRUCTION

In unconﬁ ned spaces in buildings, inﬁ ltration may be adequate to provide air for combustion, ventilation and dilution of ﬂ ue gases. However, in buildings of unusually tight construction (e.g., weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in the “Conﬁ ned Space” section that follows.

CONFINED SPACE

A Conﬁ ned Space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr of the total input rating of all appliances installed in the space. Openings must be installed to provide fresh air for combustion, ventilation and dilution in conﬁ ned spaces. The required size for the openings is dependent on the method used to provide fresh air to the conﬁ ned space

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and the total Btu/hr input rating of all appliances installed in the space.

DIRECT VENT APPLIANCES

Other appliances installed in a Direct Vent conﬁ guration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/hr calculations used to determine the size of openings providing fresh air into conﬁ ned spaces.

EXHAUST FANS

Where exhaust fans are installed, additional air should be provided to replace the exhausted air. When an exhaust fan is installed in the same space with a water heater, sufﬁ cient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan. Undersized openings will cause air to be drawn into the room through the water heater’s vent system causing poor combustion. Sooting, serious damage to the water heater and the risk of ﬁ re or explosion may result. It can also create a risk of asphyxiation.

FRESH AIR OPENINGS FOR CONFINED SPACES

The following instructions should be used to calculate the size, number and placement of openings providing fresh air for combustion, ventilation and dilution in conﬁ ned spaces. The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into conﬁ ned spaces only. Do not refer to these illustrations for the purpose of vent installation. See “Installation of Vent System” section for complete venting installation instructions.

Figure 16.

B. ALL AIR FROM OUTDOORS: (See Figure 17 thru

Figure 19)

The confined space shall be provided with two

permanent openings, one commencing within 12” of the top and one commencing within 12“ 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. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btu/hr of total input rating of all equipment in the enclosure (see Figure 17).

Chemical vapor corrosion of the ﬂ ue, blower assembly and vent system may occur if the air supply contains certain chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride (water softener salt), waxes, bleach and process chemicals are typical compounds which are potentially corrosive.

A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 16) The confined space shall be provided with two

permanent openings communicating directly with an additional room(s) of sufﬁ cient volume so that the combined volume of all spaces meets the criteria for an unconﬁ 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/hr of the total input rating of all gas utilization equipment in the conﬁ ned space, but not less than 100 square inches. One opening shall commence within 12” of the top and one commencing within 12” of the bottom of the enclosures.

Figure 17.

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/hr of total input rating of all equipment in the enclosure (see Figure 18).

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 Btu/hr of total input rating of all equipment in the enclosure (see Figure 19).

18 www.americanwaterheater.com

Figure 18.

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” (see Figure 19).

Figure 19.

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/ hr of total input rating of all equipment in enclosure (see Figure 20).

Figure 20.

6. Louvers and Grilles: In calculating free area, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4” 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 speciﬁ 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 ﬁ 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 ﬁ replaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.

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 the 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.

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INSTALLING THE NEW WATER HEATER

WATER PIPING

Water temperature over

DANGER

HOT

BURN

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, 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 inﬁ rm, or physically/ mentally handicapped. If anyone using hot water ﬁ ts into one of these groups or if there is a local code or state law requiring certain temperature water at the hot-water tap, then you must take special precautions. In addition to using lowest possible temperature setting that satisﬁ es your hot water needs, a means such as a mixing valve, should be used at hot-water taps used by these people or at the water heater (see Figure 8 & Figure 9). Valves for reducing point of use temperature by mixing cold and hot water are also available.

SPACE HEATING AND POTABLE WATER SYSTEMS

This appliance has been design certiﬁ ed as complying with American National Standard/CSA Standard for water heaters and are considered suitable for Water (Potable) Heating and Space Heating. Note: Water heaters used in combination water/space heating shall not be used in space heating only applications.

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

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

Feel water before bathing or showering.

Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures.

WARNING

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

• This water heater should not be connected to any

heating systems or components previously used with a non-potable water heating appliance.

• All piping components connected to this unit for space

heating applications should be suitable for use with potable water.

• Toxic chemicals, such as those used for boiler treatment

shall not be introduced into the potable water used for space heating.

• When the system requires water for space heating at

temperatures higher than required for domestic water purposes, a mixing valve must be installed. Please refer to Figure 8 & Figure 9 for suggested piping

arrangement. Note: Water piping and vent piping occupy the space above the water heater. Plan the water piping to ensure it does not cause interference with the vent piping (see “Planning the Vent System”). If this water heater is to be used to supply both space heating and potable water, the instructions listed below must be followed:

• Be sure to follow the manual(s) shipped with the air

handler or other type heating system.

• This water heater is not to be used as a replacement

for an existing boiler installation.

• Do not use with piping that has been treated with

chromates, boiler seal or other chemicals and do not

add any chemicals to the water heater piping.

• If the space heating system requires water temperatures

in excess of 120°F, a mixing valve must be installed,

per the manufacturer’s instructions, in the potable hot-

water supply to limit the risk of scald injury.

• Pumps, valves, piping and ﬁ ttings must be compatible

with potable water.

• A properly installed ﬂ ow control valve is required to

prevent thermosiphoning. Thermosiphoning is the

result of a continuous ﬂ ow of water through the air

handler circuit during the off cycle. Weeping (blow off)

of the temperature-pressure relief valve (T&P) or higher

than normal water temperatures are the ﬁ rst signs of

thermosiphoning.

• The hot-water line from the water heater should be

vertical past any mixing valve or supply line to the

heating system to remove air bubbles from the system.

• Do not connect the water heater to any system or

components previously used with non-potable water

heating appliances when used to supply potable water.

Toxic Chemical Hazard

• Do not connect to non-potable water system.

20 www.americanwaterheater.com

COMBO HEATING

This section serves as a guide for the installation and use of “Combo” heating systems utilizing a domestic water heater that has been speciﬁ cally approved for such use. It is written for those knowledgeable in the required trades and professionals involved in the design and installation of Combo Heating Systems. It is the responsibility of the installer/designer to follow all applicable codes to ensure the effectiveness and safety of the installation.

System Requirements

The following requirements must be met for the installation of Combo Heating Systems:

1. All components used for the distribution of water in the heating loop must be suitable for potable water. These include all piping, ﬁ ttings, solder and ﬂ uxes, pumps for circulation of water, valves, etc.

2. The water heater must not be connected to a hydronic heating system that has been used previously.

3. No boiler treatment chemicals of any kind shall be introduced into the system.

4. The Combo System components must be selected and sized to meet and maintain the total calculated demands for both domestic service hot water and space heating requirement. The sizing and installation must be performed in accordance with good engineering practice such as “ASHRAE

Handbooks”, HRAI’s Uniﬁ ed Combo Guidelines, “Hydronics Institute Manuals”, ANSI Z223.1, CSA F280, National/Provincial Building Codes, ANSI

and/or codes having jurisdiction.

5. The air handler (fan coil) and/or the circulating pump in a baseboard hydronic loop will require a dedicated 120V circuit. This must be provided and identiﬁ ed for this purpose.

6. All piping between the water heater and the air handler or hydronic baseboard loop must be adequately insulated to reduce heat loss.

7. If the local jurisdiction requires a back-ﬂ ow preventer in the cold water line, an expansion tank of adequate size must be installed.

8. “Combo” Heating Systems require higher water temperatures than other applications. When the system is used to supply water for Combo Heating applications, a means, such as mixing valve, must be installed to temper the water in order to reduce scald hazard potential (see Figure 21 & Figure 22).

Installation

The heating mode may be one of the following options: A. A fan coil/air handler (Figure 21). B. A hydronic baseboard (ﬁ nned tube) loop/In ﬂ oor heating

(Figure 22). The following is a list of requirements for the installation of option A or B.

1. Install shut-off valves and unions so that the water

heater can be isolated from the heating module should servicing of the water heater become necessary.

2. Install a drain valve at the lowest point of the heating loop so that water can be drained from the heating module without affecting the water heater.

3. If the air handler does not have a venting means at the highest point of the piping arrangement, install an air bleed at the highest point of the plumbing arrangement.

HOT WATER

TO HOUSE

FIXTURE

MIXING

VALV E

8 in TO

12 in MAX.

HOT

OUTLET

EXPANSION TANK (OPTIONAL)

WATER

HEATER

COLD SUPPLY

code requirements

CHECK VALVE (IF USED REQUIRES EXPANSION TANK)

CHECK

COLD INLET

AIR

HANDLER

VALV E

FLOW CONTROL

HOSE BIB

(OPTIONAL)

SUPPLY

(see also

Massachusetts

on pg 8)

EXTERNAL CIRCULATOR

RETURN

DRAIN/ PURGE VALV E

INTERNAL

CIRCULATOR

Figure 21.

HOT WATER

TO HOUSE

FIXTURE

MIXING

VALV E

8 in TO

12 in MAX.

HOT

OUTLET

EXPANSION TANK (OPTIONAL)

WATER

HEATER

COLD SUPPLY

code requirements

CHECK VALVE (IF USED REQUIRES EXPANSION TANK)

CHECK

COLD INLET

VALV E

FLOW CONTROL

HOSE BIB

(OPTIONAL)

SUPPLY

(see also

Massachusetts

on pg 8)

EXTERNAL CIRCULATOR

RETURN

HYDRONIC

BASEBOARDS

(SERIES

CONNECTED

SHOWN)

Figure 22.

www.americanwaterheater.com 21

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 ﬂ 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 increase. As the volume of water increases, 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 temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

A properly-sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank.

Note: To protect against untimely corrosion of hot and cold water ﬁ ttings, it is recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe.

HOT-WATER

OUTLET

UNION

3/4” SWEAT

FITTING

SOME

COMPONENTS

NOT SHOWN

FOR CLARITY.

Figure 23.

SHUT-OFF VALVE

UNION

3/4” SWEAT

FITTING

TEMPERATUREPRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

6” MAX. AIR GAP

COLD-

WATER

INLET

DRAIN VALV E

METAL DRAIN PAN

FLOOR DRAIN

CAUTION

Property Damage Hazard

• Avoid water heater damage.

• Install thermal expansion tank if necessary.

• Do not apply heat to cold water inlet.

• Contact qualified installer or service agency.

Figure 21 shows typical attachment of water piping to the water heater. The water heater is equipped with 3/4” NPT water connections.

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 heat traps and damage the tank.

22 www.americanwaterheater.com

TEMPERATURE-PRESSURE RELIEF VALVE

WARNING

Explosion Hazard

• Temperature-pressure relief

valve must comply with ANSI Z21.22-CSA4.4 and ASME code.

• Properly sized temperature-

pressure relief valve must be installed in opening provided.

• Do not plug, block, or cap the

discharge line.

• Failure to follow this warning

can result in excessive tank pressure, serious injury or death.

This water heater is provided with a properly rated/sized and certiﬁ ed combination Temperature-Pressure Relief Valve (T&P valve) by the manufacturer. The valve is certiﬁ 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.

If replaced, the new T&P valve must meet the requirements of local codes, but not less than a combination temperaturepressure relief valve rated/sized and certiﬁ ed as indicated in the above paragraph. The new valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi) and a discharge capacity not less than the water heater Btu/hr input rate as shown on the water heater’s model rating plate.

For safe operation of the water heater, the temperaturepressure relief valve must not be removed from its designated opening nor plugged. The T&P valve must be installed directly into the ﬁ tting of the water heater designed for the relief valve. Install discharge piping so that any discharge will exit the pipe within 6” above an adequate ﬂ oor drain, or external to the building. In cold climates it is recommended that it be terminated at an adequate drain inside the building. 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), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve.

No valve or other obstruction is to be placed between the T&P valve and the tank. Do not connect discharge piping directly to the drain unless a maximum of 6” air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water ﬂ ow may cause property damage.

CAUTION

Water Damage Hazard

• Temperature-pressure relief valve discharge pipe

must terminate at an adequate drain.

T&P valve discharge pipe requirements:

• Shall not be smaller in size than the outlet pipe size

of the valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall not be exposed to freezing temperatures.

• Shall be of material listed for hot water distribution.

• Shall 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 ﬂ 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

• Shall not have any valve or other obstruction between

the relief valve and the drain.

DANGER

• Burn hazard.

• Hot water discharge.

HOT

BURN

The T&P valve must be manually operated at least once a year. Caution should be taken to ensure (1) no one is in front of or around the outlet of the 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 in this manual, and replace the temperature-pressure relief valve with a properly rated/ sized new one.

• Keep clear of

temperature-pressure relief valve discharge.

www.americanwaterheater.com 23

Note: The purpose of a temperature-pressure relief valve is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see “Closed Water Systems” and “Thermal Expansion” section.

Temperature-Pressure Relief Valve and Pipe Insulation

The T&P valve installed on this water heater is covered by insulation to minimize heat loss. The insulation has a hole on the bottom side to accommodate the valve outlet and allow for the piping connection. Do not restrict the outlet opening of the T&P valve.

HIGH ALTITUDE INSTALLATION

WARNING

Breathing Hazard - Carbon Monoxide Gas

• For operation above 10,100 ft.

(3,079 metres) a high altitude orifice must be installed.

• Contact a qualified installer or service agency.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

T&P Relief Valve Insulation (Outlet opening on underside)

Manual Relief Lever

T&P Relief Valve

T&P Relief Valve Drain Line

Figure 24.

Locate the temperature and pressure relief valve on the water heater (also known as a T&P relief valve). See Figure 24.

1. Locate the slit running the length of the T&P relief valve insulation.

2. Spread the slit open and ﬁ t the insulation over the T&P relief valve. See Figure 24. Apply gentle pressure to the insulation to ensure that it is fully seated on the T&P Relief Valve. Once seated, secure the insulation with duct tape, electrical tape, or equivalent. IMPORTANT: The insulation and tape must not block the discharge opening or hinder access to the manual relief lever (Figure 24). Ensure a discharge pipe is installed into the T&P valve discharge opening per the instructions in this manual.

3. Locate the hot water (outlet) & cold water (inlet) pipes to the water heater.

4. Locate the slit running the length of a section of pipe insulation.

5. Spread the slit open and slip the insulation over the cold water (inlet) pipe. Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe. Also, ensure that the base of the insulation is ﬂ ush with the water heater. Once seated, secure the insulation with duct tape, electrical tape, or equivalent.

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

7. Add additional sections of pipe insulation as needed.

This heater is approved for operation up to 10,100 feet without alteration.

Failure to replace standard oriﬁ ce with a high altitude oriﬁ ce when installed above 10,100 feet could result in improper and inefﬁ cient operation of the appliance, producing carbon monoxide gas in excess of safe limits, which could result in serious injury or death. Contact your gas supplier for any speciﬁ c changes which may be required in your area.

GAS PIPING

WARNING

Fire and Explosion Hazard

• Do not use water heater with

any gas other than the gas shown on the rating plate.

• Excessive pressure to gas control valve can cause serious injury or death.

• Turn off gas lines during installation.

• Contact qualified installer or service agency.

WARNING

Explosion Hazard

Have a qualified technician make sure that the L.P. gas operating pressure does not exceed 13" water column.

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

24 www.americanwaterheater.com

Make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 14 inch w.c. for natural gas and propane gas. The minimum inlet gas pressure shown on the rating plate is that which will permit ﬁ ring at rated input. All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1/ NFPA-

54). Copper or brass tubing and ﬁ ttings (except tin lined copper tubing) should not be used. If the gas control valve/thermostat is subjected to pressures exceeding 1/2 psi, the damage to the gas control valve/thermostat could result in a ﬁ 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 sufﬁ cient size must be run to the water heater. Consult the current edition of National Fuel Gas Code (ANSI Z223.1/NFPA 54) 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 sediment trap (dirt leg) ahead of gas control valve/

thermostat to help prevent dirt and foreign materials from entering the gas control valve/thermostat.

• A ﬂ exible gas connector or a ground joint union between

the shut-off valve and gas control valve/thermostat 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 ﬂ ame. Repair and retest as required. When ﬁ nished, rinse off soapy solution and wipe dry.

excess of 1/2 psi. It should 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 psi.

Connecting gas piping to the gas control valve/thermostat of water heater can be accomplished by either of two methods shown in Figure 25 & Figure 26.

Figure 25.

Figure 26.

SEDIMENT TRAPS/DIRT LEG

WARNING

Fire and Explosion Hazard

• Use joint compound or tape

compatible with propane.

• Leak test before operating heater.

• Disconnect gas piping and shut-off valve before pressure testing system.

Use pipe joint compound or Teﬂ on tape marked as being resistant to the action of 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 should be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in

www.americanwaterheater.com 25

Fire and Explosion Hazard

• Contaminants in gas lines can

cause fire or explosion.

• Clean all gas piping before installation.

• Install sediment trap in accordance with NFPA54.

A sediment trap should be installed as close to the inlet of the water heater as practical at the time of water heater installation. The sediment trap should be either a tee ﬁ tting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap. If a tee ﬁ tting is used, it should be installed in conformance with one of the methods of installation shown in Figure 25 & Figure 26. Contaminants in the gas lines may cause improper operation of the gas control valve/thermostat that may result in ﬁ 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 sediment

trap (sometimes called a dirt leg) must be incorporated in the piping. The sediment trap must be readily accessible. Install in accordance with the “Gas Piping” section. Refer to the current edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 5 4).

HOT-WATER

OUTLET

UNION

SOME

COMPONENTS

NOT SHOWN

FOR CLARITY.

SHUT-OFF VALVE

COLD-

WATER

INLET

SIDE TAP (OUTLET)

TEMPERATUREPRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

To ﬁ ll the water heater with water:

1. Close the water heater drain valve by turning handle to the right (clockwise). The drain valve is on the lower front of water heater (see Figure 27).

2. If the heater is equipped with plumbing side taps and they are not connected to piping, ensure that the side taps have been closed with pipe plugs.

3. Open all hot-water faucets served by the water heater to allow air to escape from the tank and the water piping. Ensure any shut-off valves between the heater and the faucets are the open position.

4. Open the cold-water supply valve to the water heater. Notes:

• The cold-water supply valve must be left open when

the water heater is in use.

• Avoid water leakage when ﬁ lling the tank. Do not

allow the insulation of the water heater to get wet as water can reduce the effectiveness of the insulation.

5. To ensure complete ﬁ lling of the tank, allow air to exit by opening nearest hot-water faucet. Allow water to run until a constant ﬂ ow is obtained. This will let air out of the water heater and the piping.

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

SIDE TAP (INLET)

DRAIN VALV E

6” MAX. AIR GAP BELOW DISCHARGE PIPE

METAL DRAIN PAN

FLOOR DRAIN

Figure 27.

FILLING THE WATER HEATER

CAUTION

Property Damage Hazard

• Avoid water heater damage.

• Fill tank with water before operating.

• Do not insert the power cord into the electrical

receptacle until the heater has been fully installed.

• Never use this water heater unless it is completely full

of water. To prevent damage to the tank, the tank must be ﬁ lled with water. Water must ﬂ ow from the hot-water faucet before turning “ON” gas to the water heater.

VENTING

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Install vent system In accordance with codes.

• Do not operate water heater if flood damaged.

• Install water heater in accordance with the

instruction manual.

• Do not operate if soot buildup is present.

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

insulating blanket.

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

• Gas and carbon monoxide detectors are available.

• Never operate the heater unless it is vented to the

outdoors and has adequate air supply to avoid risks of improper operation, fire, explosion or asphyxiation.

• Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

Important: DO NOT common vent this water heater with any power vented appliance. DO NOT vent into a common chimney.

26 www.americanwaterheater.com

TERMINATION CLEARANCES SIDEWALL POWER VENT

INSIDE CORNER

DETAIL

Vent terminal

Air supply inlet

Area where is not permitted

Vent terminal clearances for “Power Vent” installations. Power Vent conﬁ gurations use room air for combustion.

Clearance above grade,

veranda, porch, deck or balcony

Clearance to window or door

that may be opened

Clearance to permanently

closed window

Vertical clearance to ventilated sofﬁ t located above the

terminal within a horizontal distance of 2 ft. from the center line of the terminal

Clearance to unventilated

sofﬁ t

F Clearance to outside corner 2 ft.* M

G Clearance to inside corner 18 in.*

In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code. † A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the ﬂ oor. * Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.

FIXED

CLOSED

OPERABLE

Figure 28.

12 in. H

4 ft. below or to side of opening; 1 ft. above opening

12 in.* J

12 in.* K

12 in.* L

OPERABLE

FIXED

CLOSED

Gas meter / regulator

Clearance to each side of center line extended above meter/regulator assembly

Clearance to service regulator vent outlet

Clearance to a non mechanical air supply inlet into building or combustion air inlet to any other appliance

Clearance to a mechanical air supply inlet

Clearance above paved sidewalk or paved driveway located on public property

Clearance under veranda, porch, deck, or balcony

N/A

3 ft.*

4 ft. below or to side of opening; 1 foot above opening.

3 ft. above if within 10 ft. horizontally

7 ft.†

12 in.‡

www.americanwaterheater.com 27

BLOWER ASSEMBLY INSTALLATION

1. This power vented water heater comes with blower assembly installed (see Figure 29).

2. After unit is set in place, make sure blower assembly is still mounted securely. Make sure there is no damage to blower.

g. Close the panel on the junction box. Make sure

that the access panel is secured shut.

7. The blower discharge boot is made to accept only straight sections of 2” or 3” pipe. To start off with an elbow, a short section of the straight pipe must be cut and glued into the end of the elbow that will mount on the discharge boot.

HOSE

CONNECTION

PORT FOR

CONDENSATE

DRAIN

DILUTION

AIR

INLETS

BLOWER

ASSEMBLY

8 in.

LOOP

DRAIN

Figure 29.

3. Make sure there is no packing material in the inlet or discharge of the blower.

4. Make sure that the plastic tubing is still attached from the air pressure switch to the port on the blower housing. Make sure the plastic tubing is not folded anywhere between the pressure switch and the blower housing (see Figure 37 thru Figure 41).

5. This water heater is a polarity sensitive appliance and will not operate if the power supply polarity is reversed. Power to this water heater must be wired properly (correct polarity).

6. Do not plug in power cord until vent system is completely installed. The Power Vent operates on 110

-120 VAC. therefore a grounded outlet must be within reach of the 6 foot ﬂ exible power cord supplied with the heater. The power cord supplied may be used on a unit only where local codes permit. If local codes do not permit use of ﬂ exible power supply cord:

a. Make sure the unit is unplugged from the wall

outlet. Remove the screw and open panel on the front of the junction box on the blower.

b. Cut the ﬂ exible power cord, leaving enough to be

able to make connections. Remove the strain relief

ﬁ tting from the box. c. Install a suitable conduit ﬁ tting inside the enclosure. d. Splice ﬁ eld wiring into existing wiring using code

authorized method (wire nuts, etc). e. Be certain that the neutral and line connections

are not reversed when making these connections. f. Ground heater properly. This water heater must be

grounded in accordance with the National Electrical

Code NFPA 70 and/or local codes. These must be

followed in all cases. The water heater must be

connected to a grounded metal, permanent wiring

system or an equipment grounding conductor must

be run with the circuit conductors and connected

to the equipment grounding terminal or lead on the

water heater (see Figure 12; the wiring diagram).

INSTALLATION OF VENT SYSTEM

Before beginning installation of piping system, thoroughly read the “Vent Pipe Preparation” section of this manual.

PLANNING THE VENT SYSTEM

Plan the layout of the vent system from the vent termination to the water heater considering all of the 90 degree and 45 degree elbows plus the number of feet of pipe that would be needed to install the total vent system. The water heater must be vented to the outdoors as described in these instructions. This water heater must be vented separately from all other appliances.

The unit may be vented horizontally through a wall or vertically through the roof. Pipe runs must be adequately supported along both vertical and horizontal runs.

Note: Do not use an elbow as a support point. Elbows are not designed to carry the load or stresses of the venting system if they are rigidly held.

It is imperative that the ﬁ rst hanger (or support) be located on the horizontal run immediately adjacent to the ﬁ rst 90-degree elbow from the vertical rise. Support method used should isolate the vent pipe from the ﬂ oor joists or other structural members to prevent the transmission of noise and vibration. Do not support, pin, or otherwise secure the venting system in a way that restricts the normal thermal expansion and contraction of the chosen venting material.

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 in below, has been used, and that the minimum or maximum vent lengths and terminal location as detailed in this manual have been met.

HIGH AMBIENT TEMPERATURE INSTALLATIONS

This heater requires room air to lower the flue gas temperatures before the gases pass through the vent system. The dilution air inlets are located on the rear of the blower assembly (see Figure 2 & Figure 29). As the room temperature rises, the ability to lower the ﬂ ue gases lessens so special attention to the choice of venting material is required. Establishing the ambient temperatures where the heater and the venting is installed is very important, especially in regions with warmer climates or any region that experiences hot summers. Ambient conditions hotter than 110°F require that the venting

28 www.americanwaterheater.com

material be either CPVC or polypropylene. Areas that can experience high ambient environments include closets, alcoves, areas under staircases, attics-especially in metal roofed buildings, areas with restricted air movement, rooms with large solar gains, metal sheds, industrial or commercial enterprises and venting systems exposed to direct sunlight. For high temperature environments, obtain high limit switch upgrade Kit # 9008306015 and use the higher rated vent piping. Note: This unit can be vented with the following piping:

PVC pipe materials (solid pipe)

PVC pipe

DWV ASTM-D2665 Schedule 40, 80* & 120* ASTM-D1785, SDR Series ASTM-D2241

ASTM-D4396 materials (cellular core)

CPVC pipe materials

ABS pipe materials

ABS pipe

CPVC 41 ASTM-D2846

Schedule 40, 80* & 120* ASTM-F441

SDR Series ASTM-F442,

DWV ASTM-D2661

Schedule 40

ASTM F-628 materials (cellular core)

Polypropylene

UL-1738 vent system

* NOTE: USING SCHEDULE 80 OR 120 SIGNIFICANTLY REDUCES THE VENT LENGTH.

Note: If local codes require venting to be marked suitable for use as gas venting, type BH venting may be used. The fittings, other than the Termination should be equivalent to:

PVC pipe

PVC DWV ASTM D-2665

CPVC pipe CPVC ASTM F-438

ABS pipe ABS ASTM D-2661/3311

Polypropylene

UL-1738 vent system

If CPVC or ABS pipe and ﬁ ttings are used, the proper cement must be used for all joints, including joining the pipe to Termination (PVC Material). If local codes do not allow the use of the PVC termination when a material other than PVC is used for venting, an equivalent ﬁ tting of that material may be substituted if the screen in the PVC terminal is removed and inserted into the new ﬁ tting. This water heater is supplied with a 45 degree PVC termination elbow and the applicable vent screens. A 90 degree termination elbow is optional. ASTM D-2564 Grade Cement should be used on PVC Materials and ASTM F-493 Grade Cement on CPVC Materials.

POLYPROPYLENE VENT SYSTEMS

Polypropylene vent systems do not use cement to connect the pipe and elbow sections but use a push together gasket

seal method. Do not attempt to connect polypropylene with sealant cement. Polypropylene vent systems are designed to use speciﬁ c adaptors to connect into the rubber coupling on the top of the blower. These are available through your venting supplier. The PVC vent termination elbow supplied with this heater has been certiﬁ ed to be used with polypropylene vent systems. A polypropylene to PVC end connection is required and is available through your supplier. Optional wall plates that ﬁ t the polypropylene venting are also available through your supplier. Carefully inspect the entire venting system for any signs of cracks or fractures, particularly at joints between elbows and other ﬁ 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. The vent piping shall be connected to the blower with the rubber coupling and secured with gear clamps. The coupling and clamps are provided with the heater. Even though the ﬂ ue gas temperature leaving the blower is hot, some installations will have water condense in the vent piping. If this occurs, then adequate means of draining and disposing of the condensate shall be made by the installer.

CONDENSATE

Condensate formation does not occur in all installations of power vented water heaters, but should be drained on installations where it can form in the venting system. 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 discharge and slope, and product usage. In certain conditions, installations in unconditioned space or having long horizontal or vertical vent runs can accumulate condensate. Long lengths of venting that pass through cool/cold areas will experience condensation. The vent pipe should be sloped upwards away from the blower assembly, then adequate means for draining and disposing of the condensate needs to be made by the installer. If installation conditions cause condensation, install a condensate trap loop approximately 8 in. in diameter using 3/8” plastic hose. Connect the hose to the built-in drain port of the rubber coupling of the blower assembly (see Figure 29). Loop the hose in a vertical position as shown. The tube loop must be ﬁ lled with water at least half way prior to operating the heater. Ensure the end of the tube has access to a drain as condensate will ﬂ ow from the end. Secure the tubing to the side of the heater. Prior to operating the water heater, make sure the removable cap is installed on the drain port (if a drain hose is not needed). Note: This cap must remain in place if a drain hose is not installed.

www.americanwaterheater.com 29

EXHAUST VENTING

This heater is designed to exhaust the products of combustion (ﬂ ue gases) to the outdoors using a sealed piping system. Table 2 lists the allowable vent materials and sizing information. Figure 33 shows the general venting layout while Figure 37 thru Figure 41 show various end termination details and clearances. Connection of the venting piping to the blower is shown in Figure 37 thru Figure 41.

Correct installation of the venting system is essential to the safe and efﬁ cient operation of this water heater. Vent piping must be installed in accordance with all applicable codes. All installations shall meet the requirements as stated in the current edition of the “National Fuel Gas

Code, ANSI Z223.1/NFPA 54”.

Note: The information provided in Figure 28 is intended

as a guideline for good vent installation practices only and is not intended to restrict venting options beyond those restrictions established by the current edition of the “National Fuel Gas Code, ANSI Z223.1/NFPA 54” or any applicable local and state codes.

STREET ELBOW

NORMAL ELBOW

6 in. min.

Important Notes and Warnings

• This heater is certiﬁ ed to be installed using PVC, CPVC,

ABS or polypropylene plastic vent material. Only use approved material. All venting material and components must be joined with the approved primer/cleaner and solvent cement.

• Do not common vent this heater with any other

appliance.

• During operation the plastic piping will expand as it

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

• Use long sweep elbows wherever possible. Closely-

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

• All power vented water heaters generate a certain

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

• Most power vent installations develop some

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

BACK TO BACK ELBOWS

PREFERRED PRACTICE

90° SHORT SWEEP ELBOW

(MORE RESTRICTIVE)

Figure 30.

30 www.americanwaterheater.com

90° LONG SWEEP ELBOW

(LESS RESTRICTIVE)

Venting terminations and sizing

• Refer to Figure 33 and Table 2 for vent pipe materials

and sizing. Examples of the vent terminations are shown in Figure 34 & Figure 35. If the installation requires a vent riser, suitable drainage must be provided to ensure condensation does not accumulate. Termination through a roof is shown Figure 36.

• 40, 50 and 60 gallon heaters with rated inputs of 50k

Btu/hr or less are supplied with a 2”-3” rubber coupling to attach the venting to the blower and a 2”, 45° vent termination elbow.

For heaters with rated inputs of 50k Btu/hr or less:

with 2 in. venting (short) with 2 in. venting (long)

VENT LENGTH LESS THAN OR EQUAL TO 20 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

with 3 in. venting

VENT LENGTH GREATER THAN

20 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

with 3 in. venting

• 50 and 75 gallon heaters with a rated input of 60k Btu/

hr or more are supplied with a 3”-3” rubber coupling to attach the venting to the blower and a 3”, 45° vent termination elbow.

• Supplied with this heater are several vent termination

screens (see Figure 31 & Figure 32).

Installed in the vent termination elbow, the vent screen is required to keep foreign objects, rodents and small birds from entering the venting system. These screens have been sized to ensure maximum energy efﬁ ciency of the vent system based on the “equivalent length” of the vent piping. CHOOSE ONLY the ONE SCREEN THAT MATCHES YOUR VENTING CONFIGURATION (see Figure 31 & Figure 32). How to determine the “equivalent length” is shown in Figure 33 and in Table 2.

Vent screen installation

• Install the appropriate vent screen into the vent

termination elbow.

• Gently push the screen into the termination elbow until

it sits against the inside shoulder.

• The metal wire screens are self-securing.

• Plastic screens must be secured with (2) drops of

silicone sealant. This will allow for easy removal for inspection and cleaning.

For heaters with rated inputs of 60k Btu/hr or more:

with 3 in. venting (short) with 3 in. venting (long)

VENT LENGTH LESS THAN OR EQUAL TO 50 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

VENT LENGTH GREATER THAN

50 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

with 4 in. venting

VENT LENGTH GREATER THAN

125 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

Figure 31.

www.americanwaterheater.com 31

VENT LENGTH LESS THAN OR EQUAL TO 20 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

with 4 in. venting

VENT LENGTH GREATER THAN

50 EQUIVALENT FT.

USE THIS SCREEN

(SUPPLIED).

Figure 32.

VENT LENGTH GREATER THAN

20 EQUIVALENT FT.

USE THIS SCREEN (SUPPLIED).

Calculating Equivalent Feet

WATER

HEATER

MODEL

40 & 50 gal. 40,000

HEATER

INPUT

(Btu/hr)

VENT SIZE

(Inside Diam.)

PRESSURE

SWITCH

SETTING

- 0.27 in. w.c.

2”

40 & 50 gal. 50,000 - 0.37 in. w.c

MAXIMUM EQUIVALENT

VENT LENGTH

50 ft. + termination elbow 7 ft. termination elbow60 gal. 42,000 - 0.27 in. w.c.

MINIMUM EQUIVALENT

VENT LENGTH

40 & 50 gal. 40,000

3”

- 0.27 in. w.c.

125 ft. + termination elbow 7 ft. termination elbow60 gal. 42,000 - 0.27 in. w.c.

40 & 50 gal. 50,000 - 0.37 in. w.c.

50 gal. (short) 62,000

3”

- 0.99 in. w.c.

50 ft. + termination elbow 7 ft. + termination elbow50 gal. (tall) 65,000 - 0.99 in. w.c.

75 gal. 72,000 - 0.99 in. w.c.

40 & 50 gal. 40,000

4”

- 0.27 in. w.c.

180 ft. + termination elbow 125 ft. + termination elbow60 gal. 42,000 - 0.27 in. w.c.

40 & 50 gal. 50,000 - 0.37 in. w.c.

50 gal. (short) 62,000

50 gal. (tall) 65,000 - 0.99 in. w.c.

4”

- 0.99 in. w.c.

125 ft. + termination elbow 50 ft. + termination elbow

75 gal. 72,000 - 0.99 in. w.c.

Equivalent lengths of straight pipe for various elbows using Schedule 40 PVC, CPVC and polypropylene.

Size Type

2” 3"

90° elbow 8 ft. 5 ft.

Short Sweep/

Short Radius

Long Sweep/ Long Radius

Notes:

1. Use long radius elbows where possible. Minimum distance between 90º elbows should be 6” wherever possible.

2. Venting systems may use a maximum

2” 3" 4"

45° elbow 4 ft. 2.5 ft.

of ﬁ ve (5) 90° elbows.

3. Use proper screen termination (see Figure 31 & Figure 32).

Note: The vent pipe must be supported every 4 ft.. To prevent vibration and sagging, it is recommended to use

COVER PLATE

(OPTIONAL)

TERMINATION

ELBOW

RODENT SCREEN

(INSTALL INTO

ELBOW)

12” MIN. OR ABOVE

ANTICIPATED SNOW

LEVEL.

GROUND LEVEL

32 www.americanwaterheater.com

isolation pads when attaching straps to ﬂ oor joists, walls or ceilings. PVC and CPVC vent pipe should be sloped upwards away from the blower assembly at a pitch of 1/8 in. rise per 4 ft.. Polypropylene vent systems require a 1/4” per 1 ft. upward slope to ensure proper drainage.

Example for calculating equivalent feet. Section “A” 0.5 ft. 90° elbow 8.0 ft. Section B 1.0 ft. 45° elbow 4.0 ft. Section C 1.5 ft. 45° elbow 4.0 ft. Section D 15.0 ft. Total Equivalent 34.0 ft. Based on this example use the (fully open) rodent screen for vent length greater than 20 equivalent ft. (see Figure 31 & Figure 32).

Table 2.

45° SHORT

ELBOW

STRAP

90° SHORT

ELBOW

Figure 33.

Venting instructions

1. Plan the venting layout starting at the vent termination and work back toward the heater. Take into consideration the style and position of the vent termination, the vent pipe routing, elbows and connectors required and the necessary support hangers.

2. Venting should be as direct as possible with the fewest number of ﬁ ttings. Use long radius 45 degree and long radius 90 degree elbows wherever possible.

3. Avoid using 90 degree elbows “back to back” and do not use street elbows. Maintain a minimum 6” straight section between elbows. Closely coupled and short radius elbows reduce the venting capacity. Figure 30 shows examples of vent pipe connections.

4. DO NOT USE AN ELBOW AS A SUPPORT POINT. Elbows are not designed to carry the weight of the venting system.

5. Calculate “Equivalent Vent Length” before starting. Do not exceed the values shown in Table 2. An example of how this length is determined is shown in Figure

33. The value from your calculations should also be used to determine which rodent screen to install into the vent termination elbow.

6. Measure the vent piping and cut to required lengths. Pipes must be cut at right angles and deburred to ensure a good smooth ﬁ t with sufﬁ cient overlap for the glue joints. Correct any interference conditions.

7. Provide support hangers for horizontal vent piping every 4 ft. to prevent sagging and stress. Provide a minimum of 1/8” rise per 4 ft. of vent piping to ensure adequate drainage (polypropylene vent systems require a 1/4 in. rise per 1 ft. of vent pipe). Horizontal vent piping must not sag to form valleys where condensate can collect. Vertical venting shall be supported every 5 ft.. Use appropriate support straps and vibration isolators (foam pads) on straight sections only. Allow sufﬁ cient clearance for expansion and contraction of the venting system.

8. At the point where the venting exits the building, cut a 2-1/2” hole for 2” venting, a 3-1/2” hole for 3” venting or a 4-1/2” hole for 4” venting. For sidewall applications, use the appropriate metal 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.

9. Insert the vent piping through this hole and secure into position. Connect the vent pipe to the end termination elbow as shown in Figure 34 thru Figure 36.

10. Dry ﬁ t all vent pipes, elbows, connectors and ﬁ ttings before joining any parts with solvent cement. PARTS MUST FIT WITHOUT STRESS OR BENDING OF ANY SECTION and each connection must overlap a minimum of 1/2”. Do not force fit any of the connections. Use only the appropriate solvent cement. Caution: Solvent cements may produce flammable vapors. Use only in well-ventilated areas and keep away from all sources of ignition.

Note: DO NOT use solvent cement on polypropylene vent systems.

11. Install the properly sized rodent screen into the outlet elbow and secure with a small quantity of silicone sealant. Refer to Figure 31 & Figure 32 to determine the proper screen.

12. Do not seal the vent piping to the wall until the venting is properly connected to the blower assembly.

13. Complete the venting installation by sealing around the termination assembly where it passes through the outside wall, inside and out, with silicone or other suitable sealant. Apply enough sealant to secure the (optional) cover plate to the wall.

CAUTION

Use of Solvent Cement and Primer

• Use only in well-ventilated areas.

• Do not use near flame or open fire.

• Use only the Solvent Cement and Primer appropriate for

the venting material being used.

• Solvent cements for plastic pipe are flammable liquids and must be kept away from all sources of ignition.

ATTACH TERMINATION ELBOW (MAY ALSO BE 90°)

RODENT SCREEN

12” MIN.*

* WHERE SNOW COVER IS NORMAL DURING WINTER, ENSURE OUTLET IS INSTALLED ABOVE ANTICIPATED SNOW LEVEL.

(INSTALL INTO ELBOW)

GROUND LEVEL*

6”

COVER PLATE

(OPTIONAL)

SEALANT

(UNDER

PLATE)

Figure 34.

ATTACH TERMINATION ELBOW (MAY ALSO BE 90°)

RODENT SCREEN (INSTALL INTO ELBOW)

12” MIN.*

COVER PLATE (OPTIONAL)

GROUND LEVEL*

* WHERE SNOW COVER IS NORMAL DURING WINTER, ENSURE OUTLET IS INSTALLED ABOVE ANTICIPATED SNOW LEVEL.

BRACKET

VENT RISER

SEALANT

(UNDER

PLATE)

Figure 35.

SEALANT

VENT PIPING MAY BE SLOPED IN ANY DIRECTION, AS LONG AS A WATER TRAP IS NOT CREATED IN THE VENTING SYSTEM. THE SLOPE SHOULD BE KEPT TO A MINIMUM SO AS NOT TO EXERT ANY UNDUE STRESS ON THE PIPE.

EQUIVALENT VENT LENGTH MEASURED FROM THIS POSITION

SEALANT

VENT PIPING TO BE SLOPED (DOWN) TOWARD HEATER TO PREVENT WATER FROM COLLECTING (MAY REQUIRE A CONDENSATE TEE).

www.americanwaterheater.com 33

3” MIN. LENGTH

A VENT USED IN A SPECIAL VENTING SYSTEM WITH POSITIVE VENT PRESSURE AND PASSING THROUGH A ROOF SHALL EXTEND AT LEAST 18” ABOVE THE HIGHEST POINT WHERE IT PASSES THROUGH THE ROOF SURFACE AND ANY OTHER OBSTRUCTION WITHIN A HORIZONTAL DISTANCE OF 18”. A VERTICAL VENTING SYSTEM MUST BE SUPPORTED EVERY 5 ft..

18” OR

ABOVE ANTICIPATED SNOW LEVEL

TERMINATION MAY BE 90° ELBOW

RODENT SCREEN (INSTALL INTO ELBOW)

ROOF LINE

Different coupling installations according to vent sizes

CONFIGURATION FOR 40, 50 AND 60-GALLON (LOINPUT) HEATERS CONNECTED TO 2" VENTING.

2” RUBBER COUPLING

(SUPPLIED)

BLOWER

2” VENT

PIPE

Figure 36.

Vent pipe connection to blower

1. The plastic vent piping connects into the rubber coupling located on the top of the blower assembly. This coupling includes gear clamps to connect the venting to the blower. These connections must be properly seated and tightened to prevent the leakage of ﬂ ue gases into the area. See Figure 37 thru Figure

41.

2. The 40, 50 and 60-gallon heaters with rated inputs of 50k Btu/hr or less are designed and supplied with a 2” rubber coupling to accept the vent pipe.

3. The 50 and 75-gallon models with rated inputs of 60k Btu/hr or more are supplied with a 3” rubber coupling to accept the vent pipe. Note: Polypropylene vent systems require separate adaptor.

4. Before installing clean and lightly sand the end of the PVC/CPVC plastic vent piping that will connect into the rubber coupling. For polypropylene vent systems follow manufacturer’s instructions.

5. Loosen the upper clamp on the rubber coupling and insert the sanded end of the vent piping a full 1-1/4”. Do not use glue or sealant in the rubber coupling. Check that there is no stress on the connection or the vent piping that may be caused by twisting or bending.

6. Tighten the upper clamp so that the vent piping is ﬁ rmly secured in the coupling and is gas tight. Do not over tighten or cause distortion of any of the parts. Ensure the bottom of the rubber coupling is ﬁ rmly seated on the blower outlet and that the lower gear clamp is also secure. Check to ensure there is no distortion or movement of the clamped assembly once it is completed.

CAUTION

Property Damage Hazard

• Do not overtighten the top and bottom gear clamps of the

rubber coupling.

• Do not apply solvent cement or silicone to the rubber coupling connection.

CONFIGURATION FOR 40, 50 AND 60-GALLON (LOINPUT) HEATERS CONNECTED TO 3” VENTING.

* FOR 3” DIRECT CONNECTION TO THE BLOWER, ORDER COUPLING Kit # 9008311005 (SEE ALSO Figure

41).

CONFIGURATION FOR LO-INPUT HEATERS CONNECTED TO 4” VENTING.

LOW-INPUT HEATERS ARE SUPPLIED WITH A 2” RUBBER COUPLING.

CONFIGURATION FOR HI-INPUT HEATERS CONNECTED TO 3” VENTING.

(OPTIONAL CONFIGURATION FOR LO-INPUT HEATERS CONNECTED TO 3” VENTING.)

Figure 37.

2” RUBBER COUPLING (SUPPLIED)

BLOWER

Figure 38.

3” RUBBER COUPLING

(ORDER COUPLING

Kit # 9008311005

TO REPLACE 2”

RUBBER COUPLING

SUPPLIED.)

BLOWER

Figure 39.

3” RUBBER COUPLING

(SUPPLIED)

BLOWER

3” VENT

PIPE

2”-3”

ADAPTER*

(FIELD

SUPPLIED)

2” VENT PIPE,

75mm (3 in.)

MAX LENGTH

4” VENT

PIPE

3”-4”

ADAPTER

(FIELD

SUPPLIED)

3” VENT PIPE,

3 in. MAX

LENGTH

3” VENT

PIPE

34 www.americanwaterheater.com

Figure 40.

CONFIGURATION FOR HI-INPUT HEATER CONNECTED TO 4” VENTING.

3” RUBBER COUPLING

(SUPPLIED)

BLOWER

4” VENT

PIPE

3”-4”

ADAPTER

(FIELD

SUPPLIED)

3” VENT PIPE,

3 in. MAX

LENGTH

Figure 41.

BLOWER EXHAUST DIRECTION

The blower assembly may be rotated 90 degree clockwise or counterclockwise to allow horizontal venting in areas having restricted space above the water heater. To rotate the blower outlet, remove the four nuts (with 11/32” nut driver) (see Figure 42), securing the ﬂ ue collector to the blower housing. Pull the blower assembly forward to free it from the mounting studs. Rotate the blower housing clockwise or counter-clockwise and align the four holes and screws together. Reattach the blower housing to the ﬂ ue collector.

Note: Coupling to vent system not shown for clarity.

11/32” nut

• Know your own qualifications or those of your

contractor. The solvent welding technique of joining PVC and CPVC pipe is a specialized skill just as any other pipe ﬁ tting technique.

• Closely supervise the installation and inspect the

ﬁ nished job before start-up.

• Contact the manufacturer, supplier, or competent

consulting agency if you have any questions about the application or installation of PVC and CPVC pipe.

• 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 (PCV and CPVC VENTING)

• 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 only

• 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

ﬁ ttings 6” and above.

Figure 42.

VENT PIPE PREPARATION

1. INITIAL PREPARATION

• Make sure the solvent cement you are planning to use is designed for the speciﬁ c application you are attempting.

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

• Know the reputation of your manufacturer and their products.

www.americanwaterheater.com 35

WARNING

Fire or Explosion Hazard

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

liquids in the vicinity of this or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Primer: It is recommended that Tetrahydrofuran (THF) be

used to prepare the surfaces of pipe and ﬁ 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 ﬁ ttings.

WARNING

Fire Hazard

• Primers and cements are

extremely flammable, and must not be stored or used near heat or open flame.

• Also, use only in a well ventilated area.

Applicators: Select a suitable pure bristle type paint brush. Use

a proper width brush or roller to apply the primer and cement (see chart below). 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.

RECOMMENDED BRUSH* SIZE FOR

PRIMER AND CEMENT APPLICATIONS

Nominal

Pipe (IPS)

2 1.5”

3 1.5” - 2.5”

*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 ﬁ 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 ﬂ are the corner of the pipe end. If this type of cutter is used, the ﬂ are on the end must be completely removed.

Note: Power saws, if used, should be speciﬁ cally

designed to cut plastic pipe.

Brush Size

Table 3.

Figure 43.

B. Deburring Use a knife, plastic pipe deburring tool, or ﬁ le 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 ﬁ tting. Failure to chamfer the edge of the pipe may remove cement from the ﬁ tting socket, causing the joint to leak.

Figure 44.

C. Test dry ﬁ t of the joint Tapered fitting sockets are designed so that

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

36 www.americanwaterheater.com

D. Inspection, cleaning, priming Visually inspect the inside of the pipe and ﬁ 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 ﬁ tting socket

in Step F. Measure the ﬁ tting 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 ﬁ rst one. Apply primer to the surface of the pipe and ﬁ 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.

E. Application of solvent cement

• Apply solvent cement evenly and quickly around

outside of pipe at a width a little greater than the

depth of the ﬁ tting socket.

• Apply a light coat of cement evenly around the inside

of the ﬁ tting socket. Avoid puddling.

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

A good joint will have sufﬁ cient cement to make a bead all the way around the outside of the ﬁ tting hub. The ﬁ tting will have a tendency to slide back while the cement is still wet so hold the joint together for about 15 seconds.

Figure 46.

G. Cleanup and joint movement Remove all excess cement from around the pipe

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

WARNING

Fire Hazard

• Cans of cement and primer should

be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement.

• They are also very flammable and should be kept away from heat or flame.

Figure 45.

Figure 47.

F. Joint assembly Working quickly, insert the pipe into the ﬁ tting socket

bottom and give the pipe or ﬁ 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 ﬁ tting socket.

www.americanwaterheater.com 37

INSTALLATION CHECKLIST

Note: Use and complete this checklist before lighting the

heater. Correct any conditions that do not meet these instructions.

Check Here

Water Heater Location

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

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

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

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

5. Installation area free of corrosive elements and ﬂ ammable material.

6. Sufﬁ cient room to service the water heater.

Gas Supply and Piping

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

2. Gas line equipped with shut-off valve, union and dirt leg

3. Approved pipe joint compound used.

4. Adequate pipe size and of approved material.

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

Vent Pipe System

1. Vent pipe and ﬁ ttings of approved material.

2. Acceptable size, length and number of elbows on exhaust vent system.

3. Installed in accordance with prevailing provisions of local codes, or in the absence of such, the latest edition of “National Fuel Gas Code” ANSI Z223.1 (NFPA 54).

4. Horizontal piping slopes at an upward pitch of 1/8 in. rise per 4 ft. away from the water heater.

5. Not obstructed in any way.

Check Here

Vent Termination

Horizontal

1. 12 in. min. above grade/snow level.

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

Vertical

1. Exhaust vent termination 18 in. min. above roof/snow level.

Water System Piping

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

2. All piping properly installed and free of leaks.

3. Heater completely ﬁ lled with water.

4. Closed system pressure build-up precautions installed.

Electrical Connections

1. Unit connected to a dedicated 120V electrical supply.

2. Proper polarity.

3. Water heater properly grounded.

4. Installed in accordance with prevailing provisions of local codes, or in the absence of such, the latest edition of “National Electrical

Code” (NFPA 70)”.

After all actions on checklist are checked/

completed, read the Lighting Instructions and

proceed with lighting the heater.

38 www.americanwaterheater.com

FLAMMABLE

LIGHTING INSTRUCTIONS

Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner viewport is not missing or damaged. Make sure the tank is completely ﬁ lled with water before operating the water heater. The gas control valve/thermostat has an “On/Off Switch” and must be turned on before the water heater is operational. Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas. Do not start this water heater with any gas other than the one listed on the label. If you have any questions or doubts, consult the gas supplier or gas utility company. The following Lighting Instruction label appears on the front of the water heater.

This heater is equipped with a Honeywell gas control/thermostat and a hot-surface igniter. This control is a combination gas valve, thermostat and ignition controller for use on this power vented water heater. The valve contains a microcontroller that supervises the ignition sequence and monitors the temperature settings and operation of the heater. The controller also monitors the ﬂ ammable vapor safety features of this heater.

This heater is equipped with a hot-surface ignition system that automatically ignites the burner. Do not attempt to light this heater manually with a match or ﬂ ame-producing device.

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 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 phone in your building.

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

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

C. Use only your hand to turn the gas control

buttons. Never use tools. If the control buttons will not turn, don't try to repair them, 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 contact a qualified installer or service agency to replace a flooded water heater. Do not attempt to repair the unit. It must be replaced!

FLAMMABLE

OPERATING INSTRUCTIONS

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

2. Turn off all electric power to the appliance.

3. Turn the thermostat counter-clockwise to the lowest setting.

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

5. Do not attempt to light manually.

6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don't smell gas, go the next step.

TO TURN OFF GAS TO APPLIANCE

1. Turn the thermostat counter-clockwise to the lowest setting.

2. Set the gas control switch to the “OFF” position.

3. Turn off electrical power to the appliance if service is to be performed.

www.americanwaterheater.com 39

7. Turn on all electric power to the appliance.

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

9. Turn thermostat to desired setting.

DANGER

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

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

323546-000

OPERATING THE TEMPERATURE CONTROL SYSTEM

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 temperature be set for the lowest temperature which satisﬁ es your hot-water needs. This will also provide the most energy efﬁ cient operation of the water heater. Short repeated heating cycles caused by small hot-water uses can cause a temperature increase of the hot water by 20F° higher than the heater’s temperature settings. If you experience this type of use you should consider using lower temperature settings to reduce scald hazards.

Should overheating occur or the gas supply fails to shut off, turn off the main manual gas shut off valve to the appliance (see Figure 1).

Water temperature over

DANGER

HOT

BURN

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

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

Feel water before bathing or showering.

Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures.

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.

This water heater is equipped with an adjustable thermostat to control water temperature (see Figure 48). 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 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 hot setting shown on the dial is approximately 120°F. This is a good starting point to set the temperature.

Setting the water heater temperature at 120°F will reduce the risk of scalds. Some states require settings at speciﬁ c lower temperatures.

The thermostat settings on the gas control valve are shown in Figure 48.

The water temperature setting was factory set at the lowest (VAC) temperature setting.

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 inﬁ rm or physically/mentally handicapped. If anyone using hot water from this heater ﬁ ts into one of these groups or if there is a local code or state law requiring certain temperature water at the hot-water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisﬁ es your hot-water needs, a means such as a mixing valve, should be used at the hot-water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores (see Figure 8 & Figure 9). Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, in this manual, see Table 4.

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GAS CONTROL VALVE/THERMOSTAT

155°F

70°F

ON/OFF SWITCH

TEMPERATURE SETTING DIAL

130°F 140°F 150°F

120°F 110°F

Figure 48.

Temperature

Dial Setting

Approximate Temperature

°F

Time to induce a 2nd

and 3rd Degree burn

to adult skin

VERY HOT 155 Less than 1 second

C 150 About 1.5 seconds

B 140 Less than 5 seconds

A 130 More than 30 seconds

HOT 120 More than 5 minutes

LOW 110 Normal shower temp

VAC 70 N/A

Table 4.

Note: The temperatures indicated are approximates. The

actual temperature of the heated water may vary. The Vacation Setting (VAC) sets the controller at approximately 70°F. This setting is recommended when the water heater is not in use for a long period of time. This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy.

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FOR YOUR INFORMATION

START UP CONDITIONS

Condensate

Whenever the water heater is ﬁ lled with cold water, some condensate will form while the burner is ON. A water heater may appear to be leaking when in fact the water is condensate. This usually happens when: a. A new water heater is ﬁ lled with cold water for the ﬁ rst

time.

b. Burning gas produces water vapor in water heaters,

particularly high efficiency models where flue temperatures are lower.

c. Large amounts of hot water are used in a short time

and the reﬁ ll water in the tank is very cold.

Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a “sizzling” or “frying” noise. Because of the suddenness and amount of water, condensate water maybe diagnosed as a “tank leak”. After the water in the tank warms up (about 1-2 hours), the condition should disappear. Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up. An undersized water heater will cause more condensation. The water heater must be sized properly to meet the family’s demands for hot water including dishwashers, washing machines and shower heads. Excessive condensate maybe noticed during the winter and early spring months when incoming water temperatures are at their lowest. Good venting is essential for a gas ﬁ red water heater to operate properly as well as to carry away products of combustion and water vapor (see also “Condensate” section).

Thermal expansion

See “Thermal Expansion” section elsewhere in this manual.

CAUTION

Property Damage Hazard

• Avoid water heater damage.

• Install thermal expansion tank if necessary.

• Do not apply heat to cold water inlet.

• Contact qualified installer or service agency.

Closed water systems

See “Closed Water Systems” section elsewhere in this manual.

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.

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” section in this manual.

OPERATIONAL CONDITIONS

Smelly water

Each water heater contains at least one anode rod 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 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.

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“AIR” IN HOT-WATER FAUCETS

WARNING

Explosion Hazard

• Flammable hydrogen gases may

be present.

• Keep all ignition sources away from faucet when turning on hot water.

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 ﬂ ammable and explosive. To prevent the possibility of injury under these conditions, it is recommended that 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 hotwater faucet is opened. There must be no smoking or open ﬂ ame near the faucet at the time it is open.

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PERIODIC MAINTENANCE

GENERAL UPKEEP

Make it a habit to look around the heater, the vent piping, and the hot and cold water pipes. Do not allow any material to be piled up against the heater. Do not place any object on top of the vent pipes. Every 3 - 6 months or as necessary:

• Clean lint from blower, top of heater.

Once per year:

• Inspect the Vent System.

• Burner Operation and Inspection.

• Combustion Chamber for scaling or sooting.

• Temperature-Pressure Relief Valve Test.

• Anode Rod Inspection.

• Flush a pail of water from the heater drain valve, once

per year. If any deﬁ ciencies or abnormalities are encountered during these inspections call a qualiﬁ ed service technician.

VENTING SYSTEM INSPECTION

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Flue gases may escape if vent pipe is not properly

connected.

• Be alert for obstructed, sooted or deteriorated vent system to avoid serious injury or death.

• Do not store corrosive chemicals in vicinity of water heater.

• Chemical corrosion of flue and vent system can cause serious injury or death.

• Analyze the entire vent system to make sure that condensate will not become trapped in a section of vent pipe and therefore reduce the open cross sectional area of the vent.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

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

• Obstructions which could cause improper venting. The

combustion, dilution and ventilation air ﬂ ow must not be obstructed.

• 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 ﬂ ue gasses which could cause deadly asphyxiation. Obstructions and deteriorated vent systems may present serious health risk or asphyxiation.

Chemical vapor corrosion of the ﬂ 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 ﬂ ue and venting before resuming operation of the water heater.

BLOWER MAINTENANCE

Inspect the top of the heater and around the ventilation openings of the blower motor and the rear blower dilution air intakes for any lint and dust that may have accumulated. Depending on the location of the heater, significant quantities of lint may accumulate. The lint may obstruct the free ﬂ ow of air to the motor, and cause the motor and blower to run hotter than normal (see Figure 49).

To clean any dust and lint, proceed as follows:

1. Unplug the water heater.

2. Using a nylon bristled paint or toothbrush, brush away any lint. Pick up the lint with a cloth.

Better results can be achieved by using the small brush on a vacuum cleaner to remove all lint and dust which have accumulated on top of the heater, the louvres of the air intake snorkel, the motor ventilation openings and the rear blower dilution air intakes. Important: Do not insert any foreign object into the ventilation openings of the motor.

CLEANING THE BLOWER.

In dusty and contaminated air conditions, the interior of the blower and the blower wheel may require periodic cleaning. This is often indicated by nuisance failures of the air pressure switch or the high limit temperature control. A collection of dust or debris on the rear blower dilution air intakes can also indicate reduced blower capacity. To clean the inside of the blower assembly and the blower wheel requires the removal of the blower/motor from the mounting plate located on the top of the heater. Tools required include an 11/32” nut driver, small (1”) paint brush, toothbrush and vacuum cleaner.

1. Turn the thermostat on the gas control to the lowest

setting. If the heater is running, wait for it to shut down (see Figure 48).

2. Turn the gas control switch to the “OFF” position.

3. Disconnect the electrical power to the water heater

from the wall outlet.

4. Disconnect the vent piping from the top of the blower.

Loosen the lower gear clamp that holds the rubber coupling to the blower (see Figure 49).

5. Remove and retain the (4) 11/32” nuts located on the

back of the blower with the nutdriver (see Figure 42 & Figure 49).

6. Holding the blower motor and the blower housing,

pull the assembly forward to disengage it from the mounting plate. The blower will still be connected to the junction box so exercise care not to stress the wiring.

44 www.americanwaterheater.com

7. Accessing the blower wheel through the outlet, use the paint brush to brush off the outer edge of the blower wheel to dislodge the dirt stuck on the blades and the inside of the housing. Rotate the wheel until all blades are clear. Note: The wheel is a balanced component. Do not bend, dent or distort the blades as this can upset the wheel balance and affect the blower operation. Vacuum out the loosened dirt.

8. Accessing the inside of the blower wheel through the rear of the housing, gently brush off the inside of the blades using the toothbrush. Again, take care not to distort the blades. Rotate the wheel until all blades are cleaned and vacuum the debris. Do not remove any of the balancing chips attached to the blades.

9. Inspect the ﬂ ue collector hood (still attached to the heater) and vacuum out the dust and debris that may have accumulated.

10. With all parts cleaned and the blower wheel turning freely, reinstall the blower to the mounting plate aligning the (4) studs and pushing tight against the mounting plate.

11. Reinstall the (4) 11/32” nuts and tighten securely. All (4) nuts must be in place and secure to safely operate the blower.

12. Reattach the vent piping and coupling to the top of the blower, tighten the bottom gear clamp and ensure the piping is secure.

13. With all components clean and secure, reconnect the electrical power to the heater.

14. Reset the thermostat to the desired temperature setting and turn the gas control switch back to the “ON” position. Note: If the water in the heater is hot, the unit will wait to operate until there is a need for more hot water.

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 ﬂ ooded water heater will create dangerous conditions which can cause death, serious bodily injury, or property damage. Contact a qualiﬁ ed installer or service agency to replace a ﬂ 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 ﬂ ame characteristics and ignition sequences. This can be done by removing the outer door and viewing the main burner operation through the viewport on the inner door (see Figure 50). The main burner should provide complete combustion of gas, ignite rapidly, give reasonably quiet operation, and cause no excessive ﬂ ame lifting from the burner ports. If the proper ﬂ ame characteristics are not evident (see Figure 51), make sure that the ﬂ ow of combustion and ventilation air is not blocked.

You should also check for sooting. Soot is not normal and will impair proper combustion. A visual inspection of the main burner and hot surface igniter should also be done at least once a year (see Figure 50).

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

IGNITER

AND FLAME

ROD

MAIN

BURNER

VENT

PIPE

MOTOR

BLOWER

MOUNTING

PLATE

Figure 49.

COUPLING

GEAR

CLAMP

11/32” NUTS

FLUE

COLLECTOR

HOOD

BLOWER

DILUTION

AIR INTAKES

BLUE TIPS

LIGHT BLUE INNER

CONES ARE

SATISFACTORY

IGNITER

AND

FLAME

ROD

VIEWPORT

Figure 50.

INCORRECT FLAME LAZY

YELLOW

CORRECT FLAME

SOFT BLUE

Figure 51.

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COMBUSTION CHAMBER AND BURNER CLEANING

In the event your burner or burner air openings require cleaning, Call your service agency to remove and clean the burner and correct the problem that required the burner to be cleaned.

The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement. Note: Artiﬁ cially softened water requires the anode rod to be inspected annually.

HOUSEKEEPING

DANGER

Fire and Explosion Hazard

• Do not obstruct combustion air

openings at the rear of the water heater.

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

• Can cause serious injury or death.

INSTALLED IN SUITABLE AREA: To ensure sufficient ventilation and combustion air supply, proper clearances from the water heater must be maintained. See “Locating the New Water Heater” section. Combustible materials such as clothing, cleaning materials, or ﬂ ammable liquids, etc. must not be placed against or adjacent to the water heater which can cause a ﬁ 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, hydronic heating devices 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 sulﬁ de gas dissolved in the water. Important: Do not remove this anode rod permanently as it will void any warranties. A special anode rod may be available if water odor or discoloration occurs. Note: This anode rod may reduce but not eliminate water odor problems. The water supply system may require special ﬁ ltration equipment from a water conditioning company to successfully eliminate all water odor problems.

Artiﬁ cially softened water can be exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions. The use of a excessively soft water may decrease the life of the water heater tank.

The following are typical (but not all) signs of a depleted anode rod:

• The majority of the anode rod’s diameter is less than

3/8”.

• Signiﬁ cant sections of the support wire (approx. 1/3

or more of the anode rod’s length) are visible (see Figure 52).

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.

Figure 52.

ANODE ROD

Important: Use only factory authorized replacement parts.

If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualiﬁ ed service technician.

• Tools required:

• Ratchet with 1-1/16” Socket

• Pliers

• Teﬂ on

Removing Anode Rod:

1. Set the gas control valve/thermostat to its lowest

2. Turn gas control switch to the “OFF” position.

3. Disconnect the electrical power to the water heater

4. Shut off the incoming water supply to the water heater

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

6. Remove the anode cap on top of the heater and

7. Remove the anode rod by using a ratchet and a

Tape or an approved pipe sealant

setting by turning the knob counter-clockwise to the VAC point (see Figure 48). If the water heater is running, wait for it to shut down.

from the wall outlet.

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

adequate drain or to the exterior of the building. Open the drain valve and allow at least 5 gallons of water to drain from the tank. Close drain and remove hose.

remove just enough insulation so you can access to the anode head (see Figure 53). Keep the anode cap in a safe place for reinstallation later.

1-1/16” socket turning counter-clockwise (see Figure

53).

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Installing Anode Rod:

1. Use Teﬂ on® tape or an approved pipe sealant on threads of the new anode rod.

2. Place the anode rod in the spud (top of the tank) and turn clockwise until the threads are hand tight. Using a ratchet and 1-1/16” socket tighten down water tight.

3. Open a nearby hot-water faucet to purge air from the water line. Open the incoming water supply and ﬁ ll water heater tank completely (Note: To assure the water heater tank is full, keep the hot-water faucet open for 3 minutes after a constant ﬂ ow of water is obtained).

4. Turning off the hot-water faucet, check for water leaks around anode rod and immediately correct any if found.

5. Reinstall the insulation and anode cap which were removed in step 6 of removal instructions.

6. With all components clean and secure, reconnect the electric power to the heater.

7. Reset the thermostat to the desired temperature setting and turn the gas control switch back to the “ON” position (see Figure 48).

TEMPERATURE-PRESSURE RELIEF VALVE TEST

DANGER

• Burn hazard.

• Hot water discharge.

HOT

BURN

It is recommended that the temperature-pressure relief valve be checked to ensure it is in operating condition at least once a year.

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

To check the relief valve, lift lever at the end of valve several times (see Figure 54). The valve should seat properly and operate freely.

• Keep clear of

temperature-pressure relief valve discharge.

* THE ANODE ROD IS COVERED BY URETHANE FOAM LOCATED

UNDER THE CAP. CHIP AWAY

THE FOAM TO EXPOSE THE

TOP OF THE ANODE ROD

Figure 53.

CAP

ANODE ROD *

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 and drain the water heater, see “Draining and Flushing” section. Replace the T&P valve with a properly rated/sized new one, see “Temperature-Pressure Relief Valve” for instructions on replacement.

Figure 54.

If the Temperature-Pressure Relief Valve on the water heater weeps or discharges periodically, it may be due to thermal expansion.

Note: Excessive water pressure is the most common cause of temperature-pressure relief valve leakage. Excessive water system pressure is most often caused by “thermal expansion” in a “closed system.” See “Closed Water Systems” and “Thermal Expansion” sections of this manual. The T&P valve is not intended for the constant relief of thermal expansion.

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Temperature-pressure relief valve leakage due to pressure build up in a closed system that does not have a thermal expansion tank installed is not covered under the Limited Warranty. Thermal expansion tanks must be installed on all closed water systems.

WARNING

Explosion Hazard

• Temperature-pressure relief

valve must comply with ANSI Z21.22-CSA4.4 and ASME code.

• Properly sized temperature-

pressure relief valve must be installed in opening provided.

• Do not plug, block, or cap the

discharge line.

• Failure to follow this warning

can result in excessive tank pressure, serious injury or death.

To drain the water heater storage tank:

1. Turn “OFF” the electrical supply to the water heater.

2. Turn “OFF” the gas supply at the Main Gas shut-off Valve if the water heater is going to be shut down for an extended period.

3. CLOSE the cold-water inlet valve to the water heater.

4. OPEN a nearby hot-water faucet and leave open to allow for draining.

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

Note: If the water heater is going to be shut down and drained for an extended period, the drain valve should be left open with hose connected allowing water to terminate to an adequate drain.

6. Close the water heater drain valve when all water in the storage tank has drained.

7. Follow instructions in the “Filling the Water Heater” section.

8. Turn “ON” the gas supply at the main gas shut-off valve.

9. Follow the lighting instructions on the label or see “Lighting Instruction” to restart the water heater.

DRAINING AND FLUSHING

Periodic draining and cleaning of sediment from the tank maybe necessary. It is recommended that the tank be drained and ﬂ 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. See “Typical Installation” section in this manual for location of the water heater components described below.

DANGER

• Burn hazard.

• Hot water discharge.

HOT

BURN

• Keep hands clear of drain

valve discharge.

To ﬂ ush the water heater storage tank:

1. Turn “OFF” the electrical supply to the water heater.

2. Ensure the cold-water inlet valve is open.

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

4. Ensure the drain hose is secured before and during the entire ﬂ ushing procedure. Flushing is performed with system water pressure applied to the water heater.

5. Open the water heater drain valve to ﬂ ush the storage tank. Caution: Water will be hot.

6. Flush the water heater storage tank to remove sediment and allow the water to ﬂ ow until it runs clean.

7. Close the water heater drain valve when ﬂ ushing is completed.

8. Remove the drain hose.

9. Ensure the heater is full of water.

10. Turn “ON” electrical supply to place water heater back in operation and follow the lighting instructions.

11. Allow the water heater to complete several heating cycles to ensure it is operating properly.

Caution: Do not turn on power to the water heater unless the tank is full. Open a hot-water faucet and allow the water to run until the air is purged and the water ﬂ ows uninterrupted from the faucet.

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Important: When operating a cold tank, condensation can occur and drip on the burner. This should not be confused with a tank leak.

LEAKAGE CHECKPOINTS

SERVICE

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

If you are not thoroughly familiar with gas codes, your water heater and safety practices, contact your gas supplier or qualiﬁ ed installer to check the water heater.

Ensure the venting is properly attached and secured.

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

A. Water at the blower assembly is water vapor which

has condensed out of the combustion products. This is caused by a problem in the vent. A drainage port is included at the vent pipe connection. Contact the gas utility.

B. *Condensation may be seen on pipes in humid weather

or pipe connections may be leaking. C. *The anode rod ﬁ tting may be leaking. D. Small amounts of water from temperature-pressure

relief valve may be due to thermal expansion or high

water pressure in your area. E. *The temperature-pressure relief valve may be leaking

at the tank ﬁ tting. F. Water from a drain valve may be due to the valve being

slightly opened. G. *The drain valve may be leaking at the tank ﬁ tting. H. Combustion products contain water vapor which can

condense on the cooler surfaces of the tank. Droplets

form and drip onto the burner. This is common at the

time of start-up after installation and when incoming

water is cold. I. Water in the water heater bottom 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 ﬁ tting. If cotton is wet, follow “Draining” instructions in the “Periodic Maintenance” section and then remove ﬁ tting. Put pipe dope or Teﬂ on tape on the threads and replace. Then follow “Filling the Water Heater” instructions in the “Installing the New Water Heater” section.

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Figure 55.

REFERENCE PARTS LISTING

Replacement parts may be ordered through your plumber or the local distributor. When ordering replacement parts, always have the following information ready:

1. Model, Serial and Product number

2. Type of gas

3. Item number

4. Parts description

1. Vent Termination Elbow with Rodent Screen

2. **Vent Pipe

3. **Vent Pipe Coupling (if required)

4. **Vent Pipe Elbow (long radius)

5. Blower High Limit Switch (see Figure 61)

6. T&P Valve

7. Cold-Water Inlet Nipple/Diptube

8. Bafﬂ e Assembly

9. ** Discharge Pipe

10. Gas Control Valve/Thermostat (Honeywell)

11. Gas Valve Electronic Control Module And Cover (Honeywell)

12. Drain Valve

13. Outer Gas Door

14. Manifold Door Assembly (behind outer door) (see Figure 58 & Figure

59)

15. **Floor Drain

16. **Metal Drain Pan

17. Flammable Vapor Sensor (under cover) (see Figure 60)

18. Combo Heating System Return Inlet (Optional)

19. Air Inlet Snorkel

20. Combo Heating System Supply Outlet (Optional)

21. Blower with Power Cord (see also Figure 61)

22. Air Switch (inside box) (see Figure 61)

23. Junction Box (see Figure 61)

24. Junction Box Cover (see Figure 61)

25. Air Tubing (see Figure 61)

26. Rubber Coupling (see also Figure 61)

27. Gear Clamp (see also Figure 61)

28. Flue Collector

29. Hot-Water Outlet Nipple

30. Anode (under cap)

32. Flexible Manifold Tube (see Figure 58 & Figure 59)

33. V iewport (see Figure 58 & Figure 59)

34. Flame Sensor Rod (see Figure 58 & Figure 59)

35. Gas Orifice (see Figure 58 & Figure 59)

36. Sheet Metal Burner (see Figure 58 & Figure 59)

37. Gas Manifold (see Figure 58 & Figure 59)

38. Hot-Surface Igniter (see Figure 58 & Figure 59)

39. Manifold Door Gasket (see Figure 58 & Figure 59)

40. Manifold Door (see Figure 58 & Figure 59)

41. Two Piece Grommet With Clip (Figure 58 & Figure 59)

** parts not supplied with the water

heater

Blower

Dilution Air

Inlets

Combustion

Air Inlets

50 www.americanwaterheater.com

Front View Rear View

Figure 56. Figure 57.

Natural gas and Propane main burner with igniter assembly for 40k to 50k Btu/hr models

Flare Nut**

Figure 58.

Natural gas and Propane main burner with igniter assembly for 60k to 75k Btu/hr models

32 34

Flare Nut**

Figure 61.

Notes: * Natural gas models have Right-hand thread,

4041

** For Natural gas models the Flare Nut has Right-

Propane models have Left-hand thread.

hand thread. For Propane models the Flare Nut has Left-hand thread.

Figure 59.

Figure 60.

www.americanwaterheater.com 51

TROUBLESHOOTING GUIDELINES

These guidelines should be utilized by a qualiﬁ ed service agent.

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER FLAME

TOO HIGH

FLAME BURNS

AT ORIFICE

INSUFFICIENT

HOT WATER

WATER IS TOO HOT

SLOW HOT WATER

RECOVERY

DRIP FROM

RELIEF VALVE

GAS CONTROL VALVE/

THERMOSTAT FAILS TO

SHUT OFF

SMELLY WATER

1. Air inlets blocked

2. Insufﬁ cient secondary air

3. Oriﬁ ce too large

1. Low gas pressure

2. Defective gas control valve/thermostat

1. Low gas pressure

2. Oriﬁ ce too small

3. Thermostat set too low

4. Gas control error codes

5. Sediment or lime in tank

6. Water heater too small

7. Wrong piping connections

8. Leaking faucets

9. Wasted hot water

10. Long runs of exposed piping

11. Hot-water piping in outside wall

1. Thermostat is too high

2. Defective gas control valve/thermostat

1. Insufﬁ cient air/ ﬂ ue blockage

2. Low gas pressure

3. Oriﬁ ce too small

4. Thermostat set too low

5. Heater too small

6. Wrong piping connection

7. Wasted hot water

8. Flue clogged

9. Air inlets blocked

1. Pressure build-up

2. Heater stacking

3. Closed water system

4. Improperly seated valve

1. Defective gas control valve/thermostat 1. Replace gas control valve/thermostat

1. Sulﬁ des in water supply

2. Bacteria in water supply

3. Incompatible anode

1. Unblock inlet air openings

2. Provide ventilation to water heater

3. Replace with correct oriﬁ ce

1. Check with gas utility company

2. Replace gas control valve/thermostat

1. Check with gas utility company

2. Replace with correct oriﬁ ce (see rating plate)

3. Turn temperature knob to higher setting

4. Refer to gas control error codes

5. Drain/ﬂ ush-provide water treatment if needed

6. Install adequate heater

7. Correct piping: dip tube must be in cold inlet

8. Repair faucets

9. Advise customer

10. Insulate piping

11. Insulate piping

1. Turn temperature knob to lower setting

2. Replace the gas control valve/ thermostat

1. Provide ventilation to water heater. Check ﬂ ue way, ﬂ ue bafﬂ e and burner

2. Check with gas utility company

3. Replace with correct oriﬁ ce (see rating plate)

4. Turn temperature knob to higher setting

5. Install adequate heater

6. Correct piping-dip tube must be in cold inlet

7. Advise customer

8. Clean ﬂ ue, locate source and correct

9. Unblock inlet air openings

1. Use a pressure-reducing valve and relief valve

2. Lower the thermostat setting

3. See thermal expansion section

4. Check Relief valve for proper operation (Do Not plug T&P valve)

1. Chlorination procedure

2. Chlorination procedure

3. Replace with anode appropriate for water conditions

52 www.americanwaterheater.com

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

CONDENSATION

COMBUSTION ODORS

SMOKING AND CARBON

FORMATION

UNABLE TO LIGHT

THE BURNER

SIZZLING, RUMBLING

NOISE

WATER LEAKAGE

BLOWER WILL

NOT START

1. Filling the new water heater for the ﬁ rst time

2. Moisture from the products of combustion

3. Water dripping from blower assembly

4. Undersized water heater

1. Air inlets blocked

2. Insufﬁ cient air

3. Flue clogged

4. Heater installed in a conﬁ ned area

5. House too tight

1. Air inlets blocked

2. Insufﬁ cient air

3. Low gas pressure

4. Oriﬁ ce too large

5. Flue clogged

6. Defective gas control valve/thermostat

7. Heater installed in a conﬁ ned area

1. Air in gas line

2. Pressure switch

3. Blocked exhaust

4. Wire connection

5. Defective gas control valve/thermostat

1. Scale and sediment

2. Condensation dripping on burner

1. Condensation

2. Dripping Temperature & Pressure Relief Valve

3. Drain valve dripping/leaking

4. Tank Leak

1. No power to unit

2. Thermostat set too low

3. Defective air pressure switch

4. Defective blower

5. Disconnected or loose wire

6. Control locked out

1. Normal operation: the condensation should disappear after heater warms up

2. Normal operation: the condensation should disappear in time

3. Install condensate hose to drain port on the rubber coupling

4. Install adequate heater

1. Unblock inlet air openings

2. Provide fresh air ventilation to the water heater

3. Clean, locate source and correct

4. Provide fresh air ventilation to the water heater

5. Provide fresh air ventilation to the water heater

1. Unblock inlet air openings

2. Provide ventilation to water heater. Check ﬂ ue way, ﬂ ue bafﬂ e and burner

3. Check with gas utility company

4. Replace with correct oriﬁ ce (see rating plate)

5. Clean, locate source and correct

6. Replace gas control valve/thermostat

7. Provide fresh air ventilation

1. Purge the air from gas line

2. Check the pressure switch, make sure the pressure switch hose is not kinked

3. Check vent pipe for blockage

4. Check wire connections

5. Replace the gas control valve/ thermostat

1. Drain/ﬂ ush-provide water treatment if needed

2. Refer to “Condensate” section

1. Refer to “Condensate” section

2. Refer to “Temperature & Pressure Relief Valve” section

3. Back flush to clean- out sediment, replace if necessary.

4. Check “Leakage Checkpoints”

1. Plug in power cord, check fuses and/or supply voltage

2. Turn temperature knob to higher setting

3. Replace air pressure switch

4. Replace blower

5. Repair and reconnect wires

6. Refer to “Resetting The Heater Control” – determine cause of lockout

www.americanwaterheater.com 53

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BLOWER RUNS

CONTINUOUSLY

HOT SURFACE IGNITER

NOT GLOWING

FOLLOWING WARM-UP

PERIOD

VENT PIPE TOO HOT

1. Air pressure switch not closing due to insufﬁ cient draft – check for:

a. Vent piping blocked b. Piping length too long c. Clogged/dirty blower

2. Disconnected, torn or blocked pressure switch hose from air pressure switch to blower housing

3. Defective pressure switch

4. High limit switch open due to excessive vent temperature or defective switch

1. 120VAC polarity reversed at 120VAC

outlet receptacle

2. Defective hot surface igniter

3. Defective gas control valve/thermostat

1. Blower high limit switch fails to open -

switch defective

2. Not enough dilution air to mix with ﬂ ue

gases

3. Air in room too hot for mixing with ﬂ ue

gases

4. Wrong burner oriﬁ ce

1. Determine cause of insufﬁ cient draft. Check draft with manometer at pressure switch

a. Remove blockage b. Reduce vent length/increase vent

size

c. Clean blower wheel

2. Reconnect or replace pressure switch hose

3. Replace defective pressure switch

4. Determine cause of overheating check for: overﬁ ring, insufﬁ cient air supply, high ambient air temperature

1. Reverse polarity at 120VAC outlet

receptacle

2. Replace igniter

3. Replace gas control valve/thermostat

1. Replace blower high limit switch Replace

blower high limit switch

2. Proper air circulation must be provided

for combustion and dilution of ﬂ ue temp

3. Increase ventilation to lower room

temperature

4. Install correct oriﬁ ce.

RESETTING THE HEATER CONTROL

• Soft lockouts as diagnosed by the system error codes

require the gas control to be reset.

• To reset the control, slide the “ON/OFF” switch to the

“OFF” position. Wait for 10 seconds and move the switch back to the “ON” position.

• If the problem that caused the control to lock out has

not been corrected, the control will remain or again go back into lockout.

LOCKOUTS

Soft Lockout

• occurs when a system safety device trips to break the

sequence of operation. The control will retry the system in a timed basis but will not reinstate operation until the failure is corrected.

Hard Lockout

• occurs when the main controller fails and must be

replaced.

The gas control valve\thermostat includes a temperature limiting ECO (Energy Cut Off) system that will shut off the water heater if the water temperature is too high. Should the water temperature get too high, the diagnostic status light will indicate a code (4 ﬂ ashes), indicating an over-temperature condition and the main burner will be shut off. If a high temperature condition occurs, turn the main gas supply OFF and have the water heater repaired by a qualiﬁ ed service technician. Contact your local dealer for service information.

Note: Should an over-temperature condition occur, restart the water heater and verify the LED ﬂ ash sequence. If the 4 ﬂ ash sequence is observed, slide the “ON/OFF” switch to the “OFF” position. Turn Main Gas Supply “OFF”. Replace the gas control valve\thermostat. See “Removing and Replacing the Gas Control Valve/Thermostat.”

54 www.americanwaterheater.com

IGNITION STATE AND TIMING

IGNITION STATE TIMING

Pre-purge

Hot Surface Igniter (HSI) Warmup

Ignition Activation Period (IAP)

Flame Recognition Period (FRP)

5 seconds (NG models)

15 seconds (LP models)

10 seconds

3.5 seconds maximum

0.5 second

Trial For Ignition IAP + FRP

Flame Stabilization Period

Not Applicable

Inter-purge 30 seconds

Flame Failure Response Time

2 seconds max (@ 1uA ﬂ ame current)

Post-purge 30 seconds

Pressure Switch (PS) Prove Period

2 minutes

Pressure Switch (PS) Fault Delay (failed

2 minutes

open/closed)

Soft Lockout 20 minutes

Energy Cut Off (ECO) Limit Lockout

Flammable Vapor (FV) Sensor Lockout

Indeﬁ nite

Indeﬁ nite (see “Resetting The Heater Control”)

SYSTEM STATUS AND ERROR CODES

The micro-controller inside the gas control monitors the ﬂ ammable vapor safety features, the ignition sequence, temperature settings and overall operation of the heater. If any of these parameters does not operate properly the controller will shut down the water heater, diagnose the failure and ﬂ ash an error code. The table below lists the System Status Codes for the Honeywell control. Refer to it and to the “Trouble Shooting Guidelines” to diagnose the problem before attempting corrective action. See also “Flammable Vapor Sensor”.

LED Flash Sequence Control Status

Short ﬂ ash once every four seconds

“Heartbeat”, alternates bright/dim

One Flash, three second pause

Two Flash, three second pause

Three Flash, three second pause

IDLE (no call for heat, no fault conditions)

Call For Heat (no fault conditions)

Low Flame Signal (control continues to operate)

Pressure Switch Failed Closed

Pressure Switch Failed Open

ECO (Energy Cut Off) Limit Four Flash, three second pause

Lockout

thermostat temperature limit

was exceeded.

Five Flash, three second pause

Six-One Flash, three second pause

Flame Out Of Sequence

Soft Lockout

- Retry Limit

- Failed Trial For Ignition

Soft Lockout Six-Two Flash, three second pause

- Recycle Limit

- Pressure Switch/ High Limit

opened

Six-Three Flash, three second pause

Six-Four Flash, three second pause

Seven Flash, three second pause

Eight-One Flash, three second pause

Eight-Two Flash, three second pause

Eight-Three Flash, three second pause

Eight-Four Flash, three second pause

Hardware Fault Lockout

Soft Lockout

- Recycle Limit

- Flame Lost

Soft Lockout

- Flame out of Sequence

Sensed

Flammable Vapor Sensor

(FVS) Lockout

Flammable Vapor Sensor

FVS Fault Detected

Temperature Sensor Fault

Detected

Electronics Fault Detected

Valve Fault Detected

Indeﬁ nite

www.americanwaterheater.com 55

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56 www.americanwaterheater.com

This page intentionally left blank. May be used for notes or to record other installation information.

www.americanwaterheater.com 57

LIMITED WARRANTY

RESIDENTIAL TYPE WATER HEATER FOR INSTALLATION IN A SINGLE FAMILY DWELLING

A. WHO IS COVERED. AMERICAN WATER HEATER COMPANY, (herein collectively referred to as “Manufacturer”) warrants only to the origi-

nal consumer purchaser (hereinafter “Owner”) of the water heater so long as he or she continuously occupies the single family dwelling in which this water heater is initially installed for the period speci¿ ed below. This warranty is not transfer- able. The warranty is restricted to the water heater used in a single-family residence in the United States of America. This warranty is reduced to one year if the water heater is used in a commercial, or industrial application, or if the water heater is used to supply more than one dwelling unit.y more than one dwelling unit. Consumers must retain point-of-sale proof

of purchase to validate warranty entitlement. B. WHEN IT IS COVERED. The water heater is warranted only when it is installed, operated and maintained in accordance with the printed instruc-

tions accompanying the water heater. A water heater should be installed in such a manner that, if the tank or any con-

nection thereto should leak, the resulting À ow or water will not cause damage to the area in which it is installed. A water

heater’s temperature and pressure relief valve must be piped to the nearest drain to avoid damage in the event the valve

is actuated. For detailed instructions read the manual accompanying the water heater and review drawings in the manu-

al. C. WHAT THE MANUFACTURER WILL DO AND THE PERIOD OF COVERAGE.

1. The Inner Tank. If the inner tank leaks within the warranty period listed on the data plate label after the original instal-

lation, Manufacturer will furnish a new water heater of Manufacturer’s then prevailing comparable model. If industry standards, product improvements or product obsolescence prohibits Manufacturer from furnishing an identical model replacement water heater under this warranty, the Owner will be furnished with a new water heater of comparable capacity; however, the Owner will be charged for the additional value of the item(s) which Manufacturer has incorporated in the replacement water heater. A prior authorization number must be obtained from the Manufacturer before replac ing the water heater. This warranty is limited to one replacement water heater at the original installation site.

2. Component Part. f any component part other than the inner tank proves to Manufacturer’s satisfaction to be defec-

tive in material or workmanship within the warranty period listed on the data plate label, the Manufacturer will furnish the Owner with a replacement for the defective part(s). This warranty is limited to one replacement component part for each original part.

3. Return of Defective Water Heater and Component Parts. Manufacturer reserves the right to examine the alleged

defect in the water heater or component part(s), and it will be the Owner’s obligation (See paragraph 0.5) to return the

water heater and/or component part(s) to the Manufacturer. a. When returning a water heater it must include all component parts and the data plate label. b. When returning component part(s), they must be individually tagged and identi¿ ed with the water heater’s product

number, model number, serial number, date of purchase and date of installation.

D. WHAT THIS WARRANTY DOES NOT COVER.

1. THE LIMITED WARRANTY STATED HEREIN IS IN LIEU OF ANY AND ALL WARRANTIES, EXPRESS OR IMPLIED

(WHETHER WRITTEN OR ORAL), INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OR MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

2. MANUFACTURER SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, SPECIAL OR CONTIN-

GENT DAMAGES OR EXPENSES, ARISING, DIRECTLY OR INDIRECTLY, FROM ANY DEFECT IN THE WATER

HEATER OR THE USE OF THE WATER HEATER.

3. Manufacturer shall not be liable for any water damage arising, directly or indirectly, from any defect in the water heater

or component part(s) or from its use.

4. Manufacturer shall not be liable under this warranty and this warranty shall be void and have no effect if the following

events occur: a. The water heater or any of its component parts have been subject to misuse, alteration, neglect or accident; or b. The water heater has not been installed in accordance with the applicable local plumbing and/or building code(s)

and/or regulations or in their absence, with the latest issue of the National Fuel Gas Code Z223.1, and/or National Electric Code; or

c. The water heater is not installed, operated and maintained in accordance with the printed Manufacturer’s instruc-

tions; or

d. The water heater or any of its component parts are damaged or fails from operation with an empty or partially empty

tank (such as, but not limited to elements burned out in a dry tank); or e. The water heater or any part has been under water; orr f. The water heater is exposed to highly corrosive atmospheric conditions; or g. The water heater is not continuously supplied with potable water; or h. The water heater replacement is requested for reasons of noise, taste, odor, discoloration and/or rust; or i. The water heater is not operated within the factory calibrated temperature limits; or j. The water heater is supplied or operated with desalinated (deionized) water; or k. The water heater is supplied or operated with water not meeting the water quality requirements listed in the manual

accompanying the water heater; or

58 www.americanwaterheater.com

l. The water heater is removed from its original installation location; or m. The water heater is installed outdoors (this water heater is intended only for indoor installation); or n. The water heater is converted, or is attempted to be converted, from one voltage or wattage to another, if an electric

water heater, or from one type gas to another, if a gas water heater; or o. The water heater has not been ¿ red at the factory rated input and fuel for which it was factory built; or p. he water heater or any of its component parts fail due to sediment build-up; or q. The water heater does not have installed a temperature and pressure relief valve, certi¿ ed to ANSI Z21.22 and ap-

proved by the American Society of Mechanical Engineers; or r. The water heater or any of its component parts fail because of ¿ re, À oods, lightening, or any other act of God; or s. The water heater is installed in a closed system without adequate provision for thermal expansion.

5. Except when speci¿ cally prohibited by the applicable state law, the Owner, and not the Manufacturer, shall be liable

for and shall pay for all charges for labor or other expenses incurred in the removal, repair or replacement of the water heater or any component part(s) claimed to be defective or any expense incurred to remedy any defect in the product. Such charges may include, but are not necessarily limited to:

a. All freight, shipping, handling and delivery costs of forwarding a new water heater or replacement part(s) to the

owner. b. All costs necessary or incidental in removing the defective water heater or component part(s) and installing a new

water heater or component part(s). c. Any material required to complete, and/or permits required for, installation of a new water heater or replacement

part(s), and d. All costs necessary or incidental in returning the defective water heater or component part(s) to a location desig-

nated by the manufacturer.

6. The terms of this Limited Warranty cannot be modi¿ ed by any person, whether or not he/she claims to represent or

act on behalf of the Manufacturer. E. HOW STATE LAW MAY RELATE TO THIS WARRANTY. Some States do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to

you. Similarly, some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. Further, this warranty gives you speci¿ c legal rights and you may also have other rights, which may vary from State to State.

F. HOW THE ORIGINAL OWNER CAN MAKE A WARRANTY CLAIM.

1. The Owner should submit the warranty claim directly to Manufacturer’s Service Department, at the address or phone

number listed below, and Manufacturer will arrange for the handling of the claim and if valid, will give the Owner an authorization number which must appear on any document presented for warranty exchange.

2. Whenever any inquiry or request is made, be sure to include the water heater’s product number, model number, serial

number, date of purchase, date of installation, and location of installation.

FOR TECHNICAL ASSISTANCE, SERVICE OR WARRANTY INFORMATION

PHONE TOLL FREE: 1-800-999-9515

MONDAY THROUGH FRIDAY

8:00 AM to 8:00 PM EASTERN STANDARD TIME

Write to:

AMERICAN WATER HEATER COMPANY

ATTN.: PRODUCT SERVICES

P.O. BOX 1597

JOHNSON CITY, TN 37605-1597

www.americanwaterheater.com 59

American Water Heaters

500 Princeton Road

Johnson City, TN 37605

Phone: 800-999-9515

Fax: 800-999-5210

www.americanwaterheater.com

PowerFlex POWER VENTED GAS Models Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual