Rudd 40 GALLON Installation Manual
VACATION
WARNING
VERY
HOT
WARM
A B C
COOLER
HOTTER
VACATION
WARNING
VERY
HOT
WARM
A B C
COOLER
HOTTER
!
Warning: This water heater is not
suitable for use in manufactured (mobile) homes!
Residential Gas
Use & Care Manual
With Installation Instructions for the Installer
PowerDirectVent
Residential 40, 50, 65 & 75 Gallon Models
The purpose of this manual is twofold: one, to provide the installer with the basic directions
and recommendations for the proper installation and adjustment of the water heater; and two,
for the owner–operator, to explain the features, operation, safety precautions, maintenance
and troubleshooting of the water heater. This manual also includes a parts list.
It is very important that all persons who are expected to install, operate or adjust this
water heater read the instructions carefully so they may understand how to perform
these operations. If you do not understand these instructions or any terms within it, seek
professional assistance.
Any questions regarding the operation, maintenance, service or warranty of this water heater
should be directed to the seller from whom it was purchased. If additional information is
required, refer to the section on “If you need service.”
Do not destroy this manual. Please read carefully and keep in a safe place for future
reference.
Recognize this symbol as an indication of Important Safety Information!
!
California Proposition 65 Warning: This product contains chemicals known to the
!
State of California to cause cancer, birth defects or other reproductive harm.
Water Heaters
!
WARNING: If the information in these instructions is not followed exactly,
a fire or explosion may result causing property damage, personal injury or death.
!
FOR YOUR SAFETY!
— Do not store or use gasoline or other
flammable vapors or liquids or other
combustible materials in the vicinity of this or
any other appliance. To do so may result in an
explosion or fire.
— WHAT TO DO IF YOU SMELL GAS
● Do not try to light any appliance.
● Do not touch any electrical switch; do not
use any phone in your building.
● Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
Printed in USA
● If you cannot reach your gas supplier, call
the fire department.
● Do not return to your home until authorized
by the gas supplier or fire department.
— Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury, or death. Refer to
this manual. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.
I
S
G
E
N
D
C
E
D
R
E
I
T
F
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®
AP14896-1 (01/10)
Safety Information
Safety Precautions . . . . . . . 3–6
LP Gas Models . . . . . . . . . . . 5
Installing the Water Heater
Location . . . . . . . . . . . . . . . . . 7
Water Supply Connections . . 8
Gas Supply . . . . . . . . . . . . . . 10
Vent and Combustion
Air-Inlet . . . . . . . . . . . . . .11-22
Wiring Diagram . . . . . . . . . . .23
Pipe Insulation . . . . . . . . . . . .24
Heat Traps . . . . . . . . . . . . . . .25
Installation Checklist . . . . . . .26
Potable/Space Heating . . . . 27
Operating Instructions
Lighting Instructions . . . . . . 28
Water Temperature . . . . 29, 30
FOR YOUR RECORDS
Write the model and serial numbers here:
#
#
You can find them on a label on the appliance.
Staple sales slip or cancelled check here.
Proof of the original purchase date is needed to obtain service under
the warranty.
READ THIS MANUAL
Inside you will find many helpful hints on how to use and maintain
your water heater properly. A little preventive care on your part can
save you time and money over the life of your water heater.
You’ll find many answers to common problems in the
Troubleshooting Guide. If you review the chart of Troubleshooting
Tips first, you may not need to call for service.
Care and Cleaning
Draining . . . . . . . . . . . . . . . . 32
Maintenance . . . . . . . . . . . . . 32
Vent System Inspection . . . . 33
Burner Inspection . . . . . . . . 33
Extended Shut-Down . . . . . .33
Troubleshooting Tips
Before You Call
For Service . . . . . . . . . . . 34, 35
Customer Service
Parts List . . . . . . . . . . . . . . . . 37
If You Need Service . . . . . . .38
READ THE SAFETY INFORMATION
Your safety and the safety of others are very important. There
are many important safety messages in this manual and on your
appliance. Always read and obey all safety messages.
This is the safety alert symbol. Recognize this symbol
as an indication of Important Safety Information!
!
This symbol alerts you to potential hazards that can
kill or hurt you and others.
All safety messages will follow the safety alert symbol and
either the word “DANGER”, “WARNING”, “CAUTION” or
“NOTICE”.
These words mean:
!
DANGER
WARNING
!
!
CAUTION
Notice:
An imminently hazardous situation
that will result in death or serious
injury.
A potentially hazardous situation that
could result in death or serious injury
and/or damage to property.
A potentially hazardous situation that
may result in minor moderate injury.
Attention is called to observe a
specified procedure or maintain a
specific condition.
2
IMPORTANT SAFETY INFORMATION
READ ALL INSTRUCTIONS BEFORE USING
Be sure to read and understand the entire Use and Care Manual before attempting to install or operate this water
heater. It may save you time and money. Pay particular attention to the Safety Instructions. Failure to follow these
warnings could result in serious bodily injury or death. Should you have problems understanding the instructions in
this manual, or have any questions, STOP, and get help from a qualified service technician, or the local gas utility.
NOTICE: This water heater is equipped with a flammable vapor sensor that will automatically shut
down the water heater in the presence of gasoline vapors and some other flammable vapors. If the
flammable vapor sensor shuts down the water heater, contact a qualified service technician. Clear any
hazardous materials and ventilate the area around the water heater. Do not turn off the appliance
or adjust the ON/OFF switch in any way. Do not tamper with the flammable vapor sensor. Do not
submerse the flammable vapor sensor in water. Do not allow the flammable vapor sensor to come into
contact with any substances such as bleach or cleaners. See the “Gas Valve LED Code” Section of this
manual for a list of diagnostic codes.
DANGER!
PROPERLY VENT THE WATER HEATER
Failure to properly vent the water heater as outlined in the Vent and Combustion Air-Inlet
Section of the Installation Instructions in this manual can result in unsafe operation of the
water heater. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide,
never operate this water heater unless both the vent and combustion air-inlet systems are
properly installed. Be sure to inspect both the vent and combustion air-inlet for proper
installation at initial start-up; and at least periodically thereafter. Refer to the Care and
Cleaning section of this manual for more information regarding vent and combustion airinlet system inspection.
WARNING!
Gasoline, as well as other flammable materials and liquids (which include but are not
limited to adhesives, solvents, paint thinners etc.), and the vapors they produce are
extremely dangerous. DO NOT handle, use or store gasoline or other flammable or
combustible materials anywhere near or in the vicinity of a water heater or any other
appliance. Be sure to read and follow warning label pictured below and other labels on the
water heater, as well as the warnings printed in this manual. Failure to do so can result in
property damage, bodily injury or death.
W A R N I N G
!
FLA MMABLE S
!
Do not store or use gasoline or other flammable vapors and liquids
in the vicinity of this or any other appliance. Storage of or use of gasoline
or other flammable vapors or liquids in the vicinity of this or any other
appliance can result in serious injury or death.
Flammable Vapors
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death.
3
!
IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING
DANGER!
WATER TEMPERATURE SETTING
Safety and energy conservation are factors to be considered when selecting the water
temperature setting of a water heater’s gas control. Water temperatures above 125°F (52°C)
can cause severe burns or death from scalding. Be sure to read and follow the warnings
outlined on the label pictured below. This label is also located on the water heater.
Time/Temperature Relationship in Scalds
!
D A N G E R
HOT
Water Temperature Time To Produce a Serious Burn
120°F (49°C) More than 5 minutes
125°F (52°C) 11/2 to 2 minutes
130°F (54°C) About 30 seconds
135°F (57°C) About 10 seconds
140°F (60°C) Less than 5 seconds
145°F (63°C) Less than 3 seconds
150°F (66°C) About 11/2 seconds
155°F (68°C) About 1 second
Table courtesy of Shriners Burn Institute
The chart shown above may be used as a guide in
determining the proper water temperature for your
home.
!
DANGER: Households with small children, disabled,
or elderly persons may require a 120°F (49
control (thermostat) setting to prevent contact with "HOT"
water.
°C) or lower gas
BURN
Water temperature over 125°
can
cause severe burns
instantly or
death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See instruction manual before
setting temperature at water
heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
Notice: Mixing valves are available for reducing point of
use water temperature by mixing hot and cold water in
branch water lines. Contact a licensed plumber or the local
plumbing authority for further information.
4
F
Maximum water temperatures occur just after the
burner has shut off. To find water temperature being
delivered, turn on a hot water faucet and place
a thermometer in the water stream and read the
thermometer. (See pages 29 and 30 for more details.)
The temperature of the water in the heater can be
regulated by pressing the "COOLER" or "HOTTER"
arrow buttons on the front of the combination
gas control. To comply with safety regulations
the combination gas control was set at its lowest
setting before the water heater was shipped from the
factory. The desired water temperature must be set.
The illustration below details the approximate
water temperature for each LED indicator of the
VACATION
WARM
COOLER
WARM = approx. 70°F (21°C)
▼ = approx. 120°F (49°C)
A = approx. 130°F (54°C)
B = approx. 140°F (60°C)
C = approx. 150°F (66°C)
C-Flashing = approx. 160°F (71°C)
A B C
VERY
HOT
HOTTER
WARNING
Temperature Setting
Combination Gas Control's
display.
DANGER: Hotter water
increases the potential for
Hot Water SCALDS.
Display
▼ A B C
● ○ ○ ○ ○ ○
○ ○ ● ○ ○ ○
○ ○ ○ ● ○ ○
○ ○ ○ ○ ● ○
○ ○ ○ ○ ○ ●
○ ○ ○ ○ ○ ●
Burns on Adult Skin
--------------------
More than 5 minutes
About 30 seconds
Less than 5 seconds
About 1-1/2 seconds
About 1/2 seconds
DANGER!
!
LIQUEFIED PETROLEUM (LP PROPANE OR BUTANE)
AND NATURAL GAS MODELS
LP and Natural gas have an odorant added to aid in detecting a gas leak. Some people
may not physically be able to smell or recognize this odorant. If you are unsure or
unfamiliar with the smell of LP or natural gas, ask the gas supplier. Other conditions,
such as “odorant fade”, which causes the odorant to diminish in intensity, can also hide or
camouflage a gas leak.
● Water heaters utilizing LP gas are
different from natural gas models. A
natural gas water heater will not function
safely on LP gas and vice versa.
● No attempt should ever be made to
convert the water heater from natural
gas to LP gas. To avoid possible
equipment damage, personal injury or
fire, do not connect the water heater to a
fuel type not in accordance with the unit
data plate. LP for LP units. Natural gas
for natural gas units. These units are not
certified for any other fuel type.
● LP appliances should not be installed
below grade (for example, in a basement)
if such installation is prohibited by
federal, state and/or local laws, rules,
regulations or customs.
● LP gas must be used with great caution.
It is heavier than air and will collect first
in lower areas making it hard to detect at
nose level.
DANGER: If a gas leak is present or
suspected:
● Do not attempt to find the cause
yourself.
● Do not try to light any appliance.
● Do not touch any electrical switch.
● Do not use any phone in your building.
● Leave the house immediately and make
sure your family and pets leave also.
● Leave the doors open for ventilation
and contact the gas supplier, a qualified
service agency or the fire department.
● Stay away from the house (or building)
until the service call has been made, the
leak is corrected and a qualified agency
has determined the area to be safe.
● Before attempting to light the water
heater, make sure to look and smell for
gas leaks. Use a soapy solution to check
all gas fittings and connections. Bubbling
at a connection indicates a leak that must
be corrected. When smelling to detect a
gas leak, be sure to sniff near the floor
also.
● Gas detectors are recommended in LP
& natural gas applications and their
installation should be in accordance
with the detector manufacturer’s
recommendations and/or local laws,
rules, regulations or customs.
● It is recommended that more than one
method, such as soapy solution, gas
detectors, etc., be used to detect leaks in
gas applications.
5
IMPORTANT SAFETY INFORMATION.
!
READ ALL INSTRUCTIONS BEFORE USING
WARNING!
For your safety, the information in this manual must be followed to minimize the risk of
fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of
life.
FOR INSTALLATIONS IN THE STATE OF CALIFORNIA
California Law requires that residential water heaters must be braced, anchored or
strapped to resist falling or horizontal displacement due to earthquake motions. For
residential water heaters up to 52-gallon capacity, a brochure with generic earthquake
bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street,
Suite 5100, Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater
dealer.
SAFETY PRECAUTIONS
Have the installer show you the location of the gas shut-off valve and how to shut it off
if necessary. Turn off the manual shut-off valve if the water heater has been subjected to
overheating, fire, flood, physical damage or if the gas supply fails to shut off.
● Read this manual entirely before installing
or operating the water heater.
● Use this appliance only for its intended
purpose as described in this Use and Care
Manual.
● Be sure your appliance is properly installed
in accordance with local codes and the
provided installation instructions.
● Do not attempt to repair or replace any part
of your water heater unless it is specifically
recommended in this manual. All other
servicing should be referred to a qualified
technician.
READ AND FOLLOW THIS SAFETY INFORMATION
CAREFULLY.
SAVE THESE INSTRUCTIONS
IMPORTANT
Carefully inspect the water heater for damage before proceeding with the installation. Of specific
interest should be any dents in the long blue cover panel for the combustion air-inlet, PVC pipe; or
damages to the blower and the combustion air-inlet, PVC pipe assembly. If you find damage, DO
NOT install or attempt any repair to the water heater. Contact the manufacturer as detailed under "IF
YOU NEED SERVICE" on page 36
6
Installing the Water Heater
!
This water heater must be installed in accordance with these instructions, local codes, utility company
requirements, and/or in the absence of local codes, use the latest edition of the American National
Standard/National Fuel Gas Code. A copy can be purchased from either the American Gas Association,
400 N. Capitol Street NW, Washington, DC 20001 as ANSI standard Z223.1 or National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269 as booklet NFPA 54.
Location
Max.
2.75 in.
(7 cm)
Flammable
Vapor
Sensor
The auxiliary catch pan
installation MUST conform
with local codes.
Diameter of water
heater plus 2 in.
(5.1 cm) min.
Notice: DO NOT allow
the catch pan to obstuct
the flammable vapor
sensor.
Notice: DO NOT allow
the flammable vapor
sensor to become
submerged in water.
Make sure the catch pan
is properly drained.
WARNING: Combustible
construction refers to
adjacent walls and ceilings
and should not be confused
with combustible or
flammable products and
materials. Combustible
and/or flammable products
and materials should never
be stored in the vicinity of
this or any gas appliance.
The water heater should not be located in an
area where leakage from the tank or connections
will result in damage to the area adjacent to the
heater or to lower floors of the structure.
When such areas cannot be avoided it is recommended that a suitable catch pan, adequately
drained, must be installed under the water
heater.
The water heater must be centered in the catch
pan.
Catch pan kits are available from the store
where the water heater was purchased, or any
water heater distributor.
Make certain the floor underneath the water
heater is strong enough to sufficiently support
the weight of the water heater once it is filled
with water.
This gas fired water heater or any other appliance should not be installed in a space where
liquids which give off flammable vapors are
to be used or stored. Such liquids include
gasoline, LP gas (butane or propane), paint or
adhesives, thinners, solvents and/or combustible
removers.
DO NOT obstruct or block the Flammable
Vapor Sensor.
Because of natural air movement in a room or
other enclosed space, flammable vapors can
be carried some distance from where liquids
which give off flammable vapors are to be used
or stored. The open flame of the water heater’s
main burner can ignite these vapors creating a
shut down condition which will not allow the
water heater to ignite.
The water heater must be located so it is not
subject to physical damage, for example, by
moving vehicles, area flooding, etc.
Rheem Water Heating FVIR certified gas water
heaters can be installed on a residential garage
floor without the use of an 18-inch stand in
accordance with the National Fuel Gas Code,
NFPA 54, ANSI Z223.1, unless otherwise directed by State and Local code requirements. The
water heater must be located so it is not subject
to physical damage, for example, by moving
vehicles, area flooding, etc
● The water heater should be installed so as
to minimize the length of plastic vent pipe
and the number of vent connection fittings
required.
● Hot water lines should be insulated to conserve water and energy.
● Protect the water heater and water lines from
exposure to freezing temperatures.
● Do not install this water heater outdoors.
● Minimum clearances from combustible con-
struction:
Front✶
5 in.
(12.7 cm)
✶ "Front" Clearance dimension is measured
from the water heater jacket to the closet
door.
✶✶ "Top" clearance dimension is measured
from the jacket top of the water heater to
the ceiling.
● If the water heater is to be installed directly on
carpeting , the water heater shall be installed
on a metal or wood panel extending beyond
the full width and depth of the water heater
by at least 3 in. (7.6 cm) in all directions or, if
the water heater is to be installed in an alcove
or closet, the entire floor must be covered by a
wood or metal panel.
Sides Rear
0 in.
(0 cm)
0 in.
(0 cm)
Top✶✶
12 in.
(30.5 cm)
7
Installing the Water Heater
Corrosive Atmospheres
NOTICE: The water heater
must not be installed near
an air supply containing
halogenated hydrocarbons.
The air in beauty shops, dry cleaning
establishments, photo processing labs,
and storage areas for liquid and powdered
bleaches or swimming pool chemicals
often contain halogenated hydrocarbons.
An air supply containing halogenated
hydrocarbons may be safe to breathe,
but when it passes through a gas flame
corrosive elements are released that
Thermal Expansion
Determine if a check valve exists in the inlet
water line. Check with your local water utility company. It may have been installed in
the cold water line as a separate back flow
preventer, or it may be part of a pressure
reducing valve, water meter or water softener.
A check valve located in the cold water inlet
line can cause what is referred to as a “closed
water system”. A cold water inlet line with no
check valve or back flow prevention device is
referred to as an “open” water system.
As water is heated, it expands in volume and
creates an increase in the pressure within the
water system. This action is referred to as
“thermal expansion”. In an “open” water system, expanding water which exceeds the capacity of the water heater flows back into the city
main where the pressure is easily dissipated.
A “closed water system”, however, prevents
the expanding water from flowing back into
the main supply line, and the result of “thermal
expansion” can create a rapid and dangerous
pressure increase in the water heater and sys-
will shorten the life of any gas burning
appliance.
Propellants from common spray cans
or gas leaks from A/C and refrigeration
equipment are highly corrosive after passing through a flame.
The water heater warranty is voided when
failure of the heater is due to operation in
a corrosive atmosphere.
tem piping. This rapid pressure increase can
quickly reach the safety setting of the relief
valve, causing it to operate during each heating
cycle. Thermal expansion, and the resulting
rapid, and repeated expansion and contraction
of components in the water heater and piping
system can cause premature failure of the relief
valve, and possibly the heater itself. Replacing
the relief valve will not correct the problem!
The suggested method of controlling thermal
expansion is to install an expansion tank in
the cold water line between the water heater
and the check valve (see illustration on page
9). The expansion tank is designed with an air
cushion built in that compresses as the system
pressure increases, thereby relieving the over
pressure condition and eliminating the repeated
operation of the relief valve. Other methods of
controlling thermal expansion are also available. Contact your installing contractor, water
supplier or plumbing inspector for additional
information regarding this subject.
IMPORTANT: Do not apply
heat to the HOT or COLD
water connections. If sweat
connections are used, sweat
tubing to adapter before
fitting adapter to the cold
water connections on heater.
Any heat applied to the cold
water supply fittings will
permanently damage the
dip tube and heat traps.
8
Water Supply Connections
Refer to the illustration below for suggested
typical installation. The installation of unions
or flexible copper connectors are recommended
on the hot and cold water connections so that
the water heater may be easily disconnected
for servicing if necessary. The HOT and COLD
water connections are clearly marked and are
3/4” NPT on all models. Install a shut-off valve
in the cold water line near the water heater.
NOTICE: The National
Fuel Gas Code (NFGC)
mandates a manual gas
shut-off valve: See (NFGC)
for complete instructions.
Local codes or plumbing
authority requirements
may vary from the instructions or diagrams provided
and take precedent over
these instructions.
Typical Installation
Vent connector
Union (Optional)
Heat trap
6 in. (15.2 cm) min.
Hot water outlet to
fixtures
Water Heater Jacket
Temperature and pressure
relief valve
Manual gas shut-off
To gas supply
Union
Sediment trap
Cap
Thermostatic gas valve
Jacket door
Flammable Vapor Sensor
Optional catch pan
(if required).
Drain Pan Pipe
to suitable drain.
1/8 in. per foot (10 mm per meter)
maximum slope down for horizontal
venting.
Combustion Air-In Connector
Blower assembly
Union (Optional)
Heat trap
6 in. (15.2 cm) min.
Shut-off
valve
Thermal expansion
tank (if required)
Drain
valve
6 in. (15.2 cm) min. Air gap
To cold water
supply
Shut-off valve
Relief valve discharge
line to suitable open
drain.
A new combination temperature and pressure relief valve, complying with the Standard for Relief Valves
and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22 /CSA 4.4, is factory
installed and must remain in the opening provided and marked for the purpose on the water heater. No
valve of any type should be installed between the relief valve and the tank. Local codes shall govern the
installation of relief valves.
Relief Valve
The pressure rating of the relief valve
must not exceed 150 PSI psi (1,034 kPA),
the maximum working pressure of the
water heater as marked on the rating plate.
The Btuh rating of the relief valve must
equal or exceed the Btuh input of the
water heater as marked on its rating plate.
Position the outlet of the relief valve
above a suitable open drain to eliminate
potential water damage. Piping used
should be of a type approved for hot water
distribution.
The discharge line must be no smaller
than the outlet of the valve and must pitch
downward from the valve to allow complete drainage (by gravity) of the relief
valve and discharge line.
The end of the discharge line should not
be threaded or concealed and should be
protected from freezing. No valve of any
type, restriction, or reducer coupling must
be installed in the discharge line.
9
Installing the Water Heater
To Fill the Water Heater
WARNING: The tank
must be full of water before
the water heater is turned
on. The water heater
warranty does not cover
damage or failure resulting
from operation with an
empty or partially empty
tank.
Make certain that the drain valve is
closed, then open the shut-off valve in the
cold water supply line.
Open each hot water faucet slowly to
allow the air to vent from the water
heater and piping.
Condensation
Condensation can form on the tank
when it is first filled with water.
Condensation might also occur with a
heavy water draw and very cold inlet
water temperatures.
Drops of water falling on the burner can
produce a sizzling or pinging sound.
This condition is not unusual, and will
disappear after the water becomes heated.
A steady flow of water from all hot water
faucet(s) indicates a full water heater.
Do not allow the flammable vapor sensor
to become submerged in water.
If, however, the condensation continues,
examine the piping and fittings for possible leaks.
NOTICE: Additional information on this
subject may be found at www.rheem.com,
under Rheem Water Heating, "Support",
scroll down to the Technical Service
Section and to Bulletins 1400 Series
Section and choose Bulletin #1402.
WARNING: Do not
attempt to convert this water
heater for use with a
different type of gas other
than the type shown on the
rating plate. Such conversion
could result in hazardous
operating conditions.
Gas Supply
The branch gas supply line to the water
heater should be clean properly sized steel
pipe or other approved gas piping material.
A union or ANSI design certified semirigid or flexible gas appliance connector
should be installed in the gas line close to
the water heater. The National Fuel Gas
Code (NFGC) mandates a manual gas
shut-off valve: See (NFGC) for complete
instructions.
If flexible connectors are used, the maximum length shall not exceed
36" (91.4 cm) and must meet the requirements in ANSI Z21.24/CSA 6.10Connectors for Gas Appliances.
Compound used on the threaded joints of
the gas piping must be of the type resistant
to the action of LP gas. Use compound
sparingly on male threads only.
Where a sediment trap is not incorporated as part of the appliance, a sediment
trap shall be installed downstream of the
equipment shutoff valve as close to the
inlet of the appliance as practical at the
time of the appliance installation.
The sediment trap shall be either a tee fitting with a capped nipple in the bottom
outlet or other device recognized as an
effective sediment trap.
”Do not use excessive force over 31.5 ft.
lbs. (42.7 Nm) in tightening the pipe joint
at the combination gas control inlet, particularly if teflon pipe compound is used,
as the valve body may be damaged.
The inlet gas pressure to the water heater
must not exceed 14.0 in. w.c. (3.5 kPa)
w.c. for natural gas, or 14.0 in. w.c. (3.5
kPa) w.c. for LP gas. For purposes of
input adjustment, the minimum inlet gas
pressure (with main burner on) is shown
on the water heater rating plate. If high or
low gas pressures are present, contact your
gas supplier for correction.
10
WARNING: Never use
!
an open flame to test for
gas leaks, as property
damage, personal injury, or
death could result.
Leak Testing
The water heater and its gas connections
must be leak tested at normal operating
pressures before it is placed in operation.
Turn on the manual gas shut-off
valve near the water heater.
Use a soapy water solution to test for
leaks at all connections and fittings.
Bubbles indicate a gas leak that must
be corrected.
The factory connections to the combination gas control should also be leak tested
after the water heater is placed in operation.
Pressure Testing the Gas Supply System
The water heater and its individual shutoff valve must be disconnected from the
gas supply piping system during any
pressure testing of that system at test
pressures in excess 1/2 psi (3.5 kPA).
The water heater must be isolated from
the gas supply piping system by closing
its individual manual gas shutoff valve
during any pressure testing of the gas
supply at test pressures equal to or less
than 1/2 psi (3.5 kPa).
WARNING: Failure to
install a water heater suitable
for the altitude at the location
it is intended to serve, can
result in improper operation
of the appliance resulting
in property damage and/or
producing carbon monoxide
gas, which could result in
personal injury, or death.
DANGER: Failure to
properly install the vent and
combustion air-inlet systems as
outlined in the Vent and
Combustion Air-Inlet section of
this manual will result in
unsafe operation of the water
heater causing bodily injury,
explosion, fire or death.
To avoid the risk of fire,
explosion, or asphyxiation from
carbon monoxide, NEVER
operate the water heater unless
it is properly vented and the
vent and combustion air-inlet
systems are properly installed
as detailed in the "Vent and
Combustion Air-Inlet" section
of this manual.
The vent and combustion air
inlet pipes must overlap a
minimum of 1/2 in. (1.3 cm)
at each joint. It is important
that the vent and combustion
air-inlet pipes engage fully into
any pipe fitting and be kept in
that position until the adhesive
has fully cured. DO NOT drill
or punch holes in the plastic
pipe or fittings.
High Altitude
Input rating of this water heater is based
on sea level operation. At higher elevations the actual input rate may be lower
than the value listed on the rating label
due to the derating of Natural Gas and LP
Gas. For Power Direct Vent models listed
in the venting tables that do not show
Vent and Combustion Air-Inlet
This water heater is a direct vent appliance and must be installed so that all air
for combustion is derived directly from
the outside atmosphere and all flue gases
are discharged to the outside atmosphere.
For proper installation of the vent and
combustion air-inlet systems, follow the
instructions as detailed in this manual.
DO NOT connect this water heater to
an existing vent or chimney - it must be
vented separately from all other appliances.
NOTICE: This water heater is approved
to use the following materials for pipe of
the vent and Combustion Air-Inlet systems:
PVC (Schedule 40, Cellular Core,
ASTM-F891)
PVC (DWV, ASTM-D2665 or CSA
B181.2)
PVC (Schedule 40, ASTM-D1785 or CSA
B137.3)
PVC (SDR Series, ASTM-D2241 or CSA
B137.3)
venting configurations above 7,700 ft.
(2,347 m), contact the water heater manufacturer for a required High Altitude Kit
that will allow the specific water heater
model to operate at altitudes between
7,700 ft. (2,347 m) and 10,200 ft. (3,109
m),(see page 40).
CPVC (CPVC 4120, ASTM-D2846 or
CSA B137.6)
CPVC (Schedule 40, ASTM-F441 or CSA
B137.3)
CPVC (SDR Series, ASTM-F442)
ABS (Schedule 40, DWV, ASTM-D2661
or CSA B181.1)
ABS (Schedule 40, DWV, Cellular Core,
ASTM-F628)
This water heater is approved to use the
following materials for the fittings of the
vent and combustion air-intake systems:
PVC (Schedule 40 DWV, ASTM D2665)
CPVC (Schedule 40, ASTM F438)
ABS (Schedule 40 DWV, ASTM D2661)
DO NOT mix ABS pipe and fittings
with PVC or CPVC pipe fittings. Note:
It is acceptable to interchange PVC and
CPVC pipe and fittings.
Vent and combustion air-inlet systems
must be adequately supported along both
vertical and horizontal lengths.
11
Installing the Water Heater
Vent and Combustion Air-Inlet continued -
The vent and combustion air-inlet
NOTICE: This unit
is equipped with a
Flammable Vapor Sensor.
Do not supply electrical
power to the water heater
until enough time has
passed to allow the vapors
from the primer and
cement to dissapate.
systems of this water heater may be
installed horizontally through a wall or
vertically through the roof
Maximum unsupported length is recommended to be no more than 4 feet
(1.22 m).
It is imperative that the first hanger be
located on the horizontal length immediately adjacent to the first
90-degree elbow from the vertical rise
of vent pipe connected to the water
heater.
The support method used should
isolate the vent and combustion airinlet pipes from floor joists or other
structural members to help prevent the
transmission of noise and vibration.
Do not support, pin or otherwise secure
the vent and combustion air-inlet systems 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
direct vent water heater, a thorough
inspection of the existing vent and
combustion air-inlet systems must be
performed prior to any installation
work.
.
Verify that the correct materials as
specified in this manual have been
used, and that the minimum or maximum vent and combustion air-inlet
lengths and terminal locations as
detailed in this manual have been
met.
Carefully inspect the entire vent and
combustion air-inlet systems for any
signs of cracks or fractures, particularly at the joints between elbows or
other fittings and the straight length
of vent pipe.
Check the vent and combustion air-
inlet for signs of sagging or other
stresses in the joints as a result of
misalignment of any components in
the systems.
If any of the conditions above are
found, they must be corrected in
accordance with the instructions in
this manual before completing the
installation and putting the water
heater into service.
Additional installation information for The Commonwealth of Massachusetts is located on the
back page of this manual.
12
Maximum and Minimum Vent and Combustion Air-Inlet
Lengths for Power Direct Vent Models:
40 Gallon with Inputs of 40,000 & 38,000 BTU/Hr.
50 Gallon with Input of 40,000 BTU/Hr.
Connect the vent system piping to the
blower assembly using the already
installed 2 in. (5.1 cm) diameter rubber coupling and clamps. Connect
the combustion air-inlet system piping to the combustion air-inlet piping
tee using the 2 in. (5.1 cm) already
installed rubber coupling and clamps
(See Figure 1). For vent and combustion air-inlet terminals, use the two (2),
2 in. (5.1 cm) diameter, Schedule 40,
PVC, 90°, 1/4 standard bend elbows
and wire mesh screen assemblies supplied with the water heater.
This water heater may also be installed
with 3 in. (7.6 cm) diameter pipe and
fittings for the vent and combustion
air-inlet systems. When using 3 in.
(7.6 cm) diameter pipe, two (2), 2 in.
(5.1 cm) to 3 in. (7.6 cm) diameter
pipe increaser fittings are required for
connection of the vent system piping to
the blower assembly and combustion
air-inlet system piping to the combustion air-inlet piping tee couplings (See
Figure 2). For vent and combustion
air-inlet terminals, 3 in. (7.6 cm)
diameter, Schedule 40, PVC, 90°, 1/4
standard bend elbows (not supplied)
along with the two (2) wire mesh
screens (supplied) must be installed.
DO NOT use unequal sizes except as
defined previously for the vent and
combustion air-inlet systems.
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