Rudd GP100-250 Installation Manual

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Page 1

Commercial Power Direct Vent Water Heater

CERTIFIED

USE & CARE MANUAL

WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR

MULTI-FLUE COMMERCIAL MODELS

Recognize this symbol as an Indication of Important Safety Information!

NOTICE: This water heater is designed for use in a commercial application and the installation and maintenance of it should be performed by a qualified, licensed service personnel. If the foregoing assumption is not appropriate, then we recommend that you obtain and retain our Residential Use & Care Manual.

CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING: If the information in these instructions are 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.

Do Not Destroy this Manual. Please read carefully and keep in a safe place for Future Reference.

Immediately call your gas supplier from a neighbor's

•

phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire

•

department.

Do not return to your building until authorized by

•

the gas supplier or fire department.

— Improper installation, adjustment, alteration, service

or maintenance can cause injury, property damage or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Printed in USA

AP13463-3 (02/07)

Page 2

TABLE OF CONTENTS

Safety Information

Safety Precautions . . . . . . . . . . . . . . . 3-4, 16

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.

Introduction

Local Installation Regulations . . . . . . . . . . 5

Water Heater Location . . . . . . . . . . . . . . . . . 5

Installation Instructions

Inspect Shipment . . . . . . . . . . . . . . . . . . . . . 6

Water Supply Connections . . . . . . . . . . . . . 6

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . 7

Vent Installation . . . . . . . . . . . . . . . . . . . 8 - 12

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation Checklist . . . . . . . . . . . . . . . . . 13

Operating Instructions

Lighting Instructions . . . . . . . . . . . . . . 14-15

Water Temperature . . . . . . . . . . . . . . . . . . . 16

Emergency Shut Down . . . . . . . . . . . . . . . 17

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

situation that will result in

death or serious injury.

WARNING

situation that could result in death or serious injury and/or damage to property.

CAUTION

situation that may result in minor or moderate injury.

Notice:

a specified procedure or maintain a specific condition.

An imminently hazardous

A potentially hazardous

Attention is called to observe

Care and Cleaning

Burner Inspection . . . . . . . . . . . . . . . . . . . 17

Venting Inspection . . . . . . . . . . . . . . . . . . . 17

Routine Maintenance . . . . . . . . . . . . . . . . . 18

Anode Inspection . . . . . . . . . . . . . . . . . . . . 18

Seasonal Operation . . . . . . . . . . . . . . . . . . 18

Troubleshooting

System Sentinel Diagnosis. . . . . . . . . 20- 24

Customer Service

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wiring Diagrams . . . . . . . . . . . . . . . . . . 26-27

How to Obtain Service Assistance . . . . . 28

Page 3

General Safety Precautions

D A N G E R

HOT

Water temperature over 125°F 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.

BURN

DANGER

140

THERMOST AT

To meet commercial water use needs, the thermostat on this water heater is adjustable up to 180°F. However, water temperatures over 125°F. can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying general purpose hot water.

Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat. The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application.

The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

Temperature Time to Produce Serious Burn

120° F More than 5 minutes

125° F 1

/2 to 2 minutes

130° F About 30 seconds

135° F About 10 seconds

140° F Less than 5 seconds

145° F Less than 3 seconds

150° F About 1

/2 seconds

155° F About 1 second

Table cour tesy of Shriners Bu rn Institute

TIME / TEMPERATURE RELATIONSHIPS IN SCALDS

The temperature of the water in the heater can be regulated by setting the temperature dial on front of the thermostat. To comply with safety regulations the thermostat was set at its lowest setting before water heater was shipped from the factory. The illustration below illustrates the thermostat and how to adjust the water temperature.

Maximum water temperatures occur just after burner has shut off. To find hot water temperature being delivered, turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer.

To adjust the water temperature, insert a small straight

screwdriver into slotted screw in hole in front of ther-

mostat and turn wheel to desired setting. Thermostat

is adjustable up to 180º F.

CAUTION!! - Hotter water increases the risk of SCALDING!

Honeywell

White-Rodgers

NOTICE: Each water heater will contain one (1) of the above thermostats. Refer to actual unit to determine which one.

Hotter water increases the Potential for Hot Water SCALDS.

NOTICE: Mixing valves are available for reducing point of use water temperature by mixing and cold water in branch water lines Contact a licensed plumber or the local plumbing authority for further information.

Page 4

General Safety Precautions

DANGER

WARNING

DANGER

WARNING

D A N G E R

FLAMMABLES

Flammable Vapors

Vapors from flammable liquids will 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.

Water heater has a main burner and pilot flame. The pilot flame:

1. which can come on at any time and

2. 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 pilot

flame by air currents.

Installation: Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames

are at least 18" above the floor. This will reduce, but not eliminate, the risk of vapors being ignited by the main burner or pilot flame.

Read and follow water heater warnings and instructions. If owners manual is missing, contact the retailer or manufacturer.

Be sure to read and understand the entire Use & Care Manual before attempting to install or operate this water heater. Pay par ticular attention to the following General Safety Precautions. Failure to follow these warnings could result in a fire or explosion, causing proper ty damage, bodily injur y or death . Should you have any problems understanding the instructions in this manual, STOP, and get help from a qualified installer or ser vice technician or the gas supplier.

Gasoline, as well as other flammable materials and liquids

(adhesives, solvents, etc.), and the vapors they produce,

are extremely dangerous. DO NOT handle, use or store

gasoline or other flammable or combustible materials any-

where near or in the vicinity of a water heater. Be sure to

read and follow the 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 dam-

age, bodily injury, or death.

Failure to properly vent the water heater to the outdoors

as outlined in the Venting Section of 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 it is properly vented

and has an adequate air supply for proper operation. Be

sure to inspect the vent system for proper installation at

initial start-up; and at least annually thereafter. Refer to

Maintenance section of this manual for more information

regarding vent system inspections.

LIQUEFIED PETROLEUM MODELS — Propane, or 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.

•

Make sure to look and smell for LP leaks before attempting to light appliance. 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 an LP leak, be sure to sniff near the floor too.

• Gas detectors are recommended in LP applications and their installation should be in accordance with the manufacturer's recommendations and/or local laws, rules, regulations or customs.

• It is recommended that more than one method be used to detect leaks in LP applications.

IF LP GAS 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.

• Keep the area clear until the service call has been made, the leak is corrected, and a qualified agency has determined the area to be safe.

Both LP and natural gas have an odorant added to help detection. Some people may not physically be able to smell or recognize this odorant. If unsure or unfamiliar about the smell associated with LP or natural gas, ask the gas supplier. Other conditions, such as "Odorant Fade", which causes the odorant to "fade", or diminish in intensity can also hide or camouflage a gas leak.

Water heaters utilizing Liquefied Petroleum gas (LP) are different from natural gas models. A natural gas heater will not function safely on LP gas and vice versa. No attempt should ever be made to convert a heater from natural gas to LP gas. To avoid possible equipment damage, personal injury or fire: DO NOT connect this water heater to a fuel type not in accordance with unit data plate. Propane for propane units. Natural gas for natural gas units. These units are not certified for any other type fuel.

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.

Page 5

Introduction

WARNING

CAUTION

Read and Review this entire Manual with special emphasis on the Venting Sections (Pages 8-12) and Operation Section (Pages 14-17) prior to any installation work.

LOCAL INSTALLATION REGULATIONS This water heater must be installed in accordance with these instructions, local codes, utility company requirements and/or, in the absence of local codes, the latest edition of the National Fuel Gas Code, ANSI Z223.1 in the United States, or CGA/CAN B149 Installation Codes in Canada.

LOCATION A. This water heater is of the direct vent design. All air for combustion

and all products of combustion are routed through the venting system, directly from and to the outside of the building.

The water heater should be installed in a clean, dry location as close

as practical to the gas vent terminals. Long hot water lines should be insulated to conser ve water and energy. The water heater and water lines should be protected from exposure to freezing temperatures.

B. A gas fired water heater 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 and propane), paint or adhesives and their thinners, solvents or removers. Because of natural air movement in a room or other enclosed space, flammable vapors can be carried some distance from where their liquids are being used or stored. The open flame of the water heater’s intermittent pilot or main burner can ignite these vapors causing an explosion or fire which may result in severe burns or death to those in range, as well as proper ty damage. For these reasons, installation of a gas fired water heater in a garage is not desirable.

If a location in a garage is the only alternative, the gas water heater should be installed so that the open flame of the pilot and main burner are no less than 18 inches above the garage floor. The water heater must be located or protected so it is not subject to physical damage by moving vehicles or area flooding. Raising the gas fired water heater will reduce BUT NOT eliminate the possibility of lighting the vapor of any flammable liquids which may be improperly stored or accidentally spilled.

C. All models are cer tified for installation on combustible floors and in

alcoves. The minimum side and top clearance to walls and ceiling for providing protection of combustible materials are shown on the water heater’s rating label. A front clearance of 18 inches (46 cm) should be provided for adequate inspection and servicing.

If the water heater must be installed on carpeting, place a metal or

wood panel beneath water heater extending beyond its full width and depth at least 3 inches (7.6 cm) in all directions. If the water heater is installed in an alcove, the entire floor must be covered by the panel.

The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adjacent

to it or to lower floors of the structure. When such areas cannot be avoided, it is recommended that a suitable catch pan, adequately drained, be installed under the water heater. The pan MUST NOT restrict the flow of combustion air flow to bottom of water heater.

NOTICE: Auxiliary catch pan installation MUST conform to the ap -

plicable local codes.

D. RESTAURANTS — If the water heater is to be installed in a restau-

rant or other location where the floor is frequently cleaned, it must be elevated to provide at least six inches (15 cm) of clearance from the floor to comply with NSF International recommendations.

E. CORROSIVE ATMOSPHERES — The heater should not be installed

near an air supply containing halogenated hydrocarbons. For example, the air in beauty shops, dry cleaning establishments, photo processing labs, and storage areas for liquid and powdered bleaches or swim pool chemicals often contain such hydrocarbons. The air there may be safe to breathe, but when it passes through a gas flame, corrosive elements are released that will shorten the life of any gas burning appliance. Propellants from common spray cans or gas leaks from refrigeration equipment are highly corrosive after passing through a flame. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (Refer to the Certificate of Limited Warranty for complete terms and conditions.)

Page 6

Installation

WARNING

The manufacturer’s warranty does not cover any damage or defect caused by installation, or attachment, or use of any special attachment such as energy saving devices (other than those authorized by the manufacturer) into, onto, or in conjunction with the water heater. The use of such unauthorized devices may shorten the life of the water heater and may endanger life and property. The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices.

1. INSPECT SHIPMENT — for possible damage. The manufacturer’s responsibility ceases upon delivery of goods to the carrier in good condition. Any claims for damage, shortage in shipments, or non delivery must be filed immediately against carrier by consignee.

2. THERMAL EXPANSION — Determine if a check valve exists in the inlet water line. 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 ”ther mal 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 system 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. 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.

If a recirculation line is installed, the return connection should be made

to a tee close to the inlet connection on the water heater. A check valve should always be installed in the recirculation line to prevent cold water from entering.

WATER CONNECTIONS — This water heater may be connected indi-

vidually, in multiples with others, or with an external hot water storage tank.

Inlet water connections are made to the lower coupling on the heater,

and outlet water connections are made to the upper coupling.

Each water heater is supplied with the necessary components (Diffuser

tubes) to make the water connections that will ensure proper performance. The components are supplied in a bag attached to the water

heater. If special instructions are required for any specific water heater, they will be included in the bag.

Cap or plug unused connections. Use only clean, new galvanized steel,

copper or approved plastic pipe for water connections. Local codes or regulations shall govern the exact type of material to be used. The installation of unions on the inlet and outlet water lines and a shut-off valve in at least the cold water inlet line is recommended, so the water heater may be easily disconnected for servicing. Dielectric unions are not required for protection of water heater.

When this water heater is supplying general purpose hot water require-

ments for use by individuals, a thermostatically controlled mixing valve is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for fur ther information.

Thermometer(s) should be installed so that they indicate the tempera-

ture of the water at or near the outlet of the water heater and storage tank(s) if provided. See Fig. 4 on page 7.

3. RELIEF VALVE — A new factory installed combination pressure and temperature relief valve, complying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22, or Standard CAN1-4.4, Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves is provided with the water heater. No valve is to be placed between the relief valve and the water heater. For a circulating tank installation, the separate storage tank(s) must have similar protection. The pressure rating of the relief valve must not exceed 150 psi (160 psi for ASME models), the maximum working pressure as marked on front of the water heater.

The Btu/h rating of the relief valve must equal or exceed the Btu/h input

of the water heater as marked on its rating plate.

Connect the outlet of the relief valve to a suitable open drain. The

discharge line must pitch downward from the valve to allow complete draining (by gravity) of the relief valve and discharge line, and be no smaller than the outlet of the valve. 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 should be installed in the discharge line. Local codes shall govern the installation of relief valves.

4. GAS SUPPLY — The inlet gas pressure to the water heater must not exceed 10.5” w.c. (2.6 kPa) for Natural gas. For purposes of input adjustment, the minimum inlet gas pressure (with main burner on) is shown on the rating plate. Check to see if high or low gas pressure is present and

then contact the gas company for correction.

The gas line should be of adequate size to prevent undue pressure

drop. Sizing based upon Table 1 (on pg. 13) is recommended. No additional allowance is necessary for an ordinary number of fittings.

A ground joint union and manual shutoff valve should be installed in

the gas line near the water heater so that the burner assembly may be easily removed. The shut-off valve must be readily accessible for turning on or off. See Fig. 4 on page 7.

A sediment trap must be installed at the bottom of the gas line. See

Fig. 4 on page 7.

LEAK TESTING — The water heater and its gas connections MUST

be leak tested at normal operating pressure 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 gas leaks at all connections and fittings. Bubbles indicate a gas leak that must be corrected. The water heater factory connections to the gas valve should also be leak tested after placing the water heater in operation.

Page 7

SYSTEM SENTINEL

POWER

THERMOSTAT

IGNITION

PILOT VALVE

MAIN VALVE

ECO

Installation

Vacuum Relief Valve

(Not Supplied)

If required, install per local codes

and valve manufacturer’s

instructions.

Cold Water

Inlet

Valve

Shut-Off

Hot Outlet

supported and aligned to minimize loads

(forces) on the water heater’s gas valve

and burner system.

lines for the Thermal Expansion Tank (if

required).

NOTES:

1.) The gas supply piping must be adequately

2.) Refer to local codes for installation guide

(if required)

Ther mal Expansion Tank

Figure 4. — Typical Installation Drawing.

Relief Valve

Refer to Venting section

Temperature & Pressure

Air Gap 6"

on pages 8-11 in this manual.

Gas

Supply

Gas Valve

Cap

Gas

Manual

Shut-Off

Ther mostat

Sediment Trap

Ground Joint Union

Page 8

Installation

WARNING

Outlet

Vent Connection

Inlet

Vent Connection

NEVER use open flame to test for gas leaks, as bodily injury or property damage could result.

PRESSURE TESTING THE GAS SUPPLY SYSTEM — The water

heater and its manual gas shut-off valve MUST be dis connect ed from the gas supply piping system during any h ig h pressure testing o f t h a t sy s t e m at pr e s s u r e s i n exc ess o f 1/ 2 ps i (14” w.c. / 3.5 kPa).

The water heater MUST be isolat ed from the gas piping system

by closing the manual gas shut-off valve during any pressure testing of the gas supply piping at pressures equal to or les s than 1/2 psi (14” w.c. / 3.5 kPa).

5. VENTING —

The water heater must be vented to the outdoors as described in these instructions. DO NOT connect this water heater to an existing Vent or Chimney it 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. Maximum unsupported span is recommended to be no more than 4 feet. It is imperative that the first hanger be located on the horizontal run immediately adjacent to the first 90-degree elbow from the vertical rise or at the blower outlet in the case of a horizontal blower position. Support method used should isolate the vent pipe from floor joists or other structural members to help 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 water heater, a thorough inspection of the existing venting system must be performed prior to any installation work. Verify that the correct materials, as detailed above have been used, and that the minimum or maximum vent length and terminal locations as detailed in this manual have been met. Carefully inspect the entire venting system for any signs of cracks or fractures, particularly at the joints between elbows or other fittings and the straight runs of vent pipe. Check the system for signs of sagging or other stresses in the 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 the installation and putting the water heater into service.

VENT PIPE CONNECTION —

Failure to properly vent the water heater to the outdoors as outlined above and in the following section can 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 this water heater unless it is properly vented and has an adequate air supply for proper operation. The vent pipe must overlap a minimum of ½" on each connection. It is important that the vent pipe engages 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.

NOTI C E : This unit can be ven t e d u s ing only the fo l l owin g

recommended pipe material. Use only 3- or 4-inch diameter pipe.

PVC (Schedule 40, ASTM D-1785)

CPVC (Schedule 40, ASTM F-441) ABS (Schedule 40, ASTM D-2661)

The fittings, other than the VENT TERMINAL, should be equivalent to the following:

PVC (Schedule 40 DWV, ASTM D-2665)

CPVC (Schedule 40 DWV, ASTM F-438) ABS (Schedule 40 DWV, ASTM D-2661)

Figure 5. — Vent Pipe Connection Locations

The blower assembly is preinstalled at the factory, so all that is required

for connecting the vent system is attaching the vent pipe to the blower and the PVC Tee. Before starting the vent installation, careful planning should be given to the routing and termination of the vent pipe. The length of the vent pipe (inlet and outlet) should be kept to a minimum. Also, see page 10 & 12 for vent terminal placement. The GP100-150 & GP100-200 model can be vented using either 3 inch or 4 inch Schedule 40 PVC pipe and fittings.

To use 3 inch PVC, you can connect directly to the blower outlet (rubber

coupling provided for outlet connection) and PVC Tee. Make sure that clamps on rubber coupling are tight, after the pipe is installed. The inlet vent pipe should be cemented into the PVC Tee.

If 4 inch PVC pipe is going to be used, then it will be necessary to have

a short piece ( at least 3 inches long ) of 3 inch PVC pipe to join into the coupling and tee. Then a 4 X 3 reducer would need to be joined to the short piece of pipe, so that the 4 inch pipe could be used. The 4 inch pipe will then need to be stepped back down, using a 4 X 3 reducer, to 3 inch PVC. To install the vent terminals, a short length of 3 inch (maximum of 16 inches long) pipe will need to be used. (Refer to Figure 9b on page

10.)

The GP100-250 model can only be vented using 4 inch Schedule 40 PVC

pipe and fittings. The 4 inch pipe can be connected directly to the blower coupling and 4 inch tee.

Page 9

MINIMUM AND MAXIMUM VENT LENGTHS

Charts are for installation from 0 - 2000 ft. elevation ONLY. (Please see supplement sheet for installations above 2000 feet.)

NOTICE: Be sure to mount inlet vent ter minal 6 inches highe r than the ou tlet vent term inal. Vent terminals need to be a minimum of 7 i nches (center to center) horizontally apar t and a maximum of 24 inches apar t.

GP100-150 & GP100-200

Venting Information for 3” Vents

Number of 90º Elbows with

Vent Terminal

Inlet Vent Outlet Vent

One (1) One (1) None 40.0

One (1) One (1) One (1) 2.5 37.5

Two (2) Two (2) None 5.0 35.0

Two (2) Two (2) One (1) 2.5 32.5

Three (3) Three (3) None 5.0 30.0

Three (3) Three (3) One (1) 2.5 27.5

Four (4) Four (4) None 5.0 25.0

Four (4) Four (4) One (1) 2.5 22.5

Number of

45º Elbows

Vent lengths for the inlet and the outlet pipes should not have a difference of more than five (5) equivalent feet.

Venting Information for 4” Vents

Minimum Pipe Length equired

(Ft)

5.0

Maximum

Pipe Length

(Ft)

GP100-250

Venting Information for 4” Vents

Number of 90º Elbows with

Vent Terminal

Inlet Vent Outlet Vent

One (1) One (1) None 10.0 45.0

One (1) One (1) One (1) 7.5 42.5

Two (2) Two (2) None 5.0 40.0

Two (2) Two (2) One (1) 2.5 37.5

Three (3) Three (3) None 5.0 35.0

Three (3) Three (3) One (1) 2.5 32.5

Four (4) Four (4) None 5.0 30.0

Four (4) Four (4) One (1) 2.5 27.5

Number of

45º Elbows

Vent lengths for the inlet and the outlet pipes should not have a difference of more than five (5) equivalent feet.

GP100-250 can only be vented with four (4) inch PVC pipe and fittings. Use only the vent terminals supplied withthe water heater

Minimum Pipe

Length Required

(Ft)

Maximum

Pipe Length

(Ft)

Number of 90º Elbows with

Vent Terminal

Inlet Vent Outlet Vent

One (1) One (1) None 10.0 50.0

One (1) One (1) One (1) 9.5 47.5

Two (2) Two (2) None 5.0 45.0

Two (2) Two (2) One (1) 2.5 42.5

Three (3) Three (3) None 5.0 40.0

Three (3) Three (3) One (1) 2.5 37.5

Four (4) Four (4) None 5.0 35.0

Four (4) Four (4) One (1) 2.5 32.5

Number of

45º Elbows

Minimum Pipe

Length Required

(Ft)

Maximum

Pipe Length

(Ft)

Vent lengths for the inlet and the outlet pipes should not have a difference of more than five (5) equivalent feet.

NOTICE: 3” and 4” vent pipe should not be mixed, other than to reduce the 4” vent for the 3” PVC Vent Terminal. This unit is supplied with two (2) 3-inch Schedule 40 PVC 45º vent terminals.

The 4” vent pipe can use up to 16 inches of 3” PVC, preceding the vent terminal. This unit uses the same vent terminals (supplied with the unit) for both 3” and 4” pipe. A 4” to 3” reducer will be required to go from 4” to 3” pipe.

HORIZONTAL VENT TERMINAL LOCATION - The location of the vent terminal depends on the minimum clearances and considerations shown in the charts on pages 11 and 12..

Page 10

Installation

Inlet

Outlet

Inlet

Outlet

Inlet

Outlet

WARNING

Inlet

Outlet

Inlet Min. 6” above outlet

GP100-150 & GP100-200

Mortar or

Silicone Caulk

3” Pipe Coupling

3” Vent Pipe

3” Pipe Coupling

From Water Heater

Figure 9a – Typical Horizontal 3” Vent Installation

Mortar or

Silicone Caulk

4x3 Reducer Coupling

4” Vent Pipe

4x3 Reducer Coupling

From Water Heater

Figure 9b – Typical Horizontal 4” Vent Installation

3” Vent Pipe

Sheet Metal Shield on Brick or Masonry Walls

Vent Terminal with 1/2" Mesh Protective Screen Inside

Sheet Metal Shield on Brick or Masonry Walls

Vent Terminal with 1/2" Mesh Protective Screen Inside

GP100-250

Mortar or

Silicone Caulk

Sheet Metal Shield on Brick or Masonry Walls

Outside of Building Wall

Additional Considerations (See Figure 9)

1. Do Not install vent ter minal under any patio or deck.

2. To help prevent moisture from freezing on walls and under eaves, do not locate vent terminal on the side of a building with prevailing winter winds.

3. Do Not ter minate vent pipe directly on brick or masonry surfaces. Use a rust-resistant sheet metal backing plate behind vent. (See Figure 9.)

4. Do Not locate vent terminal too close to shrubbery, since flue gases may damage them.

5. Caulk all cracks, seams and joints within six (6) feet of vent terminal.

6. All painted surfaces should be primed to lessen the chance of physical damage. Painted surfaces will require maintenance.

7. Insulate vent pipe exposed to cold conditions (attics, crawl spaces, etc.) to help prevent moisture from accumulating in vent pipe.

Moisture in the flue gas will condense as it leaves the vent terminal. In cold w eather this condensate can freeze on the exterior wall, under the eaves and on sur rou n di n g o bj e ct s . So me dis co l or a ti o n t o t he exterior of the building is to be expect ed. However, impro p e r lo c a t i o n or installation can result in severe damage to the structure or exterior finish of the building.

4” Pipe Coupling

4” Vent Pipe

Outlet

4” Vent Pipe

Min. 7”

Max. 24”

Inlet

6” above outlet

4” Pipe Coupling

From Water Heater

Figure 9c – Typical Horizontal 4” Vent Installation

Vent Terminal with 1/2" Mesh Protective Screen Inside

Outside of Building Wall

Short Piece of Vent Pipe

Min. 12" Above Roof

Min. 12" Above Anticipated Snow Level.

Max. 24" Above Roof (Without Additional Support)

Figure 8 – Vertical Vent Terminal Location

Elbows

Vent Pipe Through Roof

HORI ZONTAL VENT I NSTALLATION – Onc e the vent termin al

location has been determined, make a hole through the exterior wall to accommodate the vent pipe. Vent pipe must exit exterior wall horizontally only. (See Figures 9a and 9b.)

Inser t a small length of vent pipe through the wall and connect the

coupling as shown in Figure 9. Connect terminal as shown to the vent pipe on the exterior of the building. Seal any opening around the vent pipe or fittings with mortar or silicone caulk as shown in Figures 9a and 9b.

Complete the rest of the vent pipe installation to the water

he a t e r ’s vent co n n e c t o r fitting o n the bl o wer ou t l e t . I f necessary support horizontal run as previously mentioned.

Figure 6

Page 11

Installation

FIXE

VERTIC AL VENT INSTALLATION – Once the vent ter mi-

nal location has been d eter mined, make a hole thr ough the roof and interior ceiling to accommodate the vent pipe. Complete the vent pipe in stallat ion to the water hea ter ’s vent conne cto r fittin g on the blow er outlet. Suppor t ver t ica l or horizontal runs as previously mentioned.

Install adequate flashing where the vent pipe passes through the

roof. Determine the vent terminal height and cut vent pipe accordingly. Refer to Fig. 8 for proper vent terminal height. Connect vent elbow onto ver tical pipe through roof. Connect short piece of vent pipe (approximately 3" long) to elbow, then join ter minal to the short piece of vent pipe.

VERTICAL VENT TERMINAL LOCATION – The location of

vertical vent terminal depends on the following considerations (see Figure 8):

1. Minimum twelve (12) inches above roof.

2. Minimum twelve (12) inches above anticipated snow level.

3. M aximu m twe n ty-four (24) inches above roof level without additional support for vent pipe.

4. Four (4) feet from any gable, dormer or other roof structure with building interior access (i.e., vent, window, etc.).

5. Ten (10) feet fro m any forced ai r inlet to th e bui l ding . Any fres h o r make-up a ir inlet such as a dryer or furna ce area is considered to be a forced air inlet.

6. The inlet is a minimum of six (6) inches vertically above the outlet.

7. Terminals are a minimum of seven (7) inches horizontally apart with a maximum of twenty-four (24) inches.

VE N T IN S TAL L ATION – Before procee d i n g, ma ke cer t a i n you un ders t and th e proce dure an d caut i ons co ve r ed in th e sect i on “Joining Pipes and Fittings.”

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

Horizontal Vent Terminal Location

The following information should be used for determining the proper location of the vent terminal for direct vent water heaters.

US Installations

12 inches (30 cm) above anticipated

snow level.

6 inches (15 cm) for appliances < 10,000 Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and < 50,000 Btuh (15 kW), 12 inches (30 cm) for appliances > 50,000 Btuh

A= Clearance above grade, veranda,

porch, deck or balcony.

B= Clearance to window or door that may

be opened.

Canadian Installations

12 inches (30 cm) above anticipated

snow level.

6 inches (15 cm) for appliances < 10,000 Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3kW) and < 100,000 Btuh (30kW), 36 inches (91 cm) for appliances > 100,000 Btuh (30kW).

(15 kW).

C= Clearance to permanently closed

* *

window.

D= Vertical Clearance to ventilated soffit

located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal.

E= Clearance to unventilated soffit. * *

F= Clearance to outside corner. * *

G= Clearance to inside corner. 18 inches (46 cm) 18 inches (46 cm)

Figure 9 - Horizontal Vent Terminal Location

3 feet (91 cm) 3 feet (91 cm)

Page 12

H = Clearance to each side of center line

extended meter/regulator assembly. above

Canadian Installations

3 feet (91 cm) within a height 15 feet (4.57

m) above the meter/regulator assembly.

US Installations

I = Clearance to service regulator vent

outlet.

J = Clearance to nonmechanical air supply

inlet to the combustion air inlet to any building or other appliance.

K = Clearance to mechanical air supply

inlet.

L = Clearance above paved side walk or

paved driveway located on public property.

M = Clearance under veranda, porch, deck

or balcony.

1 In accordance with current CAN/CGA-B149 Installation Codes.

2 In accordance with 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.

* If clearances are not specified then follow local installation codes and the requirement of the gas supplier.

6 inches (15 cm) for appliances < 10,000

Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3kW) and < 100,000 Btuh (30kW), 36 inches (91 cm) for appliances > 100,000 Btuh (30kW).

3 feet (91 cm)

4 feet (1.2 m) below or to side of opening; 1 foot (300 mm) above opening.

6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet

(3 m) horizontally.

7 feet (2.13 m) 7 feet (2.13 m)

Not Allowed Not Allowed

DR A I NI N G T H E CON D E NS ATE – In ce r ta i n co nd i t io n s ,

installations in unconditioned space or having long horizontal or vertical runs may accumulate condensate. In order to prevent condensate from draining back into the blower, we recommend that it be drained. This unit is provided with a special fitting on the blower that allows for the draining of condensate formed in the vent. The drain hose should have two (2) loops formed, to act as traps. Before operation of the water heater, both loops should have water placed in them. Support the traps so that they remain horizontal. Condensate is known to be acidic; refer to local, state or federal codes for proper handling methods.

Figure 10 - Draining the Condensate

JOINING PIPES AND FITTIN GS – All pipe, fittings, solvent

cemen t, pr i mers and pro cedu res mus t conform to Amer ican Nati onal Standar ds Inst itute and Ameri can Soci ety for Testing and Materials (ANSI/ASTM) standards.

CEMEN TIN G JOI NTS – Al l joint s in the vent pip ing must

be properly sealed and we recommend using the following material:

PVC materials should use ASTM D-2564 grade cement. CPVC materials should use ASTM F-493 grade cement. ABS materials should use ASTM D-2235 grade cement.

Cleaner-Primer and Medium Body Solvent Cement

1. Cut pipe end square, remove jagged edges and burrs. Cham fer end of pipe, then clean fitting socket and pipe joint area of all dir t, grease or moisture.

2. Af t e r c h e cking pi p e a n d socke t for p r o p e r f i t, wipe socket and pipe with cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. Do not allow primer to dry before applying cement.

3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy co at of cem ent to the pi pe end and in sert pipe into fitting with a slight twi sting motio n until it bottoms out.

NOTICE: Cement must be fluid; if not, recoat.

4. Hold the pipe fitting for 30 seconds to prevent the tapered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow 15 minutes before handling. Cure time will vary according to fit, temperature and humidity.

NOTICE: Stir the solvent cement frequently while using. Use

a natural bristle brush or the dauber supplied with the can. The proper brush size is one inch.

Page 13

FOR PROPER INSTALLATION:

CAUTION

WARNING

• DO NOT use solvent cement that has become

curdled, lumpy or thickened.

• DO NOT thin so lvent c ement. Obs e r ve she lf

precautions printed on the containers.

• Fo r app l ica t ions b e low 32 ° F use o n ly low

temperature type solvent cement.

• Appropriate solvent and cleaner must be used for

the type of vent pipe used (PVC, CPVC or ABS).

DANGER OF FIRE OR BODILY INJURY – Solvent

cements and primers are highly flammable. Provide adequate ventilation and do not assemble near heat source or open flame. Do not smoke.

Installation Check List

Avoid skin or eye contact. Observe all cautions and warnings on material containers.

6. WIRING — A polarized 120V 50/60 Hz power supply, with suitable disconnect means, must be connected to the black and white leads provided. The current draw by the Power Direct Vent unit is 1.5 Amps. The water heater, when installed, must be electrically grounded in accordance with local codes, or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 in the United States; or CSA C22.1 Electrical Code, in Canada. Refer to Fig. 14 on page 26 & 27 of this manual for water heater inter nal wiring diagrams.

NOTICE: DO NOT use in conjunction with a GFCI.

A. Water Heater Location

❑ Close to area of vent.

C. Gas Supply

❑Gas line equipped with shut-off valve, union, and sediment trap/drip leg.

❑Indoors and protected from freezing temperatures.

❑Approved pipe joint compound used.

❑Proper clearance from combustible surfaces observed and water heater not installed on carpeted floor.

❑ Soap and water solution used to check all connections and fittings for possible gas leak.

❑Air supply free of corrosive elements and flammable vapors.

❑Gas Company inspected installation (if required).

❑Provisions made to protect area from water damage.

❑Sufficient room to service heater.

D. Relief Valve

❑Discharge line run to open drain.

B. Water Supply

❑Water heater completely filled with water.

❑Water heater and piping air vented.

❑Discharge line protected from freezing.

E. Venting

❑All pipe connections are secure (at blower, vent terminals and for

❑Water connections tight and free of leaks.

each pipe joint connection)

❑Vent terminals mounted properly and in correct location.

❑Condensate tube has water in both loops.

Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Ga s Pr es su re s of

Based o n a 0. 60 Specific Gravity Natural G as ; I f 1.5 Specific Gravity L.P. Gas is used, multiply capacity by 0.63

Nomin al I ntern al

I ron P ipe Siz e, D iameter In ches In ches

1/2 .62 2 132 92 73 63 56 5 0 46 43 40 38 34 31 2 8 26

3/4 .824 278 1 90 152 13 0 115 105 96 90 84 79 7 2 6 4 5 9 55 1 1. 049 520 3 50 285 24 5 215 195 1 80 170 16 0 15 0 1 30 120 11 0 100 1 1 /4 1.3 80 1,0 50 730 590 50 0 4 40 4 00 370 350 32 0 305 275 250 225 2 10 1 1 /2 1.6 10 1,6 00 1,1 00 890 76 0 670 610 560 530 49 0 46 0 4 10 380 35 0 320 2 2. 067 3, 050 2,10 0 1,6 50 1, 450 1,2 70 1,150 1, 050 99 0 930 870 780 710 65 0 610 2 1 /2 2.4 69 4,8 00 3,3 00 2,70 0 2,300 2,000 1,850 1,70 0 1,6 00 1,50 0 1,40 0 1,25 0 1,130 1,0 50 98 0 3 3. 068 8, 500 5,90 0 4,7 00 4, 100 3,6 00 3,250 3, 000 2,800 2,600 2,500 2, 200 2 ,000 1,8 50 1,700 4 4. 026 17,50 0 12, 000 9,700 8,3 00 7,400 6,800 6,200 5, 800 5,400 5,100 4 ,500 4,1 00 3, 80 0 3, 500

----- -- -0 .5 psig or Less and a Pressure Drop o f 0.3 Inch Water Column

10 20 30 40 50 60 70 80 90 100 12 5 1 50 175 200

TABLE 1

Len gth o f Pip e, Feet

Page 14

Operation

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

result causing property damage, personal injury or loss of life

Th i s ap p li a nc e is eq u ip p ed w i th a n ign i ti o n device which automatically lights t h e pilot. DO NOT tr y to light the pilot by hand.

A .

BE F OR E O PE R ATI NG s m e ll all a r o u nd the appliance a rea for gas. Be sure to smell next to th e floo r bec a use s o me ga s is h eavi e r than air and will settle on the floor.

B .

WHAT TO DO IF YOU SMELL GAS

• Do not tr y to light any appliance

• Do not to uch any ele ctrical switch; do n ot use any phone in your building.

• Im m e dia t ely c a ll yo u r g a s sup p lie r fro m a ne i g h b o r ' s p h o n e . Fol l ow the gas supplier's instructions.

• If you cann o t reach your g as sup p l i e r, call the fire d epartment.

Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don't try to rep air it, call a qua lifie d ser vice technician. Force or attempt to repair may result in a fire or explosion.

C .

Do not use this appliance if any par t has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas c o n trol w h ich h a s be e n un der w a t er.

D .

STOP ! REA D THE SAFET Y INFOR MATI ON ABOVE ON THIS LABEL.

1 .

USING A SLOTTED SCREW DRIVER — INSERT INTO TE MPERAT U RE AD J U STMEN T O P E NING. TU RN SCREW CLOCKWI SE TO THE LOWEST SETTING

2 .

TUR N OF F ALL E LE C T RI C POW E R TO T H E APPLIANCE.

3 .

THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT. DO NOT TRY TO LIGHT THE PILOT BY HAND.

4 .

TURN THE "GAS COCK KNOB" CLOCKWISE TO "OFF."

5 .

WAI T F I V E (5 ) MIN U TES TO CLE A R OU T ANY GAS. IF YOU THEN SMELL GA S, STOP ! FOLLOW "B " IN THE SAFETY INFORMATI ON AB OV E ON THI S L A B EL . I F Y O U DO N 'T SMELL GAS, GO TO NEXT STEP.

6 .

TU RN " GA S CO C K KN O B " CO U NT ER CLO C KW I S E TO "O N ".

7 .

TURN ON ALL ELECTRIC POWER TO THE APPLIANCE.

8 .

SET THERMOSTAT TO DESIRED SETTING9 .

IF TH E APP LI A N CE WI L L NOT OP ERATE , FOL L OW THE IN S TRUC T I ON S "TO TURN OF F GAS TO APPLIANCE" AN D CALL YOUR SE RVI C E TECHNICI A N OR GAS S UPPLIER .

10.

SET THE THERMOSTAT TO LOWEST SETTING.1 . TU R N OFF ALL ELECTRIC POWER TO THE

APPLIANCE IF SERVICE IS TO BE PERFORMED.

2 .

TURN THE "GAS COCK KNOB" CLOCKWISE TO "OFF".

3 .

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

FOR YOUR SAFETY READ BEFORE OPERATING

THERMOSTAT

GAS VALVE

TEMPE RATURE

ADJUS TMEN T

SCREW

INDEX

GAS C OCK

KNOB

OFF

Before operating this water heater, be sure to read and follow the instructions on the label pictured below and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in unsafe operation of the water heater resulting in property damage, bodily injury, or death. Should you have any problems reading or following the instructions in this manual, STOP, and get help from a qualified person.

1. LIGHTING PROCEDURE - Lighting procedures are outlined on the label pictured below. This label is also located on the water heater near the thermostat.

NOTICE: The Gas Valve supplied with this water heater may vary from the one pictured on the label below, but the Lighting Instructions are the same for all

types of valves supplied with this model water heater.

Page 15

FOR YOUR SAFETY READ BEFORE OPERATING

1. TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE IF SERVICE IS TO BE PERFORMED.

2. SET THE THERMOSTA T TO LOWEST SETTING.

TO TURN OFF GAS TO APPLIANCE

OPERATING INSTRUCTIONS

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 supplier's instructions.

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

C. Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don't try to repair it, call a qualiﬁed service technician. Force or attempted repair may result in a ﬁre or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualiﬁed ser vice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

WARNING

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

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

3. TURN THE "GAS CONTROL KNOB" CLOCK WISE TO "OFF" .

8. TURN ON ALL ELECTRIC POWER TO THE APPLIANCE.

9. SET THERMOSTAT TO D ESIRED SETTING.

INSTAL L OUTER COVER.

STOP! READ THE SAFETY INFORMATION ABOVE ON THIS LABEL.

TURN OFF ALL ELECTRIC POWER TO TH E APPLIANCE.

THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT. DO NOT TRY TO LIGHT THE PILOT

BY HAND.

TURN THE "GAS CONTROL KNOB" CLOCKWISE TO " OFF".

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 SMEL L GAS,

GO TO NEXT STEP.

TURN THE "GAS CONTROL KNOB" COUNTERCLOCKWISE TO "ON".

IF THE APPLIANCE WILL NOT OPERATE, FOLLOW THE INSTRUCTIONS "TO TURN OFF GAS TO APPLIANCE" AND CALL YOUR SERVICE TECHNICIAN

10.

OR GAS SUPPLIER.

REMOVE OUTER COVER. USING A SLOTTED SCREWDRIVER - INSERT INTO SLOT IN CENTER OF DIAL. TURN DIAL COUNTERCLOCKWISE

TO THE LOWEST SETTING .

TEMPERATURE

ADJUSTMENT

DIAL

NOTE: Thermostat shown with cover removed .

THERMOST AT

A. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand.

Index

Ga s C ock Knob

Honeywell

GAS VA LV E

Operation

1. LIGHTING PROCEDURE - Lighting procedures are outlined on the label pictured below. This label is also located on the water heater near the thermostat.

NOTICE: The Gas Valve supplied with this water heater may vary from the one pictured on the label below, but the Lighting Instructions are the same for all

types of valves supplied with this model water heater.

Page 16

Operation

CAUTION

DANGER

WARNING

140

THERMOST AT

SAFETY PRECAUTIONS

A. Do turn off manual gas shut-off valve if water heater has been sub-

jected to over heating, fire, flood, physical damage or if gas supply fails to shut off.

B. Do Not turn on water heater unless it is filled with water.

C. Do Not turn on water heater if cold water supply shut-off valve is

closed.

D. Do Not store or use gasoline or other flammable vapors and liquids,

such as adhesives or paint thinner, in vicinity of this or any other appliance. If such flammables must be used, open doors and windows for ventilation, and all gas burning appliances in vicinity should be shut off, including their pilot lights, to avoid vapors igniting.

NOTICE: Flammable vapors may be drawn by air currents from sur-

rounding areas to the water heater.

2. TEMPERATURE SETTINGS — The thermostat is adjusted to its lowest temperature position when shipped from the factory. To meet commercial water use needs, it is adjustable up to 180°F (82°C). However, water temperatures over 125°F (52°C) can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying general purpose hot water.

Safety and energy conservation are factors to be considered when

setting the water temperature on the thermostat. The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application.

Hotter water increases the Potential for Hot Water SCALDS.

E. Do not allow combustible materials such as newspaper, rags or

mops to accumulate near water heater.

F. If there is any difficulty in understanding or following the OPERA-

TION or MAINTENANCE instructions, it is recommended that a qualified person or serviceman perform the work.

Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE!! To dissipate such gas and to reduce risk of injury, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. Do not smoke or use an open flame near the faucet at the time it is open.

When this water heater is supplying general purpose hot water requirements for individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended. Contact a licensed plumber or the local plumbing authority for further information.

Outlet water temperature will vary during normal operating cycles. Reli-

able temperature readings should be taken shortly after main burner cycles off during a period of little or no use.

3. GAS MANIFOLD PRESSURE — With the gas valve supplied with this water heater, main burner ignition occurs at a low or step manifold pressure, which will then automatically build up to its normal operating level . The rated operating manifold pressure is listed on the water heater rating plate. For purposes of input adjustment, the minimum inlet gas pressure(with main burner on) is also shown on the rating plate. A 1/8” NPT tapping is provided on the outlet side of the gas valve for connecting a manometer to check this pressure. If necessary, adjust the pressure to the proper value by turning regulator adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

To adjust the water temperature, insert a small straight

screwdriver into slotted screw in hole in front of ther-

mostat and turn wheel to desired setting. Thermostat

is adjustable up to 180º F.

CAUTION!! - Hotter water increases the risk of SCALDING!

4. CHECK INPUT — Consult the local Gas Company to determine the heating value of the gas supplied. Check input by clocking gas meter with all other gas appliances turned off. Use the following formula:

INPUT (btu/h) =

(3,600) x (Heating Value) x (Number of Cubic Feet Timed)

Seconds Clocked

DO NOT exceed Input shown on the water heater's rating plate!

Honeywell

White-Rodgers

Figure 11. — Thermostat adjustment

Page 17

Operation

WARNING

CAUTION

WARNING

To insure accuracy for rating, clock enough cubic feet of gas so that

the clocked time is at least 60 seconds.

Small adjustments can be made by varying the manifold pressure from

the designated settings mentioned above.

5. INTERMITTENT PILOT FLAME ADJUSTMENT — No adjustment is required with normal inlet gas pressures. The pilot flame adjustment valve is pre-set, and does not normally require re-adjustment.

6. HIGH ALTITUDE — Ratings of gas appliances are based on installation and operation at sea level of elevations of 2000 feet.

Factory prepared high altitude models are available and are specifically

rated for installation at elevation up to 8000 feet. Refer to rating plate on the front of the water heater for number and altitude specifications. Also refer to the supplement sheet for information on venting high altitude models.

Maintenance

Properly maintained, this water heater will provide years of dependable, trouble free service. It is strongly suggested that a regular routine maintenance program be established and followed by the owner. It is fur ther recommended that a periodic inspection of the blower, thermostat, burner, relief valve, internal flueway, draft hood / damper assembly and venting system should be made by service technicians qualified in gas appliance repair.

1. ROUTINE PREVENTIVE MAINTENANCE

A. BURNERS — Visually inspect the main burner flame and the pilot flame

at least ever y three months. Refer to Figures 12 and 13 for normal flame pattern. Fallen scale can usually be dislodged from the tops of the burners with a thin rod, then vacuumed or brushed from the bottom of the burner box. If a more thorough cleaning is deemed necessary to restore a normal flame pattern, the burner tray assembly should be removed and the burners cleaned individually.

7. EMERGENCY SHUTDOWN —

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.

DO NOT use this appliance if any part has been under water. Imme diately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

If the water heater has been subjected to fire or physical damage, turn

off gas at the manual gas control (shut-off) valve. Do not operate the water heater again until it has been checked out by a qualified service technician.

TO REMOVE BURNER TRAY:

1. Turn off manual gas shut-off valve.

2. Disconnect gas pipe union and wiring to gas valve and pilot.

3. Remove retaining screws from plate on the same side as the gas valve.

4. Slide burner tray assembly out. When reinstalling the bur ner tray assembly, make certain it is pushed in all the way so that the plate lines up with the holes in the plenum side. Then reinstall the retaining screws.

5. Reconnect gas pipe union and wiring to gas valve and pilot, turn on manual gas shut-off valve and test for gas leak.

B. VENTING SYSTEM — Inspect venting system at least yearly to make

certain the passageways are free and unobstructed, and that the vent connector from the water heater’s blower assembly is properly positioned and securely attached. Remove any obstructions in vent connector or vent terminal.

Figure 12. — Pilot Flame Pattern

For your safety, removal and cleaning of burner tray and individual burners should be performed ONLY by a qualified service techni cian, as it involves disconnection of gas piping and leak testing.

C. CONTROLS — The manifold pressure and controls should be checked

at least yearly by a qualified service technician.

Figure 13. — Pilot & Main Burner Flame Pattern

Page 18

Maintenance

DANGER

CAUTION

D. BLOWER — Clean the blower periodically to remove any buildup of

lint or dirt. Remove the inlet plate and blow out any lint or dirt on the wheel and on the screen of the inlet plate. Before operation, re-install the inlet plate to the blower.

E. PRESSURE SWITCH — Inspect the inlet to the pressure switch and

the tubing for debris or blockage. Clean out the tubing periodically to prevent buildup of debris.

F. EMERGENCY CUT-OFF — This water heater is equipped with a com-

bination thermostat/temperature limiting device (ECO) that should be checked annually by qualified service personnel.

G. THERMAL CUTOFF SWITCH — Some units are equipped with a

thermal cutoff switch which will shut down the unit if the flue gas temperature is above permissible limits. The switch is a manual reset type.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

G. RELIEF VALVE — The Temperature and Pressure Relief Valve must

be free to operate properly. Check (at least once a year) by lifting the handle fully and allowing several gallons of water to flush through the discharge line. Make cer tain the discharged water is directed to a suitable drain.

Before manually operating the relief valve, make certain no one will be exposed to the danger of coming in contact with the hot water released by this valve. The water may be hot enough to create a SCALD hazard. The water released should be directed to a suitable drain to prevent injury or damage.

NOTICE: If the temperature and pressure relief valve on the water

heater discharges periodically, this may be due to thermal expansion in a “closed” water system. Contact the water supplier or local plumbing inspector on how to correct this. DO NOT plug the relief valve outlet.

H. TANK— Good maintenance requires that the tank be cleaned of de-

posits. Unless the water supply is soft (0 to 5 grains hardness), scale or lime deposits will accumulate in the tank. Hard water scale is deposited at an increasingly high rate in proportion to increased water temperature. Accumulation of these deposits may reduce efficiency, and shor ten the life of the water heater.

A wet-dry shop vac with a nozzle fashioned from 1” and/or 3/4” poly

ethylene pipe makes a good tool for scraping and removing scale.

TO CLEAN OR INSPECT TANK:

1. Shut off gas valve and drain tank.

2. Remove tank clean-out cover on jacket and with pocket knife cut and remove a circular plug of insulation the full size of jacket opening.

3. Loosen nut on seal plate assembly enough to twist yoke sideways. Hold assembly securely and push inward, then remove from tank.

4. Remove as much built-up scale from flue tubes and tank bottom as practical. Do not attempt to clean so thoroughly that the tool used damages the glass lining.

5. Clean the seal plate and install a new gasket. Wipe clean the interior surface of the tank that contacts the gasket. Reinstall the seal plate and tighten in position. Fill tank with water and check for leaks. If no leaks are found, install insulation plug and clean-out cover on jacket and re-light the water heater.

If chemical lime dissolving cleaners are preferred, cautiously follow

the instructions supplied with the cleaner. DO NOT use a muriatic or hydrochloric acid (HCl) base cleaner.

2. ANODE INSPECTION — The water supply in certain areas contains very aggressive elements. In these areas, periodic inspection of the anode is recommended to determine if replacement is necessary. The anode(s) supplied in this water heater is slowly consumed , thereby eliminating or minimizing corrosion and protecting the glass lined tank. The anode(s) should be replaced when more than 6 inches (15 cm) of core wire is exposed at either end.

3. SEASONAL OPERATION — If the water heater is to remain idle for an extended period (60 days or more) the heater should be turned off. The water heater and piping should be drained if they might be subjected to freezing temperatures. It is recommended that the water heater’s operation is thoroughly checked (by a qualified service technician) before it is placed back in service. NOTICE: Refer to Hydrogen Gas caution notation on page 16.

Any new installation should have a tank inspection program set up

initially for frequent inspection. The first inspection should be within a six month period. Once the scaling tendencies have been established, the inspection program can be modified to suit the water conditions. Cleaning should be performed if the scale has accumulated above the drain valve opening.

Page 19

SYSTEM SENTINEL

POWER

THERMOSTAT

IGNITION

PILOT VALVE

MAIN VALV E

ECO

“System Sentinel” Diagnostic System

The “System Sentinel” Diagnostic system on this water heater provides the user or ser vice technician with a visual representation of the operational status of the various sections of the water heater’s control system. A quick glance at the System Sentinel panel on the front of the heater will give an indication of where to begin trouble shooting of a non operational heater.

The LED’s (light emitting diodes) on the panel are arranged from top to bottom based on their function in the normal sequence of operation, and their function is explained as follows:

POWER

When illuminated, this green LED indicates that 120VAC power is being supplied to the heater, the ON/OFF switch is functioning and the 24V transformer is functioning properly.

(Refer to Section 1 of Troubleshooting Guide)

THERMOSTAT

When illuminated, this red LED indicates that the thermostat is functioning(calling for heat) and 24VAC power is being supplied to the relay (to turn on the blower) and the N/C terminal of the pressure switch with N/C and N/O terminals.

(Refer to Section 2 of Troubleshooting Guide)

IGNITION

When illuminated, this red LED indicates that 24 VAC power is being supplied to the Ignition Control Module, and the ignition sequence has begun. The N/O side of the pressure switch with N/C and N/O terminals closes

(Refer to Section 3 of Troubleshooting Guide)

PILOT VALVE

When illuminated, this red LED indicates that the Ignition Control Module is supplying 24 VAC power to the ECO (Energy Cut Off device), or High Limit.

(Refer to Section 4 of Troubleshooting Guide)

ECO

When illuminated, this red LED indicates that the ECO (Energy Cut Off device), or High Limit is closed, and 24 VAC power is being supplied to the PV (Pilot Valve) terminal on the Gas Control Valve.

(Refer to Section 5 of Troubleshooting Guide)

MAIN VALVE

When illuminated, this red LED indicates that the Ignition Control Module is supplying 24 VAC power to the MV (Main Valve) terminal on the Gas Control Valve.

(Refer to Section 6 of Troubleshooting Guide)

Page 20

“System Sentinel” Troubleshooting Guide

CAUTION

Section 1... the “POWER” LED

Is the “ON/OFF” Switch in the “ON” position?

YES

Is 120 VAC power present at the branch circuit connections to Black wire of the switch and White wire of the transformer ?

YES

Is 120 VAC power present between the Black and White wires to the transformer ?

Is the “POWER” LED Illuminated?

Turn switch to ON position. Is the Power LED now illuminated?

Check circuit breaker or fuse and field connection of branch circuit wiring to leads of switch. Repair or replace as required. Is “POWER” LED now illuminated?

Replace Switch, then verify that power is present. Is “POWER” LED now illuminated?

YES

Po w e r i s being supplied to the heater, the ON/OFF Switch is functioning, and the 24V AC Transformer is functioning.

YES

Is 24 VAC power present between the Yellow and Gray wires from the transformer ?

YES

The System Sentinel Panel is defective and must be replaced.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Replace Transformer, then verify that power is present. Is “POWER” LED now illuminated?

YES

Page 21

“System Sentinel” Troubleshooting Guide

CAUTION

Section 2... the “THERMOSTAT” LED

Ensure that power is being supplied to the water heater. Refer to “Section 1...the POWER LED” in this Troubleshooting Guide, and correct if necessary. Is the “THERMOSTAT LED” now illuminated.

Is Thermostat set at a temperature higher than the water temperature in tank?

YES

Is 24 VAC power present at Yellow Wire Terminal inside Thermostat?

Is the “THERMOSTAT” LED Illuminated?

YES

Adju s t Thermostat to a higher setting. Is Thermostat LED now illuminated?

Ensure that power is being supplied to the water heater. Refer to “Section 1...the POWER LED” in this Troubleshooting Guide, and correct if necessary. Is the “THERMOSTAT LED” now illuminated.

YES

Thermostat is calling for heat, and 24 VAC power.

YES

Is 24 VAC power present at

Blue Wire Terminal inside Thermostat?

Thermostat is defective or out of calibration and must be replaced.

YES

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Page 22

CAUTION

“System Sentinel” Troubleshooting Guide

Section 3... the “IGNITION” LED

Is the Blower Operating?

Is there 120 VAC across Black wire and White wire of blower?

YES

Blow er is d e f e c ti v e and must be replaced.

Check continuity of black wire to

YES

C h e c k wi r e co n nections.

relay.

Is continuity good?

W i r e is de fec t i v e an d mu s t b e replaced.

YES

Is ther e 12 0 VAC b e t ween the black wire at the relay and the white wire on the transformer?

NO YES

Check continuity of black wire from relay to blower motor and white wire to motor.

Is continuity good?

Is there 120 VAC between the black wire on the relay (power going to blower) and the white wire of the transformer?

Is the Ignition LED Illuminated?

Is Spark Ignitor operating?

(Can sparking be heard?)

Is 24 VAC present between the Gray ground wire and the Red 24 V wire connected to the Ignition Control Module?

YES

1. Remove Ignition Cable and check for good continuity, replace if necessary.

2. Check Ignitor Electrode(s) gap for proper spacing (1/8” to 5/32”). Correct if necessary.

3. Examine Ceramic Insulator on Pilot Assembly for cracks. Replace if cracks are evident.

If all of the above components check okay, replace Ignition Control Module.

Pressure Switch is defective and

YES

must be replaced.

The Thermostat has called for heat, the Blower is running, and 24 VAC power is being supplied to the Ignition Control Module and

YES

The System Sentinel Panel is defective and must be replaced.

YES

the ignition sequence will begin.

Check cont i n u i t y o f yellow wires to pressure s w i t c h e s and between switches.

Is continuity good?

Wiring harness is defective and must be replaced.

YES

Is there 24 VAC present between the common and Normally open terminal of pressure switch 1?

YES

Check Continuity of the Red wire from the Ignition Mo d u l e to the Pressure Switch.

Is continuity good?

YESNO

R e l a y i s d e f e c ti v e and must be replaced.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

YES

Is 24 VAC present across coil of relay?

YES

Recheck all connections,

should have power at blower motor.

Review pressure switch circuit on this page.

P o w e r should be at 24 VAC of Ignition Module.

Page 23

“System Sentinel” Troubleshooting Guide

CAUTION

Section 4... the “PILOT VALVE” LED

Is the Spark Ignitor operating? (Can sparking be heard?)

1. Remove Ignition Cable and check for good continuity, replace if necessary.

2. Check Ignitor Electrode gap for proper spacing (1/8” to 5/32”). Correct if necessary.

3. Examine Ceramic Insulator on Pilot Assembly for cracks. Replace if cracks are evident.

Is 24 VAC present between the Brown wire on “PV” Terminal and Gray Ground wire on Ignition Control Module?

YES

The System Sentinel Panel is

defective and must be replaced.

Is the “PILOT VALVE” LED Illuminated?

Is the Pilot Flame burning?

YES

Is 24 VAC present between the Brown wire on “PV” Terminal and White wire on “PV/MV” Terminal on the Gas Control Valve?

The Ignition Control Module is in the Ignition sequence, and is providing 24 VAC power to the ECO (Energy Cut-Off Device) inside of the Thermostat

YES

Gas Control Valve is inoperable and must be replaced

YES

I s the inlet gas pressure at or below the maximum as specified on the rating plate?

Is the “IGNITION” LED illuminated?

YES

Ignition Control Module is inoperable and must be replaced.

Refer to Section 3...the “IGNI-

TION” LED in the Troubleshooting Guide

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Check continuity of Brown wire between ECO Device (inside of Thermostat), and “PV” Terminal on Gas Control Valve. Repair or replace wire as needed to restore power to “PV” Terminal on gas valve.

Is the “ECO” LED

illuminated?

YES

Refer to Section 5...the “ECO” LED in

the Troubleshooting Guide

Page 24

CAUTION

“System Sentinel” Troubleshooting Guide

Section 5... the “ECO” LED

ECO is “open”. Allow tank to cool, and reset. If ECO again trips, the Thermostat/High limit is defective. Replace as required.

Is “ECO LED now illuminated?

Is the Pilot Flame burning?

Refe r to

Section 3...the “IGNITION” LED; and Section

4...the “PILOT VALVE”LED of Troubleshooting Guide. Repair or replace components as required.

YES

Section 6... the “MAIN VALVE” LED

Is the "ECO" LED Illuinated?

YES

The System Sentinel Panel is defective and must be replaced.

YES

T h e ECO (Energy Cut-Off device) is not tripped (open) and power is being supplied to the “PV” terminal on the Gas Control Valve.

Is the Pilot Flame burning?

YES YES

Is the Spark Ignitor operating?

(Can sparking be heard?)

Ignition Control Module is inoperative and

must be replaced.

“MV Terminal and White wire on “MV/PV” terminal on the Ignition Control Module?

Is the “MAIN VALVE” LED Illuminated?

Is Main Burner on?

Is 24 VAC present between Blue wire on

YES

Is 24 VAC present between Blue wire on “MV Terminal and White wire on “MV/PV” terminal on gas valve?

YES

The Ignition Control Module is providing 24 VAC between the “MV” and “MV/PV” terminals on Gas Control Valve, and Main Burner should be operating

The System Sentinel Panel is defective and must be replaced.

Is the inlet gas pressure at or below the maximum as specified on the rating plate?

YES

Main Gas Valve is inoperative and must be replaced.

Check Continuity of Blue and White wires between Ignition Control Module and Gas Control Valve. Repair or replace as required to restore power to gas valve.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Page 25

Replacement Parts

Blower Assembly

T&P Valve

Handhole Sealplate Gasket SP5886 (Beneath Cover)

Drain Valve

Thermostat

Ignition Control Assembly w/ Relay*

Gas Valve

Burner Assembly

Pilot/Ignitor Assembly

*Some assembly components are available individually (Control Module, Transformer, and ON/OFF Switch).

Instructions For Placing a Parts Order

All parts orders should include:

The model and serial number of the water heater from the rating

plate.

Specify type of gas (natural or LP) as marked on the rating plate.

Part description (as noted below) and number of parts desired.

CAUTION: For your safety DO NOT attempt repair of

gas piping, gas control (thermostat), burners, vent connectors or other safety devices. Refer repairs to qualified service personnel.

Page 26

Wiring and Schematic Diagrams

N O RM A L OP E R A TI O N S EQ U E N C E

I N DI C A T E D B Y B O X E D NU M E R A L S

POW ER

LED

IGN ITIO N

LED

N.C .S.W .

THE RMOS TAT LED

LED

IND ICAT ORS

TRA NSFO RMER

THE RMOS TAT

AND

HIG H LI MIT

WHI TE

BLA CK

OFF

12 0V

BL - 4

BR - 3

BR - 4

L1 L2

SWI TCH

BK- 2

Y-2

BK3

C C

TEMP

SWIT CH

GR/Y L

BLO WER

PS1

PS2

Y-5

BL6

BR- 1

BR- 3

BL- 2

W-1

GAS VALV E

PV MV

BR -2

GRA Y

GY-5

R-3 BL- 5 GY-1

MV / PV

GND

24V

IGN ITIO N CONTRO L

PIL OT

ELE CTRO DE A SSY.

GY-2

GY-1

R- 3

BL-5

Y-3

REL AY

POW ER

THE RMOS TAT

IGN ITIO N

PIL OT V ALVE

ECO

MAI N VA LVE

MAI N VA LVE L ED

IGN ITIO N

CON TROL

GND

IGN .

SC HEM A TICCO NNE C TIO N D I AGR AM

24 MV/PV

LIM IT

ECO LED

PIL OT VA LVE

LED

THE RM.

B L OW E R

1 4

1 2 0 V

2 4 V

L 1 L 2

MGV

PGV

N O RM A L O P E R AT I O N S E Q U E N CE

I N DI C A T E D B Y B O X ED N UM E R A L S

POW ER

LED

IGN ITIO N

LED

N.C .S.W .

THE RMOS TAT LED

LED

IND ICAT ORS

TRA NSFO RMER

THE RMOS TAT

AND

HIG H LI MIT

WHI TE

BLA CK

OFF

12 0V

BL - 4

BR - 3

BR - 4

L1 L 2

SWI TCH

BK- 2

Y-2

BK3

C C

TEMP

SWIT CH

GR/Y L

BLO WER

PS1

R- 1

PS2

Y-5

BL6

BR- 1

BR- 3

BL- 2

W-1

GAS VALV E

PV MV

BR -2

GRA Y

GY-5

R- 3 BL- 5 GY-1

MV / PV

GND

24V

IGN ITIO N CON TROL

PIL OT

ELE CTRO DE A SSY.

GY-2

GY-1

R- 3

BL- 5

Y-3

REL AY

POW ER

THE RMOS TAT

IGN ITIO N

PIL OT V ALVE

ECO

MAI N VA LVE

MAI N VA LVE L ED

IGN ITIO N

CON TROL

GND

IGN .

SC HEMA TICCO NNEC TION DIA G RAM

24 MV/ PV

LIM IT

ECO LED

PIL OT VA LVE

LED

THE RM.

B L OW E R

1 4

1 2 0 V

2 4 V

L 1 L 2

MGV

PGV

Figure 14. — Diagrams for units supplied with Honeywell VR8304P or VR8304M Gas Valve and Honeywell S8600M Ignition Control, Honeywell Thermo-

stat and Temperature Limiting Switch for vent pipe..

NOTICE: If any of the original wire as supplied with this appliance must be replaced, it MUST be replaced with 18 GA., 600V, 105°C wire or its equivalent, unless otherwise noted.

CAUTION! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Figure 14. — Diagrams for units supplied with Honeywell VR8304P or VR8304M Gas Valve and Honeywell S8600M Ignition Control, White-Rodgers

Thermostat and Temperature Limiting Switch for vent pipe..

Page 27

Wiring and Schematic Diagrams

IGNITION

LED

THERMOSTAT LED

POWER

LED

BR-3

Y-3

BL-5

R-3

GY-1

BR-4

BR-3

BL-4

GY-1

BL-5

R-3

BR-4

BR-3

BL-4

IGNITION

CONTROL

LED

INDICATORS

MAIN VALVE

ECO

PILOT VALVE

IGNITION

THERMOSTAT

POWER

24V

MV/PV

GY-2

BR-1

GND

GAS VALVE

BR-2

24V

120V

PILOT

ELECTRODE ASSY.

LIMIT

CONNECTION DIAGRAM

SCHEMATIC

IGN.

MV/PV

GND

MGV

BLACK

WHITE

GRAY

IGNITION CONTROL

THERMOSTAT

AND

LIMIT

TRANSFORMER

SWITCH

OFF

Y-2

PGV

L1 L2

THERM.

W-1

120V

BL-2

ANY REPLACEMENT WIRE MUST BE RATED FOR 250°C.

NORMAL OPERATION SEQUENCE

INDICATED BY BOXED NUMERALS

ECO LED

PILOT VALVE

LED

MAIN VALVE LED

GR/YL

R-1

BK-2

BK3

BL6

BLOWER

GY-5

BLOWER

PS2

PS1

Y-5

RELAY

N.C.S.W.

NOTICE: If any of the original wire as supplied with this appliance must be replaced, it MUST be replaced with 18 GA., 600V, 105°C wire or its equivalent, unless otherwise noted.

CAUTION! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!

Figure 14. — Diagrams for units supplied with Honeywell VR8304P or VR8304M Gas Valve and Honeywell S8600M Ignition Control.

Page 28

How to Obtain Service Assistance

1. Should you have any questions about your new water heater, or if it

requires adjustment, repair, or routine maintenance, it is suggested

that you first contact your installer, plumbing contractor or previously

agreed upon service agency. In the event that the firm has moved, or

is unavailable, refer to the telephone directory commercial listings or

local utility for qualified service assistance.

2. Should your problem not be solved to your complete satisfaction, you

should then contact the Manufacturer’s National Service Depar tment

at one of the following address:

In The U.S.A.:

Rheem Manufacturing Co., Water Heater Division

2600 Gunter Park Drive

Montgomery, Alabama 36109-1413

Phone: 1-800-432-8373.

In CANADA:

Rheem Canada, Ltd. / Ltée

P.O. Box 2846

Hamilton, ON L8N 3P3

Phone: 1-800-268-6966.

When contacting the manufacturer, the following information should

The following Gaskets are required for Normal Maintenance for all Models:

be made available:

a. Model and serial numbers of the water heater as shown on the rating

plate attached to the jacket of the heater.

b. Address where water heater is located and can be seen.

c. Name and address of installer and any service agency who performed

service on the water heater.

d. Date of original installation and dates any ser vice work was per-

formed.

e. Details of the problem as you can best describe them.

f. List of people, with dates, who have been contacted regarding your

problem.

SP5886 Tank Handhole Sealplate Gasket

All other Parts can be ordered by providing the following information:

1. Description of Part(s), such as: Main Gas Valve Pilot Burner Main Bur ner Thermostat Blower Assembly Anode Rod Or other parts as required.

2. Quantity of each part required.

3. Complete models number and name of the water heater.

4. Serial Number of water heater.

5. Specify Type of Gas.

6. Address Parts Orders to your distributor or dealer.

Rudd GP100-250 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual