State GP6 75 YTPDT User Manual
RESIDENTIAL GAS WATER HEATERS
500 Tennessee Waltz Parkway
Ashland City, TN 37015
Instruction Manual
POWER VENT/POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
MODELS GP650(Y,H)TPDT/GP675(Y,H)TPDT
SERIES 130/131
• For Your Safety •
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
PRINTED 1213 326462-000
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
APPROVALS .................................................................................3
GENERAL SAFETY INFORMATION .............................................4
Precautions ..............................................................................4
Grounding Instructions .............................................................4
Hydrogen Gas Flammable .......................................................4
INTRODUCTION ...........................................................................7
Abbreviations Used ..................................................................7
Qualications ............................................................................7
iCOMM™ & BACnet Compatible ..............................................7
Preparing For The Installation ..................................................7
DIMENSIONS AND CAPACITY DATA ...........................................8
Rough In Dimensions: 50 Gallon Unit ......................................8
Rough In Dimensions: 75 Gallon Unit ......................................8
FEATURES AND COMPONENTS ..............................................10
Controls And Switches ...........................................................13
INSTALLATION CONSIDERATIONS ..........................................14
Locating The Water Heater ....................................................14
Insulation Blankets .................................................................15
Combustion Air And Ventilation ..............................................15
Unconned Space ..................................................................16
Conned Space ......................................................................16
Fresh Air Openings For Conned Spaces ..............................16
Outdoor Air Through Two Openings .......................................16
Outdoor Air Through One Opening.........................................16
Outdoor Air Through Two Horizontal Ducts ............................17
Air From Other Indoor Spaces ...............................................17
INSTALLATION REQUIREMENTS .............................................18
Chemical Vapor Corrosion......................................................18
Water Piping ...........................................................................18
Power Supply .........................................................................18
Mixing Valves..........................................................................19
Gas piping ..............................................................................19
Gas Supply Systems ..............................................................20
Gas Pressure Requirements ..................................................20
Supply Gas Regulator ............................................................20
Space Heating And Potable Water System ............................21
Closed Water Systems ...........................................................21
Thermal Expansion ................................................................21
Temperature-Pressure Relief Valve ........................................22
Condensate Piping .................................................................23
High Altitude Installations .......................................................23
Filling The Water Heater .........................................................23
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH
OF MASSACHUSETTS ...............................................................24
VENTING INSTALLATION ..........................................................25
Vent Installation Considerations .............................................25
Polypropylene Installations .....................................................26
Vent Pipe Termination.............................................................27
Planning The Vent System .....................................................27
Installation Of Horizontal Through The Wall Vent System ......27
Direct Vent Terminal Installation .............................................28
Installation Sequence .............................................................28
Termination Clearances Sidewall Power Vent ........................29
Termination Clearances Sidewall Direct Vent .........................30
Vertical Vent Terminal Installation ...........................................31
Direct Vent Diagram ...............................................................32
Concentric Vent Installation ....................................................33
Low Prole Termination Installation ........................................36
LIGHTING AND OPERATION LABELS .......................................37
TEMPERATURE REGULATION .................................................38
CONTROL SYSTEM OPERATION .............................................39
Overview ................................................................................39
Control System Navigation .....................................................39
User Settings & Control System Menus .................................42
FOR YOUR INFORMATION ........................................................47
Start Up Conditions ................................................................47
Operational Conditions ...........................................................47
PERIODIC MAINTENANCE ........................................................48
Venting System Inspection .....................................................48
Anode Rod INSPECTION ......................................................48
Powered Anode Rod (optional models) ..................................49
Temperature-Pressure Relief Valve Test ................................49
Draining and ushing ..............................................................49
Service ...................................................................................50
LEAKAGE CHECKPOINTS .........................................................51
TROUBLESHOOTING ................................................................52
Installation Checklist ...............................................................52
Sequence Of Operation ..........................................................52
Sequence Of Operation Flow Chart .......................................53
Operational Problems .............................................................54
Fault And Alert Conditions ......................................................55
WIRING DIAGRAM .....................................................................58
2
SAFE INSTALLATION, USE AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER indicates an imminently
DANGER
WARNING
CAUTION
hazardous situation which, if not avoided,
will result in injury or death.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
CAUTION
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This
water heater can cause low level exposure to some of the substances listed in the Act.
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
3
CAUTION
GENERAL SAFETY INFORMATION
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN
UNDER WATER. Immediately call a qualied service agency to
inspect the water heater and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater until all
corrective steps have been made by a qualied service agency.
1. External re.
2. Damage.
3. Firing without water.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all
cases. Failure to ground this water heater properly may also cause
erratic control system operation.
This water heater must be connected to a grounded permanent
wiring system; or an equipment grounding conductor must be
run with the circuit conductors and connected to the equipment
grounding terminal or lead on the water heater.
HYDROGEN GAS FLAMMABLE
Explosion Hazard
Flammable hydrogen gases
may be present.
Keep all ignition sources away
from faucet when turning on
hot water.
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
ammable. To reduce the risk of injury under these conditions, it is
recommended that a hot water faucet served by this water heater
be opened for several minutes 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 ow. THERE SHOULD BE NO SMOKING
OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
Verify the power to the water heater is turned off before performing any service procedures.
Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Improper installation, use and service may result
in property damage.
Do not operate water heater if flood damaged.
•
Inspect anode rods regularly, replace if damaged.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
•
closed water systems.
Refer to this manual for installation and service.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized temperature and
pressure relief valve must be
installed in the opening provided.
4
GENERAL SAFETY INFORMATION
5
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating plate.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose water heater controls to excessive gas
pressure.
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
GENERAL SAFETY INFORMATION
Fire Hazard
For continued protection against
risk of fire:
Do not install water heater on
carpeted floor.
Do not operate water heater if
flood damaged.
Fire and Explosion Hazard
Use joint compound or Teflon tape
compatible with propane gas.
Leak test before placing the
water heater in operation.
Disconnect gas piping and main
gas shutoff valve before leak
testing.
Install sediment trap in
accordance with NFPA 54.
Electrical Shock Hazard
Turn off power to the water heater
•
before performing any service.
Label all wires prior to disconnecting
•
when performing service. Wiring errors
can cause improper and dangerous
operation.
Verify proper operation after servicing.
•
Failure to follow these instructions can
•
result in personal injury or death.
Fire and Explosion Hazard
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Excessive gas pressure to gas valve can
cause serious injury or death.
Turn off gas lines during installation.
Contact a qualified installer or service
agency for installation and service.
6
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• CSA - Canadian Standards Association
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI below)
in the eld involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition to
electrical testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualied (as dened by ANSI above) and licensed or
certied as required by the authority having jurisdiction to perform
a given task do not attempt to perform any of the procedures
described in this manual. If you do not understand the instructions
given in this manual do not attempt to perform any procedures
outlined in this manual.
ICOMM™ & BACNET COMPATIBLE
This water heater is compatible with the iCOMM™ remote
monitoring system. The iCOMM™ system hardware and monitoring
service is purchased separately. It allows users to monitor critical
operational, diagnostic and energy usage data from a secure web
site.
The iCOMM™ system can automatically notify selected personnel
via email and/or cellular phone text messages if operational
problems or user dened Alert Conditions occur.
iCOMM™ system hardware is compatible with BACnet compliant
supervisory controls and building management systems. For more
information call 888 928-3702
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on Page 4 thru Page 6. If you don’t follow the safety
rules, the water heater may not operate safely. It could cause
property damage, injury and/or death.
Detailed installation diagrams are also found in this manual.
These diagrams will serve to provide the installer with a
reference. It is essential that all venting, water piping, gas piping
and wiring be installed as shown.
Particular attention should be given to the installation of
thermometers at the locations indicated in the piping diagrams
as these are necessary for checking the operation of the water
heater.
The principal components of the water heater are identied in
Features And Components on Page10 & Page 11 in this manual.
Use this reference to locate and identify various components on
the water heater.
See the Installation Checklist and Troubleshooting on Page 51.
By using this checklist the user may be able to make minor
operational adjustments and avoid unnecessary service calls.
However, service and diagnostic procedures should only be
performed by a Qualied Service Agency.
NOTE: Costs to correct installation errors are not covered under
the limited warranty.
2. Be sure to turn off power when working on or near the electrical
system of the water heater. Never touch electrical components
with wet hands or when standing in water.
3. The installation must conform to all instructions contained in
this manual and the local code authority having jurisdiction.
These shall be carefully followed in all cases. Authorities having
jurisdiction should be consulted before installation begins if
there are any questions regarding compliance with local, state
or national codes.
In the absence of local codes, the installation must comply
with the current editions of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and the National Electrical Code, NFPA 70.
All documents are available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from the National
Fire Protection Association, 1 Batterymarch Park, Quincy, MA
02269.
4. If after reading this manual you have any questions or do
not understand any portion of the instructions, call the toll
free number on the back cover of this manual for technical
assistance. In order to expedite your request, please have the
full Model, Serial and Series number of the water heater you
are working with available for the technician. This information is
located on the water heater’s rating plate.
5. Carefully plan the placement of the water heater. Examine
the location to ensure that it complies with the requirements
in Locating The Water Heater on Page 14 and the Rough In
Dimensions on Page 8.
.
6. For installation in California this water heater must be braced or
anchored to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may
be obtained from California Ofce of the State Architect, 1102 Q
Street, Suite 5100, Sacramento, CA 95811.
This manual contains instructions for the installation, operation,
and maintenance of the water heater. It also contains warnings
throughout the manual that you must read and be aware of.
All warnings and all instructions are essential to the proper
operation of the water heater and your safety.
7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5. See Commonwealth of Massachusetts
on Page 24.
7
DIMENSIONS AND CAPACITY DATA
ROUGH IN DIMENSIONS: 50 GALLON UNIT
Figure 1: DIMENSIONS FOR 50 GALLON UNIT
ROUGH IN DIMENSIONS: 75 GALLON UNIT
Figure 1A: DIMENSIONS FOR 75 GALLON UNIT
Table 1 – ROUGH-IN-DIMENSIONS
Units A B C D E F G H I
50G
75G
Top Inlet and Outlet: 50G - 3/4” NPT; 75G - 1” NPT
Side Inlet and Outlet: 3/4” NPT
Gas Inlet: 1/2” NPT
Inches 66.75 49.25 22.00 15.75 3.00 8.00 8.00 62.00 65.00
cm 169.5 125.09 55.88 40.00 7.62 20.32 20.32 157.48 165.1
Inches 64.71 45.64 27.75 16.00 3.71 8.00 7.93 57.36 58.98
cm 164.4 115.9 70.5 40.6 9.4 20.3 20.1 145.7 149.8
8
DIMENSIONS AND CAPACITY DATA
Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS
Approximate Capacity Manifold Pressure Electrical Characteristics
U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes
50 189 Nat./LP 0 0 120/60 <5
75 284 Nat/LP 0 0 120/60 <5
All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)
Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)
Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)
Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.
Table 3 – RECOVERY CAPACITIES
Input Recovery Capacities
Rating
(Btu/hr)
100,000 29.3
Recovery capacity based on 96% thermal efciency.
Rating
(kW)
Temp.
Rise
F 30 40 50 60 70 80 90 100 110 120 130 140
C 17 22 28 33 39 44 50 56 61 67 72 78
GPH 387 291 233 194 166 145 129 116 106 97 90 83
LPH 1465 1102 882 734 628 549 488 439 401 367 341 314
9
**29
FEATURES AND COMPONENTS
50 GALLON UNIT
20
23
22
21
**14
21
30
32
18
16
1
12
**15
25
11
ACCESS PANEL
5
17
13
26, 27
24
33
19
18
35
Caution:
This access panel covers
a 2” NPT plug that was required
during the manufacturing of this
water heater. This 2” NPT ange is
not a cleanout tting, removing the
2” NPT plug and using this tting as
a cleanout could void your warranty.
31
9
34 (SEE
ACCESS
3
2
4
PANEL
CAUTION)
VACUUM RELIEF
VALV E
28
*INSTALL PER
LOCAL CODES
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Planning the Vent System, Installation of Vent System and Condensate Piping for more information.
Figure 1B: 50 GALLON UNIT
10
**29
FEATURES AND COMPONENTS (CONT.)
75 GALLON UNIT
21
13
18
**14
21
20
23
22
**15
5
12
11
17
1
18
16
25
24
3
2
26, 27
31
4
33
19
9
35
32
30
34
VACUUM RELIEF
VALV E
28
*INSTALL PER
LOCAL CODES
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Planning the Vent System, Installation of Vent System and Condensate Piping for more information.
Figure 1C: 75 GALLON UNIT
11
FEATURES AND COMPONENTS (CONT.)
1: Control Assembly
2: Blocked Intake Switch
3: Blocked Outlet Switch
4: Blower Prover Switch
5: Blower Assembly
6: Burner Assembly
7: Flame Sensor
8: Igniter Assembly
9: Junction Box
10: Gas Control Valve Assembly
11: Display Board
12: Top Plastic Enclosure
13: Display Enclosure
** 14: Exhaust Elbow Assembly
** 15: Condensate Tubing
16: Off/On Switch
17: Display Label
18: Hot Water Outlet
19: Gas Supply
20: Main Manual Gas Shutoff Valve
21: Union
22: Inlet Water Shutoff Valve
23: Cold Water Inlet
24: Inlet Dip Tube
25: T/P Relief Valve
26: Rating Plate
27: Labels
28: Drain Valve
** 29: Vent Terminal
30: Drain Pan
31: Anode Rod
32: Insulation
33: Temperature Probe
34: Access Door
35: Spark Module
12
CONTROLS AND SWITCHES
This model is provided with three pressure switches. These switches
are essential to the safe and proper operation of the unit. All switches
are wired in series. The controller is set up to shut the unit down
whenever there is a failure of any of the switches. It is important to
understand the purpose of each switch.
BLOCKED EXHAUST SWITCH
The Blocked Exhaust Switch is set up to shut the unit off when a buildup of positive pressure in the exhaust vent pipe occurs. This switch
is a positive pressure switch that requires an increase in pressure to
change the electrical contacts from normally closed to open. When
this switch prevents the unit from igniting, most likely the exhaust is
blocked by some means. Check to see if the condensate is allowed
to ow freely from the exhaust elbow and for obstructions in the
exhaust venting and exhaust vent terminal. Also verify that the vent
length does not exceed the maximum allowed as shown in the Vent
Section of this manual.
Blocked Exhaust
Switch
Blocked
Intake
Switch
Blower
Prover
Switch
50 GALLON UNIT
Blocked
Intake
Switch
Blower
Prover
Switch
BLOCKED INTAKE SWITCH
The Blocked Intake Switch is set up to shut the unit off when a
build-up of negative pressure in the intake air pipe occurs. This
switch is a negative pressure switch that requires an increase
in negative pressure to change the electrical contacts from
normally closed to open. The switch is connected to the pressure
tap on the PVC pipe connected to the inlet of the blower. When
this switch prevents the unit from igniting, most likely the intake
is blocked. Verify that the screen on the intake air connection
(conventional vent), the intake air pipe and termination (direct
vent installations) are free of obstructions that may prevent air
from entering the unit. Insure the screen on intake air connection
has been removed on direct vent installations, see “Figure 13:
AIR INTAKE SCREEN”. Also verify the intake air pipe length
does not exceed the maximum allowed as shown in the Vent
Section of this manual.
WATER HEATING ENABLE/DISABLE (ON/OFF) SWITCH
The Water Heating Enable/Disable (On/Off) Switch is a single-pole,
single-throw rocker switch. This switch provides 24V power to the
gas control valve.
SPARK IGNITER
The Spark Igniter is a device that ignites the main burner by spark.
When high voltage is applied to the igniter, spark is generated to
ignite the main burner.
75 GALLON UNIT
Figure: 2
BLOWER PROVER SWITCH
The Blower Prover Switch is provided on the heater to verify that
the fan is operating. It is a positive pressure switch whose electrical
contacts are normally open. When the fan increases the pressure in
the burner, the pressure switch will allow the electrical contacts to
close. The pressure switch is connected to the blower pressure tap
by a piece of tygon tubing. This tubing must be connected in order for
the switch to change the electrical contacts. The controller requires
that the electrical contacts on this air ow switch be open before it will
allow the blower to come on.
13
CAUTION
INSTALLATION CONSIDERATIONS
LOCATING THE WATER HEATER
Carefully choose a location for the new water heater. The
placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
water heater.
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
Whether replacing an existing water heater or installing the
water heater in a new location observe the following critical
points:
1. The water heater must be located indoors.
2. The water heater must not be located in an area where it
will be subject to freezing temperatures.
3. Locate the water heater so it is protected and not subject
to physical damage by a moving vehicle.
4. Locate the water heater on a level surface.
5. Locate the water heater near a floor drain. The water heater
should be located in an area where leakage of the tank or
connections will not result in damage to the area adjacent
to the water heater or to lower floors of the structure. When
such locations cannot be avoided, it is recommended that
a metal drain pan, piped to adequate drain, be installed
under the water heater. Drain pan should be fabricated
with sides at least 2” deep with diameter at least 2” greater
than diameter of heater. Pan must not restrict combustion
air flow.
6. Locate the water heater close to the point of major hot
water usage.
7. Locate the water heater close to a 120 VAC power supply.
See Power Supply on Page 18 for requirements.
8. Locate the water heater where an adequate supply of fresh
air for combustion and ventilation can be obtained. See
Combustion Air and Ventilation on Page 15.
9. Locate the water heater where the vent and intake air
piping, when installed, will remain within the maximum
equivalent lengths allowed. See Venting on Page 25.
10. Do not locate the water heater where noise (such as
the Combustion Blower) during normal operation will be
objectionable in adjacent areas.
11. Do not locate the water heater where the subsequent
installation of the vent (exhaust) or intake air terminations
would be objectionable due to noise at the termination(s).
This includes locations close to or across from windows
and doors. See Venting starting on Page 25.
Do not locate water heater areas where flammable liquids
(vapors) are likely to be present or stored (garages, storage
and utility areas, etc.): Flammable liquids (such as gasoline,
solvents, propane (LP or butane, etc.) and other substances
(such as adhesives, etc.) emit flammable vapors which can be
ignited by a gas water heater’s ignition device or main burner.
The resulting flashback and fire can cause death or serious
burns to anyone in the area.
Also, the water heater must be located and/or protected so it
is not subject to physical damage by a moving vehicle.
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
water heater extending beyond the full width and depth of the water
heater by at least 3” (7.6 cm) in any direction, or if the water heater
is installed in an alcove or closet, the entire oor must be covered
by the panel. Failure to heed this warning may result in a re hazard.
14
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5.5” (14.0 cm) from
the front and 18” (45.7 cm) from the top. (Standard clearance.) If
clearances stated on the heater differ from standard clearances, install
water heater according to clearances stated on the heater.
Adequate clearance 30” (76 cm) for servicing this water heater should
be considered before installation, such as changing the anode rods,
control system components and gas control valve.
A minimum clearance of 5.5” (14.0 cm) must be allowed for access to
replaceable and/or serviceable parts such as the thermostats, drain valve,
condensate drain, temperature-pressure relief valve, clean out opening,
and the vent connection (exhaust elbow).
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the wall as practicable
and as centralized with the water piping system as possible.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
• Do not cover the control system LCD on top of the water heater.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air ow.
COMBUSTION AIR AND VENTILATION
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a conned area such
as a closet, unless you provide air as shown in the Facts to Consider
About Location section. Never obstruct the ow of ventilation air. If
you have any doubts or questions at all, call your gas supplier. Failure
to provide the proper amount of combustion air can result in a re or
explosion and cause death, serious bodily injury, or property damage.
Figure 3: CLEARANCES
INSULATION BLANKETS
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the Energy Policy Act standards with respect to insulation and
standby loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identication of components
mentioned below, see “Figure 1B: 50 GALLON UNIT” & “Figure 1C:
75 GALLON UNIT”. Failure to follow these instructions can restrict
the air ow required for proper combustion, potentially resulting in
re, asphyxiation, serious personal injury or death.
Figure 4: COMBUSTION AIR AND VENTILATION
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater(s) be installed
direct vent so that all air for combustion and ventilation is taken
from outdoors.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly ammable in many cases, will also react to form corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
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UNCONFINED SPACE
An Unconned Space is one whose volume IS NOT LESS THAN
50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconned space.
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions shall be used to calculate the size, number
and placement of openings providing fresh air for combustion,
ventilation and dilution in conned spaces. The illustrations shown
in this section of the manual are a reference for the openings
that provide fresh air into conned spaces only. DO NOT refer to
these illustrations for the purpose of vent installation. See Venting
Installation on Page 25 for complete venting installation instructions.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and replaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconned spaces in buildings, inltration may be adequate to
provide air for combustion, ventilation and dilution of ue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in the
Conned Space section that follows.
CONFINED SPACE
A Conned Space is one whose volume IS LESS THAN 50 cubic
feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input
rating of all appliances installed in the space.
Openings must be installed to provide fresh air for combustion,
ventilation and dilution in conned spaces. The required size for
the openings is dependent on the method used to provide fresh
air to the conned space AND the total Btu/hr input rating of all
appliances installed in the space.
DIRECT VENT APPLIANCES
Appliances installed in a Direct Vent conguration that derive all
air for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total appliance input Btu/hr
calculations used to determine the size of openings providing fresh
air into conned spaces.
EXHAUST FANS
OUTDOOR AIR THROUGH TWO OPENINGS
Figure: 5
The conned space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 5.
Each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all
appliances installed in the enclosure. Each opening shall not be
less than 100 square inches (645 cm2).
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed in
the same space with a water heater, sufcient openings to provide
fresh air must be provided that accommodate the requirements
for all appliances in the room and the exhaust fan. Undersized
openings will cause air to be drawn into the room through the water
heater’s vent system causing poor combustion. Sooting, serious
damage to the water heater and the risk of re or explosion may
result. It can also create a risk of asphyxiation.
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
The required size of openings for combustion, ventilation and
dilution air shall be based on the net free area of each opening.
Where the free area through a design of louver or grille or screen is
known, it shall be used in calculating the size of opening required to
provide the free area specied. Where the louver and grille design
and free area are not known, it shall be assumed that wood louvers
will have 25% free area and metal louvers and grilles will have 75%
free area. Non motorized louvers and grilles shall be xed in the
open position.
OUTDOOR AIR THROUGH ONE OPENING
Figure: 6
16
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 6. The water heater shall have clearances of at
least 1 inch (25 mm) from the sides and back and 6 inches (150
mm) from the front of the appliance. The opening shall directly
communicate with the outdoors or shall communicate through a
vertical or horizontal duct to the outdoors or spaces that freely
communicate with the outdoors and shall have a minimum free
area of the following:
1. 1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
AIR FROM OTHER INDOOR SPACES
Figure: 8
The conned space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 8.
Figure: 7
The conned space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The horizontal ducts shall communicate directly with the
outdoors. See Figure 7.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect. The
minimum dimension of rectangular air ducts shall be not less than
3 inches.
Each opening shall communicate directly with an additional room(s)
of sufcient volume so that the combined volume of all spaces
meets the criteria for an Unconned Space.
Each opening shall have a minimum free area of 1 square inch per
1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure. Each opening shall not be
less than 100 square inches (645 cm2).
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INSTALLATION REQUIREMENTS
CHEMICAL VAPOR CORROSION
Corrosion of the ueways and vent system may occur if air for
combustion contains certain chemical vapors. Such corrosion may
result in failure and risk of asphyxiation.
Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium
and sodium chloride (water softener salt), waxes, and process
chemicals are typical compounds which are potentially corrosive.
Do not store products of this sort near the heater. Also, air which is
brought in contact with the heater should not contain any of these
chemicals. If necessary, uncontaminated air should be obtained
from remote or outside sources. The limited warranty is voided
when failure of water heater is due to a corrosive atmosphere. (See
limited warranty for complete terms and conditions).
WATER PIPING
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing,
dish washing, cleaning and other sanitizing needs can scald and
permanently injure you upon contact. Some people are more likely
to be permanently injured by hot water than others. These include
the elderly, children, the physically or developmentally disabled. If
anyone using hot water ts into one of these groups or if there is a
local code or state law requiring a certain temperature water at the
hot water tap, then you must take special precautions. In addition
to using the lowest possible temperature setting that satises your
hot water needs, a means such as a mixing valve should be used
at the hot water taps used by these people or at the water heater.
Valves for reducing point of use temperature by mixing cold and hot
water are also available:
This water heater shall not be connected to any heating
systems or component(s) used with a non-potable water heating
appliance.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall
not be introduced into this system.
When the system requires water for space heating at
temperatures higher than required for domestic water purposes,
a mixing valve must be installed.
These water heaters cannot be used in space heating
applications only.
POWER SUPPLY
The water heaters covered in this manual require a 120
VAC, 1Ø (single phase), 60Hz, 15 amp power supply and
must also be electrically grounded in accordance with local
codes or, in the absence of local codes, with the National
Electrical Code, ANSI/NFPA 70.
POWER FLUCTUATIONS AND ELECTRICAL NOISE
The water heater’s control system requires a source of
stable clean electricity for proper operation. Connecting the
water heater to a branch circuit that is subject to fluctuations
in voltage level or electrical line noise such as EMI (electro
magnetic interference) or RFI (radio frequency interference)
may cause erratic control system operation and malfunction.
A high quality power supply filter/suppressor must be
installed if the above conditions exist. Call the technical
support phone number listed on the back cover of this
manual for more information.
NOTE: Malfunctions caused by the power supply and the
costs to install power supply filters are not covered under
the limited warranty.
DEDICATED POWER WIRING AND BREAKERS
Dedicated power supply wires, ground wiring and dedicated
circuit breakers often prevent electrical line noise and
should be considered when installing the water heater.
Consult a Qualied Installer or Service Agency. Follow
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the Temperature
Regulation section in this manual.
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