State GS6 75 YRDS L User Manual

Installation and Operating Manual

RESIDENTIAL GAS WATER HEATERS

DIRECT VENTED GAS MODELS

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

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• For Your Safety •

AN ODO RANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

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

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

1404 327537-000

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE . . . . . . . . . . .3

GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

INSTALLATION REQUIREMENTS FOR THE

COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7

TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 9

Get To Know Your Water Heater - Gas Models

(List Referencing Figures 1-5). . . . . . . . . . . . . . . . . . 9

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

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

High Limit Controls (Energy Cut Off). . . . . . . . . . . . 10

Thermostat/Water Temperature

LOCATING THE NEW WATER HEATER. . . . . . . . . . . . . 11

Facts To Consider About The Location . . . . . . . . . . .11

External/Internal Damage . . . . . . . . . . . . . . . . . . . . .11

Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Conﬁ ned Space Installations. . . . . . . . . . . . . . . . . . 12

Clearances To Combustibles Floors With Carpeting Clearance For Servicing

Chemical Vapor Corrosion . . . . . . . . . . . . . . . . . . . 12

Storage Of Flammable Liquids . . . . . . . . . . . . . . . . 13

Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . . 13

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Water Pressure Mixing Valves

INSTALLING THE NEW WATER HEATER . . . . . . . . . . .15

Water Piping Installation . . . . . . . . . . . . . . . . . . . . . 15

Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 15

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 15

Temperature-Pressure Relief Valve. . . . . . . . . . . . . 16

T&P Valve Discharge Pipe Requirements: Temperature-Pressure Relief Valve And

Pipe Insulation

Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 17

Space Heating And Potable Water Systems . . . . . . 18

Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Requirements Installation

Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Sediment Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

High Altitude Installations . . . . . . . . . . . . . . . . . . . . 21

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Vent Terminal Clearances . . . . . . . . . . . . . . . . . . . . 22

DV Termination Safety Cover . . . . . . . . . . . . . . . . . 23

Vent Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Locating Clearance Hole For Vent . . . . . . . . . . . . . 23

Standard Vent Arrangement . . . . . . . . . . . . . . . . . . 23

Vent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Securing Vent Termination Assembly To

The Exterior Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Vent Restricter Plate . . . . . . . . . . . . . . . . . . . . . . . . 24

Uncompressing The Corrugated Tubing . . . . . . . . . 24

Vent Connection To The Water Heater . . . . . . . . . . 25

Offset Vent Arrangement. . . . . . . . . . . . . . . . . . . . . 25

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 27

LIGHTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 28

TEMPERATURE REGULATION . . . . . . . . . . . . . . . . . . .29

Temperature Regulation . . . . . . . . . . . . . . . . . . . . . 29

Temperature Adjustment

Operating The Temperature Control System. . . . . . 29

Water Temperature Adjustment Operating Modes And Settings

FOR YOUR INFORMATION. . . . . . . . . . . . . . . . . . . . . . . 30

External Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 30

Condensate Smoke/Odor

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 30

Strange Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 31

Smelly Water “Air” In Hot Water Faucets High Water Temperature Shut Off System

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Flood Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Venting System Inspection . . . . . . . . . . . . . . . . . . . 32

Pilot And Main Burner . . . . . . . . . . . . . . . . . . . . . . . 32

Burner Flames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Servicing The Water Heater . . . . . . . . . . . . . . . . . . 33

Removing And Replacing The Gas Control Valve/

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Removing The Gas Control Valve/Thermostat: Replacing The Gas Control Valve/Thermostat:

Removing The Manifold/Burner Assembly . . . . . . . 33

Removing The Burner From The Manifold/Burner

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Natural Gas (Low Nox) & Propane (LP) Gas Burner

Replacing The Pilot/Thermopile Assembly . . . . . . . 34

Replacing The Manifold/Burner Assembly . . . . . . . 35

Piezoelectric Igniter System . . . . . . . . . . . . . . . . . . 36

Testing The Igniter System . . . . . . . . . . . . . . . . . . . 36

Temperature-Pressure Relief Valve Test . . . . . . . . . 36

Draining, Reﬁ lling And Flushing . . . . . . . . . . . . . . . 36

To Drain The Water Heater Storage Tank To Reﬁ ll The Water Heater Storage Tank To Flush The Water Heater Storage Tank

Drain Valve Washer Replacement . . . . . . . . . . . . . 37

Anode Rod Maintenance. . . . . . . . . . . . . . . . . . . . . 37

To Remove The Anode Rod: To Install The Anode Rod:

LEAKAGE CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . 39

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

REFERENCE PARTS LISTING . . . . . . . . . . . . . . . . . . . .40

TROUBLESHOOTING GUIDELINES. . . . . . . . . . . . . . . . 42

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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SAFE INSTALLATION, USE AND SERVICE

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

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

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

DANGER indicates an imminently

DANGER

WARNING

CAUTION

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

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

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

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

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

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

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

IMPORTANT DEFINITIONS

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

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

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

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GENERAL SAFETY

WARNING

Fire or Explosion Hazard

• Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this water heater, the vent termination hood or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive

gas pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after

extended period of non-use.

Read instruction manual before

installing, using or servicing

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water heater.

GENERAL SAFETY

DANGER

WARNING

Breathing Hazard - Carbon Monoxide Gas

• Install vent system in accordance with codes.

• Do not operate water heater if flood damaged.

• For operation above 7,700’, a high altitude orifice must be installed.

• Do not operate if soot buildup is present.

• Do not place chemical vapor emitting products near water heater or vent termination hood.

• Gas and carbon monoxide detectors are available.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

FLAMMBLE

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

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

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

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

Flammable Vapors

Water heater has a main burner and pilot. While operating, the pilot flame:

1. is in continuous operation 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 by air currents.

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INTRODUCTION

Thank You for purchasing this water heater. Properly

installed and maintained, it should give you years of trouble free service. This water heater is suitable for potable water heating and space heating applications but not for space heating only applications.

Abbreviations found in this Installation and Operating manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• UL - Underwriters Laboratories Inc.

• AHRI - Air Conditioning, Heating and Refrigeration

Institute.

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

Z21.10.1 • CSA 4.1 (current edition).

QUALIFIED INSTALLER OR SERVICE AGENCY

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

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

also contains warnings throughout the manual that you must read and be aware of. All warnings and instructions are essential to proper operation of the water heater and your safety. Since we cannot put everything on the ﬁ rst few pages, READ ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

2. The installation must conform with these instructions and local code authority having jurisdiction. In absence of local codes, installation must comply with current editions of the “National Fuel Gas Code”, ANSI

Z223.1/NFPA 54 and “National Electrical Code”, NFPA 70. All documents are available from:

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

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

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.

4. Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and ﬁ res (see Figure 6). Examine the location to ensure the water heater complies with the “Locating The New Water Heater” section in this manual.

5. NOTE: For California installation , this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. Correct installation procedure instructions may be obtained from:

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

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section of this manual ﬁ rst and then entire manual carefully. If you don’t follow safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. This manual contains instructions for installation, operation, and maintenance of the gas-ﬁ red water heater. It

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California’s Ofﬁ ce of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95811. Instructions can also be downloaded to your computer at www.dsa.dgs.ca.gov..

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

2.00: State Plumbing Code and 248-CMR 5.00.

7. This product is certiﬁ ed to comply with a maximum weighted average of 0.25% lead content as required in some areas.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

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

MUST BE VERTICAL TO REMOVE A

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

WATER HEATER ACCEPTED BY THE BOARD FOR INSTALLATION IN MASSACHUSETTS.

MASSACHUSETTS INSTALLATION REQUIREMENTS:

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

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

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

† REQUIRED FOR MASSACHUSETTS.

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

IR BUBBLES

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

& 780 CMR).

†

)

†

TYPICAL MIXING VALVE INSTALLATION

EXPANSION TANK

CHECK

VALVE

UNION

HOT

WATER

OUT

VACUUM

†

RELIEF VALVE

UNION

TEMP/ PRESSURE RELIEF VALV E

SEE NOTE ‡

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

CHECK VALVE

(1/8” HOLE

DRILLED IN CLAPPER)

PUMP

AIR

HANDLER

SHUT-OFF

VALV E

IN HEATING UNIT

COLD WATER INLET

†

FLOW CONTROL

OUT

COIL

AIR

HANDLER

†

SHUT-OFF

VALVE

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TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5)

1 Vent Termination Hood 2 Wall Plate 3 ***Vent Pipe 4 Cold Water Inlet Nipple/Diptube 5 **Combo Heating System Supply

Outlet (Optional) 6 T&P Valve 7 Gas Control Valve/Thermostat

(Honeywell) 8 **Combo Heating System Return

Inlet (Optional) 9 *Discharge Pipe 10 Drain Valve 11 Outer Gas Door 12 Manifold Door Assembly (behind

outer door) (see Figure 3 &

Figure 4) 13 *Floor Drain 14 *Metal Drain Pan 15 Flexible Manifold Tube (see

Figure 3 & Figure 4)

16 *Sediment Trap 17 *Ground Joint Union (gas

connection) 18 *Main Manual Gas Shut-off Valve 19 *Gas Supply 20 Bafﬂ e Assembly 21 Rating Plate 22 Anode (under cap) 23 Hot Water Outlet Nipple (or

Optional Nipple/Anode) 24 *Inlet Water Shut-off Valve 25 *Union (water connection) 26 Air Inlet Snorkel 27 Air Tower 28 ***Airbox 29 *Thermal Expansion Tank (required

for all closed systems) 30 Sheet Metal Burner (see Figure 3 &

Figure 4) 31 Gas Oriﬁ ce (see Figure 3 &

Figure 4)

32 Gas Manifold (see Figure 3 &

Figure 4)

33 Manifold Door Gasket (see Figure 3

& Figure 4)

34 Manifold Door (see Figure 3 &

Figure 4)

35 Two Piece Grommet With Clip (see

Figure 3 & Figure 4) 36 Viewport (see Figure 3 & Figure 4) 37 Flexible Manifold Tube (see

Figure 3 & Figure 4) 38 Pilot (see Figure 3 & Figure 4) 39 Thermopile (see Figure 3 &

Figure 4) 40 Pilot Shield (see Figure 3 &

Figure 4) *, **, *** see notes on following page

1 32

11 12

Front View

Figure 1

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Rear View

Figure 2

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

Figure 5

Natural gas and Propane (LP) main burner with igniter assembly for 38k to 42k Btu/hr models

Figure 3

Natural gas and Propane (LP) main burner with igniter assembly for 47k Btu/hr models

4039

Notes:

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

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

*** During operation the vent pipe and airbox can get hot.

REPLACEMENT PARTS AND DELIMING PRODUCTS

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

COMBO HEATING INLET AND OUTLET SIDE TAPS

Models equipped with Combo Heating capabilities are shipped with the two side plumbing taps OPEN (items 5 and 8 in Figure 1 and see also Figure 8). If the heater is to be operated without using the side taps, these openings must be closed with the two pipe plugs supplied with the heaters.

HIGH LIMIT CONTROLS (ENERGY CUT OFF)

Thermostat/Water Temperature

This feature is a part of the gas control valve/thermostat (see Figure 1, item 7) and limits the maximum water temperature. In the event of the water overheating, this safety feature shuts off the fuel supply to the burner.

Figure 4

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LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

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

1. Select a location indoors as close as practical to the vent termination position. Figure 28 shows the venting distances that the heater can be from the outside wall. Ensure the vent termination position maintains the clearances as outlined in Figure 28 thru Figure 30.

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

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

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

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

CAUTION

• Water supply shut-off devices that activate based on

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

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

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

EXTERNAL/INTERNAL DAMAGE

Do not operate the water heater until it has been fully checked out by a qualiﬁ ed technician, if the water heater:

• Has been exposed to ﬁ re or damage.

• Displays evidence of sooting.

• Produces steam or unusually hot water.

If the water heater has been ﬂ ooded it must be replaced.

Property Damage Hazard

• All water heaters eventually leak.

• Do not install without adequate drainage.

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

• Sensors mounted in the metal drain pan that trigger an

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

• Sensors mounted in the metal drain pan that turn off

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

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AIR REQUIREMENTS

For safe operation an adequate supply of fresh, uncontaminated air must be provided for combustion. This gas-ﬁ red water heater is a direct vent model. It connects directly to the outside of the building through the vent termination hood. The hood operates as both the combustion air intake and the heater exhaust port (see Figure 16). All combustion air is obtained from outside the building through this hood. Ensure the area around the termination hood is always kept clear and that the air supply is not exposed to contamination or ﬂ ammable vapo rs.

CONFINED SPACE INSTALLATIONS

This water heater connects to the vent termination hood using the sealed air intake and exhaust piping (see Figure 1 and Figure 2). During operation this piping can become hot, especially in areas experiencing high ambient temperatures. When installed in a conﬁ ned space such as a closet, it is recommended that the conﬁ ned space be ventilated to minimize the buildup of heat around the heater. Figure 6 and Figure 7 show an examples of ventilating a conﬁ ned space.

0” MIN.

TOP VIEW

OF CLOSET

WITHOUT DOOR

0” MIN.

5.5” MIN.

TOP VIEW OF

CLOSET WITH

DOOR

0” MIN.

Figure 6

ROOM AIR

FLOW

VENTILATION

AIR

OPENING

Floors With Carpeting

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

Clearance For Servicing

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

A minimum clearance of 5.5” must be allowed for access to replaceable parts such as thermostats, drain valve and relief valve. When installing the heater, consideration must be given to proper location. Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible.

CHEMICAL VAPO R CORROSION

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPO RS. 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 or the vent termination hood. Air which is brought in contact with the heater or the vent termination hood should not contain any of the chemicals. The Limited Warranty is voided when failure of water heater is due to a corrosive atmosphere. See “Limited Warranty” for complete terms and conditions.

WARNING

ROOM AIR

FRONT VIEW

OF DOOR

Clearances To Combustibles

Minimum clearances between water heater and combustibles are 0” at the sides and rear, 5.5” from the front and 12” from top. Minimum clearances from vent piping to combustibles is 1” except as noted in Figure

FLOW

Figure 7

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this water heater, the vent termination hood, or any other appliance.

• Avoid all ignition sources if you smell gas.

• Do not expose water heater control to excessive gas

pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended

period of non-use.

21. If clearances stated on the heater differ from these clearances, install water heater according to clearances stated on the heater (see Figure 6).

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Fire or Explosion Hazard

Read instruction manual before

installing, using or servicing

water heater.

WARNING

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

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

Flammable Vapors

WARNING

Fire Hazard

For continued protection against risk of fire:

• Do not install water heater on carpeted floor.

• Do not operate water heater if flood damaged.

WARNING

Breathing Hazard - Carbon Monoxide Gas

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

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

• Do not place chemical vapor emitting products near water heater or near the vent termination hood.

• Do not obstruct the vent termination hood.

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

Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly ﬂ ammable in many cases, will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater. The results can be hazardous, and also cause product failure.

INSULATION BLANKETS

Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the current standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identiﬁ cation of components mentioned below, see Figure 1 thru Figure 5). Failure to follow these instructions will restrict the air ﬂ ow required for proper combustion and dilution, potentially resulting in ﬁ re, asphyxiation, serious personal injury or death.

• Check local codes to determine if insulation blankets

are allowed.

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

valve.

• Do not cover the “Installation And Operating manual”.

Keep it on the side of the water heater or nearby for future reference.

• Do obtain new warning and instruction labels from the

manufacturer for placement on the blanket directly over the existing labels.

Breathing carbon monoxide can cause brain damage or death.

Always read and understand instruction manual.

STORAGE OF FLAMMABLE LIQUIDS

Flammable liquids (such as gasoline, solvents, propane (LP or butane, etc.) and other substances (such as adhesives, paints, etc.) emit ﬂ ammable vapo rs which can be ignited by a gas water heater’s pilot or main burner. The resulting ﬂ ashback and ﬁ re can cause death or serious burns to anyone in the area. Even though this water heater is a ﬂ ammable vapo rs ignition resistant (FVIR) water heater and is designed to reduce the chances of ﬂ ammable vapo rs being ignited, gasoline and other ﬂ ammable substances should never be stored or used in the same vicinity or area containing a gas water heater, the vent termination hood, or other open ﬂ ame or spark producing appliance. Examples of such locations are garages, storage and utility areas.

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WATER PIPING

Water Pressure

The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line. This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures. See also “Closed Water Systems” and “Thermal Expansion” sections.

Mixing Valves

HOT WATER CAN SCALD: Water heaters are intended to heat 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.

Short repeated heating cycles caused by small hot water uses can cause a temperature increase of the hot water by 20F° higher than the heater’s temperature settings.

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

MIXING VALVE

TEMPERED POTABLE WATER

SHUT-OFF

VALV E

COLD WATER

INLET

Water temperature over

DANGER

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

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

Feel water before bathing or showering.

Temperature limiting devices

HOT

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

BURN

temperatures at fixtures.

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

1978) shows the approximate time-to-burn relationship for normal adult skin. If anyone using hot water provided by the water heater being installed ﬁ ts into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use, then special precautions must be taken (see Figure 8).

CERTAIN

MODELS ARE

EQUIPPED WITH

TEMPERATUREPRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

GAS SUPPLY

6 ” MAX. AIR GAP*

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

SIDE PLUMBING

CONNECTIONS

FOR SPACE HEATING. THE HOT AND COLD FITTING

ASSEMBLIES

(PART #9001262)

CAN BE ORDERED

THROUGH THE

MANUFACTURER

METAL DRAIN

PAN

DRAIN VALV E

Figure 8

Water

Temperature

°F

Time for 1st

Degree Burns

(Less Severe Burns)

Time for Permanent

Burns 2nd & 3rd

Degree (Most

Severe Burns)

110 (normal shower temp.)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seconds 25 seconds

140 2 seconds 5 seconds

149 1 second 2 seconds

154 instantaneous 1 seconds

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

Table 1

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

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INSTALLING THE NEW WATER HEATER

WATER PIPING INSTALLATION

Note: Water piping and vent piping occupy the space

above the water heater. Plan the water piping to ensure it does not cause interference with the vent piping (see “Venting”).

• The system should be installed only with piping that is

suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping.

• Use only pumps, valves, or ﬁ ttings that are compatible

with potable water.

• It is recommend that only full ﬂ ow ball or gate valves

are used in water piping installations. The use of valves that may cause excessive restriction to water ﬂ ow is not recommended.

• Use only 95/5 tin-antimony or other equivalent solder.

Any lead based solder must not be used.

• Piping that has been treated with chromates, boiler

seal, or other chemicals must not be used.

• Chemicals that may contaminate the potable water

supply must not be added to the piping system. Piping, ﬁ ttings, and valves should be installed according to the installation drawing (see Figure 9). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Important: Heat must not be applied to the water ﬁ ttings on the heater as they may contain nonmetallic parts. If solder connections are used, solder the pipe to the adapter before attaching the adapter to the hot and cold water ﬁ ttings. Important: Always use a good grade of joint compound and be certain that all ﬁ ttings are drawn up tight.

1. Install the water piping and ﬁ ttings as shown in Figure

9. Connect the cold water supply (3/4” NPT) to the cold water inlet ﬁ tting. Connect the hot water supply (3/4”

NPT) to the hot water outlet ﬁ tting. Important: These models may contain energy saving heat traps to minimize the migration of heat to the pipes. Do not remove the inserts within the heat traps.

2. The installation of unions in both the hot and cold water

supply lines is recommended for ease of removing the

water heater for service or replacement.

3. If installing the water heater in a closed water system,

install an expansion tank in the cold water line as

speciﬁ ed under “Closed Water Systems” and “Thermal

Expansion”.

4. Install a shut-off valve in the cold water inlet line. It

should be located close to the water heater and be

easily accessible. Know the location of this valve and

how to shut off the water to the heater.

5. After piping has been properly connected to the water

heater, remove the aerator at the nearest hot water

faucet. Open the hot water faucet and allow the tank

to completely ﬁ ll with water. To purge the lines of

any excess air, keep the hot water faucet open for

3 minutes after a constant ﬂ ow of water is obtained.

Close the faucet, reinstall the aerator and check all

connections for leaks. Repair as needed.

HOT WATER

OUTLET

UNION

3/4” SWEAT

FITTING

SOME

COMPONENTS

NOT SHOWN

FOR CLARITY.

SHUT-OFF

VALV E

UNION

EXPANSION

3/4” SWEAT

FITTING

TEMPERATUREPRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

DRAIN VALV E

6 ” MAX. AIR GAP

FLOOR DRAIN

COLD

WATER

INLET

TANK

METAL DRAIN PAN

Figure 9

Figure 9 shows typical attachment of water piping to the water heater. The water heater is equipped with 3/4” NPT water connections.

CLOSED WATER SYSTEMS

Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure-reducing valves, check valves, and back ﬂ ow preventers. Devices such as these cause the water system to be a closed system.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system, the volume of water will increase when heated. As the volume of water increases, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

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