State PR6 50 NHDST2 User Manual
Instruction Manual
RESIDENTIAL DIRECT VENT GAS WRESIDENTIAL DIRECT VENT GAS W
RESIDENTIAL DIRECT VENT GAS W
RESIDENTIAL DIRECT VENT GAS WRESIDENTIAL DIRECT VENT GAS W
FOR USE ONLY IN MANUFACTURED HOMES
FOR USE ONLY WITH VENTING SYSTEMS SUPPLIED WITH THE WATER
HEATER WHETHER A NEW INSTALLATION OR A REPLACEMENT
INSTALLATION.
GAMA certification applies to
all residential gas water
heaters with capacities of 20
to 100 gallons with input rating
of 75,000 BTU/Hr. or less.
AA
TER HEATER HEA
A
TER HEA
AA
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TERSTERS
TERS
TERSTERS
• For Your Safety •
AN ODORANT 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 WRITE TO 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.
PRINTED IN THE U.S.A 0404 PART NO. 184802-000
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SAFE INSTSAFE INST
SAFE INST
SAFE INSTSAFE INST
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.
DANGER
WARNING
CAUTION
ALLAALLA
ALLA
ALLAALLA
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.
TIONTION
TION
TIONTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
could 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, may result
in minor or moderate injury.
, USE AND SERVICE, USE AND SERVICE
, USE AND SERVICE
, USE AND SERVICE, USE AND SERVICE
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.
• Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields 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 fired water heaters. The qualified installer must also be familiar with the
design features and have a thorough understanding of this instruction manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields 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 fired water heaters. The service agency must also have a thorough
understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines
provided by the manufacturer.
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.
IMPORTANT DEFINITIONS
• 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.
2
GENERAL SAFETYGENERAL SAFETY
GENERAL SAFETY
GENERAL SAFETYGENERAL SAFETY
3
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ABLE OF CONTENTSABLE OF CONTENTS
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ABLE OF CONTENTS
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ABLE OF CONTENTSABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE ................................ 2
GENERAL SAFETY ...................................................................... 3
TABLE OF CONTENTS ................................................................. 4
INTRODUCTION ............................................................................ 4
Preparing for the New Installation ........................................ 4
TYPICAL INSTALLATION .......................................................... 5-6
LOCATING THE NEW WATER HEATER ....................................... 7
Facts to Consider About Location ..................................... 7-8
Insulation Blankets............................................................... 8- 9
INSTALLING THE NEW WATER HEATER ...............................9-19
Water Heater Installation .................................................. 9-10
Securing Water Heater to Floor and Wall .......................... 10
Roof Jack Installation ...................................................... 11-14
Manufactured Home installed Over Basement or
Crawlspace-Air Intake Through an Outside wall ........ 12,13
Cutting Opening Through an Outside Wall and
Collar Installation ............................................................. 13
Cementing PVC, ABS or CPVC Pipe and Fittings ......... 14
Water Piping .......................................................................... 14
T & P Valve and Pipe Insulation ................................ 14,15
Water Piping Pressure Test ................................................. 15
Temperature Pressure Relief Valve .............................. 15,16
Filling the Water Heater ....................................................... 16
Gas Piping......................................................................... 16,17
Sediment Traps ..................................................................... 17
Fuel Conversion Instructions from Natural Gas
to Propane (L.P.) Gas ..................................................... 17,19
Fuel Conversion Instructions from Propane (L.P.)
to Natural Gas ....................................................................... 19
LIGHTING & OPERATING LABEL .............................................. 20
TEMPERATURE REGULATION ................................................... 21
FOR YOUR INFORMATION ................................................... 21-22
Start Up Conditions ............................................................... 21
Condensate ................................................................. 21,22
Smoke/Odor ...................................................................... 22
Thermal Expansion .......................................................... 22
Strange Sounds ............................................................... 22
Operational Conditions ......................................................... 22
Smelly Water .................................................................... 22
“Air” in Hot Water Faucets ............................................. 22
High Temperature Shut Off System .............................. 22
PERIODIC MAINTENANCE ..................................................... 23-25
Venting System Inspection .................................................. 23
Burner Inspection ................................................................. 23
Burner Cleaning .................................................................... 23
Housekeeping ....................................................................... 23
Anode Rod Inspection .......................................................... 24
Temperature-Pressure Relief Valve Operation ................. 24
Draining .................................................................................. 24
Drain Valve Washer Replacement...................................... 24
Service................................................................................... 25
LEAKAGE CHECKPOINTS ......................................................... 25
TROUBLESHOOTING ................................................................. 26
REPAIR PARTS ........................................................................... 27
WARRANTY ........................................................................... Insert
INTRODUCTIONINTRODUCTION
INTRODUCTION
INTRODUCTIONINTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
This gas-fired water heater is design certified by CSA INTERNATIONAL
under American National Standard/CSA Standard for Gas Water Heaters
for Manufactured Home Installation, ANSI Z21.10.1 • CSA 4.1
(current edition).
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section, page 3 of this manual first and
then the entire manual carefully. If you don’t follow the 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 the installation, operation, and
maintenance of the gas-fired 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. Since we cannot put everything
on the first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.
2. Instructions to Manufactured Home Manufacturers:
The installation must conform with the Manufactured Home
Construction and Safety Standards Title 24 CFR, Part 3280.
Instruction for replacement installation:
The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54. This publication is available from the Canadian
Standards Association, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The 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 fires, see Figures 1 and 2.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
5. For California installation this water heater must be braced, anchored,
or strapped to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may be
obtained from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.
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. Complies with SCAQMD rule #1121 and districts having equivalent
NOx requirements.
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TYPICAL INSTTYPICAL INST
TYPICAL INST
TYPICAL INSTTYPICAL INST
ALLAALLA
ALLA
ALLAALLA
TIONTION
TION
TIONTION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Securing Clamp
C Anode
D Hot Water Outlet
E Outlet
F Roof Jack
G Gas Supply
H Manual Gas Shut-off Valve
I Ground Joint Union
* INSTALL IN ACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
TO VENT
TERMINATION
ON ROOF
J Drip Leg (Sediment Trap)
K Inner Door
L Outer door
M Union
N Inlet Water Shut-off Valve
O Cold Water Inlet
P Inlet Nipple
Q Temperature-Pressure Relief Valve
R Rating Plate
Z
THERMOSTAT
SHIELD
(OPTIONAL)
S Flue Baffle
T Thermostat
U Drain Valve
V Pilot and Main Burner
W Flue
X Air Duct Assembly
Y Drain Pan
Z Thermostat Shield (optional)
(T) THERMOSTAT
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
(V) PILOT & MAIN BURNER
FIGURE 1.
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TYPICAL INSTTYPICAL INST
TYPICAL INST
TYPICAL INSTTYPICAL INST
ALLAALLA
ALLA
ALLAALLA
TIONTION
TION
TIONTION
* MIXING VALVE USAGE
FIGURE 2.
This appliance has been design certified as complying with American
National Standard/CSA Standard ANSI Z21.10.1 • CSA 4. 1 for water
heaters and is considered suitable for:
Water (Potable) Heating: All models are considered suitable for water
(potable) heating.
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, 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 infirm, or physically/mentally handicapped. If
anyone using hot water in your home fits 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
satisfies your hot water needs, a means such as a *Mixing Valve,
shall be used at the hot water taps used by these people or at the
water heater. Mixing valves are available at plumbing supply or
hardware stores. Consult a Qualified 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 “Temperature Regulation” section in this manual, see Figures
36 and 37.
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LL
OCAOCA
L
OCA
LL
OCAOCA
TING THE NEW WTING THE NEW W
TING THE NEW W
TING THE NEW WTING THE NEW W
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FACTS TO CONSIDER ABOUT THE LOCATION
Whether replacing an old water heater or putting the water heater in a
new location, the following critical points must be observed.
This manufactured home gas-fired water heater is for use in a
manufactured home. You should carefully choose an indoor location
for the new water heater, because the placement is a very important
consideration for the safety of your occupants in the building and for
the most economical use of the appliance. This water heater is for
use only in a manufactured home and not intended for outdoor
installation.
This water heater has been designed and certified as a direct vent
(sealed combustion) unit and no draft diverter is to be used.
Minimum clearances between the water heater and combustible and
noncombustible construction are 0” from sides, 0” from back, 4” from
front of jacket to closet door and 27” from top of jacket to combustible
material. Minimum vent clearances: 6”. Provide 24” front clearance for
servicing and adequate clearance between the jacket top and ceiling
for servicing the flue area.
The combustion and ventilation air flow must not be obstructed.
Combustion air must be supplied from outside the manufactured home
by way of the furnished 3” diameter (30 and 40 Gallon) or 4” diameter
(50 Gallon) air intake duct assembly. A 3 1/2” diameter (30 and 40
Gallon) or 4 1/2” diameter (50 Gallon) floor opening below the water
heater is required to accommodate the air intake duct assembly. Weight
of the water heater on duct gasket seals the water heater to air intake
duct assembly.
have no more than 3 elbows. All horizontal runs require adequate
support at 3 1/2 feet intervals., see Figure 4.
When a manufactured home is skirted, an air intake opening with a
minimum free area of 32 square inches must be provided in the skirt. If
the opening is covered by louvers or screen, the total free area must
be 32 square inches. Other gas fired appliance in the home will require
additional free air openings; consult these manufacturers for correct
sizing, see Figure 3.
FIGURE 3.
If the manufactured home is installed over a basement or crawlspace,
combustion air must be supplied from outside the manufactured home.
The combustion air intake piping can be 3” PVC for 30 and 40 gallon
models and 4” PVC for 50 gallon models. The air intake piping cannot
exceed a total of 30 feet including vertical and horizontal runs and
FIGURE 4.
The water heater should be secured to the floor and to the wall of the
enclosure with the mounting brackets provided. For bracket location
refer to Securing Water Heater to Floor and Wall” in the “Installing the
New Water heater” section.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install the
water heater in an attic or upper floor. When such locations cannot be
avoided, a suitable drain pan should be installed under the water heater.
Drain pans are available at your local hardware store. Such a drain
pan must have a minimum length and width of at least 2 inches (51 mm)
greater that the water heater dimensions and must be piped to an
adequate drain. The pan must not restrict combustion air flow. When a
drain pan is required, see installation instructions on page 9.
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 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 drain pan.
7
These devices are available from some plumbing supply wholesalers
and retailers, and detect and react to leakage in various ways:
• Sensors mounted in the drain pan that trigger an alarm or turn off
the incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to
the entire home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
• Devices that will turn off the gas supply to a gas water heater while
at the same time shutting off its water supply.
alcove or closet, the entire floor must be covered by the panel. Failure
to heed this warning may result in a fire hazard.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Provide ventilation and combustion air by means
of an air intake duct assembly as stated in “Water Heater Installation”.
Never obstruct the flow 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 fire or explosion and cause
death, serious bodily injury, or property damage.
INSTALLATIONS IN 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 pilot light or main burner. The resulting flashback
and fire can cause death or serious burns to anyone in the area, as
well as property damage. If installation in such areas is your only
option, then the installation must be accomplished in a way that the pilot
flame and main burner flame are elevated from the floor at least 18
inches. While this may reduce the chances of flammable vapors, from
a floor spill being ignited, gasoline and other flammable substances
should never be stored or used in the same room or area containing a
gas water heater or other open flame or spark producing appliance.
NOTE: Flammable vapors may be drawn by air currents from other
areas of the structure to the appliance.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
• Install water heater in accordance
with the instruction manual and
NFPA 54.
• To avoid injury, combustion and
ventilation air must be taken from
outdoors.
• Do not place chemical vapor
emitting products near water
heater.
If this water heater will be used in beauty shops, barber shops, cleaning
establishments, or self-service laundries with dry cleaning equipment,
it is imperative that the water heater or water heaters be installed so
that combustion and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being highly
flammable in many cases, will also change to 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
This water heater must not be installed directly on carpeting. Carpeting
must be protected by metal or wood panel beneath the appliance
extending beyond the full width and depth of the appliance by at least
3 inches (76.2 mm) in any direction, or if the appliance is installed in an
• 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.
8
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 National Appliance Energy Conversation 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 identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
Do not apply insulation to the top of the water heater, as this will
•
interfere with safe operation of the draft hood.
Do not cover the outer door, thermostat or temperature & pressure
•
relief valve.
Do not allow insulation to come within 2" (50.8 mm) of the floor to
•
prevent blockage of combustion air flow to the burner.
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 flow.
INSTINST
INST
INSTINST
WATER HEATER INSTALLATION
1. To locate the position of the 3 1/2” or 4 1/2” hole to be cut in the floor,
see Figures 5 and 6.
ALLING THE NEW WALLING THE NEW W
ALLING THE NEW W
ALLING THE NEW WALLING THE NEW W
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A
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AA
TER HEATER HEA
TERTER
TER
TERTER
FIGURE 5.
FIGURE 6.
2. If you have found that the water heater is being installed in an area
which, if the water heater was to leak, would cause damage and
have elected to install a drain pan refer to Figures 7, 8 and 9 on
page 10. If you are not installing a drain pan go directly to the next
step.
NOTE: Clearances from combustible or non combustible surface to
jacket will change template dimensions.
9
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