RESIDENTIAL GAS WATER HEATERS
OWNER'S MANUAL
Thank you for buying this energy efficient water heater from
State Water Heaters. We appreciate your confidence in our
products.
You should thoroughly read this manual before installation
and/or operation of this water heater. Please pay particular
attention to the important safety and operating instructions as
well as the WARNINGS and CAUTIONS.
Power Vented Gas Models
PR6 40 XCVIT
PR6 40 CCVIT
PR6 50 XCVIT
PR6 50 CCVIT
with Hot Surface Ignition
TABLE OF CONTENTS
P AGE
GET TO KNOW YOUR W A TER HEA TER 2
GENERAL SAFETY INFORMA TION 3
INSTALLATION 4-12
OPERATION & LIGHTING INSTRUCTIONS 12-15
MAINTENANCE 15-16
TROUBLESHOOTING 17-18
WARRANTY 19
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.
500 Lindahl Parkway
Ashland City, TN 37015
www.statewaterheaters.com
KEEP THIS MANUAL IN THE POCKET ON THE HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED IN U.S.A. 0305 P ART NO. 185172-000
1
GET TO KNOW YOUR WATER HEATER
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be ordered
through authorized servicers or distributors. Refer to the Yellow
Pages for where to call or contact State Water Heaters, 500
Lindahl Parkway, Ashland City, TN 37015. When ordering parts,
provide complete model and serial numbers (see rating plate),
quantity and name of part desired (as listed in Figure 1). S tandard
hardware items may be purchased locally.
(A) VENT PIPE-EXHAUST
(B) ANODE
(C) HOT WATER OUTLET
(D) OUTLET (115 VAC)
(E) FLUE BAFFLE
(F) GAS SUPPLY
(G) MAIN MANUAL GAS
SHUT OFF VALVE
(H) GROUND JOINT UNION
(J) DIRT LEG
(K) OUTER DOOR
(L) UNION
(M) INLET WATER SHUT
OFF VALVE
(N) COLD WATER INLET
NATURAL HOT SURF ACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITOR
(O) INLET DIP TUBE
(P) TEMPERATURE AND
PRESSURE RELIEF VALVE
(Q) EMBLEM AND RATING PLATE
(R) INSULATION
(S) VENT TERMINAL
(T) DRAIN VALVE
(U) HSI BURNER ASSEMBLY
(V) FLUE
(W) DRAIN PAN
(X) GAS VALVE
(Y) CONTROL HARNESS
(Z) INNER DOOR
(AA) FLOOR DRAIN
(BB) VENT ADAPTER
SENSOR
*CAUTION: 115VAC IN CONTROL HARNESS
AND INSIDE OUTER DOOR
PROPANE HOT SURF ACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITOR
SENSOR
TEMPERATURE INDICA TORS
TEMPERATURE ADJUSTMENT BUTTONS
GAS MODELS
WITH HOT SURFACE IGNITION
& - 2” OR 3” PVC VENT CAPABILITY
FIGURE 1
2
GENERAL SAFETY INFORMATION
EXTERNAL DAMAGE
Do not operate the water heater until it has been fully checked
out by a qualified technician, if the water heater:
• Has been exposed to fire or damage.
• Displays evidence of sooting.
• Produces steam or unusually hot water.
If the water heater has been flooded it must be replaced.
CHEMICAL VAPOR CORROSION
WARNING
CORROSION OF THE FLUEWAYS 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. (Reference is made to the limited warranty for
complete terms and conditions).
IMPROPER COMBUSTION
WARNING
ATTIC AND/OR EXHAUST FANS OPERATING ON THE
PREMISES WITH A W A TER HEATER CAN RESUL T IN CARBON
MONOXIDE POISONING AND DEATH.
OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEATER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE VENT PIPE.
The venting of the water heater should be inspected by a qualified
service technician at the time of installation and periodically
thereafter to ensure a down-draft condition does not exist.
then call your gas supplier or service agent. Keep area clear
until a service call has been made.
At times you may not be able to smell an LP gas leak. One cause
is odor fade, which is a loss of the chemical odorant that gives LP
gas its distinctive smell. Another cause can be your physical
condition, such as having a cold or a diminishing sense of smell
with age. For these reasons, the use of a propane gas detector
is recommended.
IF YOU EXPERIENCE AN OUT-OF-GAS SITUATION, DO NOT
TRY TO RELIGHT APPLIANCE YOURSELF. Ask your LP delivery
person to relight pilots for you. Only trained LP professionals
should conduct the required safety checks in accordance with
industry standards.
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER
SYSTEM SERVED BY THIS HEATER THAT HAS NOT BEEN
USED FOR A LONG PERIOD OF TIME (GENERALLY TWO
WEEKS OR MORE).
FLAMMABLE. To reduce the risk of injury under these conditions,
it is recommended that the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance
connected to the hot water system. If hydrogen is present, there
will probably be an unusual sound such as air escaping through
the pipe as the water begins to flow.
SMOKING OR OPEN FLAME NEAR THE FAUCET A T THE TIME
IT IS OPEN.
HYDROGEN GAS IS EXTREMELY
THERE SHOULD BE NO
INSULATION BLANKETS
Insulation blankets available to the general public for external
use on gas water heaters are not approved for use on your State
water heater. The purpose of an insulation blanket is to reduce
the standby heat loss encountered with storage tank heaters.
Your State water heater meets and exceeds the National
Appliance Energy Conservation Act standards with respect to
insulation and standby loss requirements, making an insulation
blanket unnecessary.
WARNING
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions (See Figure 1 for identification
of components mentioned below). 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 OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUA TE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.
LIQUID PETROLEUM MODELS
WARNING
Water heaters for propane or liquefied petroleum gas (LPG) are
different from natural gas models. A natural gas heater will not
function safely on LP gas and no attempt should be made to
convert a heater from natural gas to LP gas.
LP gas must be used with great caution. It is highly explosive
and heavier than air. It collects first in the low areas making its
odor difficult to detect at nose level. If LP gas is present or even
suspected, do not attempt to find the cause yourself. Go to a
neighbor's house, leaving your doors open to ventilate the house,
Do not cover the outer door, thermostat or temperature &
•
pressure relief valve.
•
Do not allow insulation to come within 2 inches of dilution air
inlet on the blower to prevent blockage of the dilution air.
•
Do not allow insulation to come within 2" 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 State
Water Heaters 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.
3
INSTALLATION
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER
REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR
SUPPL Y , VENTING AND GAS SUPPL Y ARE REQUIRED.
GENERAL
The installation must conform to these instructions and the local
code authority having jurisdiction. 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. The former is available from the
Canadian Standards Association, 8501 East Pleasant Valley
Road, Cleveland, OH 44131, and both documents are available
from the National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269.
GROUNDING
The water heater when installed must be grounded in
accordance with local codes, or in the absence of local codes:
In the United States
The National Electric Code, ANSI/NFPA 70.
AIR REQUIREMENTS
Dilution air temperature must be 100°F or less. In calculating the
free area of a vent opening, the blocking effect of screens, louvers
and grills should be considered. Screens shall not be of a mesh
smaller than 1/4 inch square. If the free area is not known, the
current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54
recommends using figures of 20-25 percent free area for wood
louvers or 60-75 percent for metal grills or louvers.
UNCONFINED SPACE
In buildings of conventional frame, brick or stone construction,
unconfined spaces may provide adequate air for combustion,
ventilation, and dilution air for power venter.
If the unconfined space is within a building of tight construction
(as defined in the most recent revision of the National Fuel Gas
Code Handbook), air for combustion, ventilation, and venter
dilution must be obtained from outdoors. The installation
instructions for confined spaces must be followed.
HIGH ALTITUDE INSTALLATION
WARNING
STANDARD MODELS ARE FOR INSTALLATION UP TO 2,000
FEET (610m) ABOVE SEA LEVEL.
IF A STANDARD MODEL IS INSTALLED ABOVE 2,000 FEET
(610m), INPUT RATING SHOULD BE REDUCED AT A RATE 4
PERCENT FOR EACH 1,000 FEET (305m) ABOVE SEA LEVEL
WHICH REQUIRES REPLACEMENT OF THE BURNER ORIFICE
IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE
(ANSI Z223.1/NFP A 54).
FAILURE TO REPLACE THE ST ANDARD ORIFICE WITH A HIGH
ALTITUDE ORIFICE WHEN INSTALLED ABOVE 2,000 FEET
(610m) COULD RESULT IN IMPROPER AND INEFFICIENT
OPERATION OF THE W A TER HEA TER, PRODUCING CARBON
MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH COULD
RESULT IN SERIOUS INJURY OR DEATH. CONTACT YOUR
LOCAL GAS SUPPLIER FOR ANY SPECIFIC CHANGES WHICH
MAY BE REQUIRED IN YOUR AREA.
LOCATION OF HEATER
The heater is design certified by the Canadian Standards
Association for installation on combustible flooring in a closet
having minimum clearances from combustible material of: 0"
clearance from sides and rear, 5" from the front and 12" from the
top. (Standard clearance.) If clearances stated on the heater
differ from standard clearances, install water heater according
to clearances stated on heater.
Adequate clearance for servicing this appliance should be
considered before installation, such as changing the anodes, etc.
A minimum clearance of 5" must be allowed for access to
replaceable parts such as the 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.
Installation:
Do not install water heater
where
flammable products
will be stored or used
unless the main burner and
hot surface igniter are at
least 18” above the floor.
This will reduce, but not
eliminate, the risk of vapors
being ignited by the main
burner or hot surface
igniter.
CONFINED SPACE
When drawing combustion and dilution air from inside a
conventionally constructed building to a confined space, such a
space shall be provided with two permanent openings; ONE
WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE IN
OR WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM. Each
opening shall have a free area of one square inch per 1000 Btuh
of the total input of all appliances in the enclosure, but not less
than 100 square inches.
If the confined space is within a building of tight construction, air
for combustion, ventilation and power venter dilution must be
obtained from outdoors. When directly communicating with the
outdoors or communicating through vertical ducts, two
permanent openings, located in the above manner, shall be
provided. Each opening shall have a free area of not less than
one square inch per 4000 Btuh of the total input of all appliances
in the enclosure. If horizontal ducts are used, each opening
shall have a free area of not less than one square inch per 2000
Btuh of the total input of all appliances in the enclosure.
4
CAUTION
In cold climates provide protection against freeze-up.
THE HEATER SHOULD BE LOCATED IN AN AREA WHERE
LEAKAGE OF THE T ANK OR CONNECTIONS WILL NOT RESUL T
IN DAMAGE TO THE AREA ADJACENT T O THE HEATER OR TO
LOWER FLOORS OF THE STRUCTURE.
cannot be avoided, a suitable drain pan should be installed
under the heater, see fig. 1. The pan should have a minimum
length and width of at least 2 inches greater than the diameter of
the heater and should be piped to an adequate drain. Drain
pans suitable for these heaters are available from your dealer or
State Water Heaters, 500 Lindahl Parkway, Ashland City, TN
37015.
When such locations
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, unanticip ated damage can be reduced
or prevented by a leak detector or water shut-off device used in
conjunction with a piped 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 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.
WARNING
DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MA Y RESUL T .
water heater must be placed on a metal or wood panel extending
beyond the full width and depth by at least 3 inches (76.2mm) in
any direction. If the heater is installed in a carpeted alcove or
closet, the entire floor shall be covered by the panel. Also, see
DRAINING.
Instead the
WARNING
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 your local dealer ,
wholesaler, public utilities or California’s Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
WATER CONNECTIONS
Refer to figure 1 for typical installation. A suitable pipe thread
sealant must be used to prevent leakage.
WATER (POTABLE) HEATING AND SPACE
HEATING
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
2. Toxic chemicals, such as those used for boiler treatment,
shall NEVER be introduced into this system.
3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a tempering valve must be installed. Please refer
to Figure 2 for suggested piping arrangement.
FIGURE 2
CLOSED WATER SYSTEM
A closed system will exist if a back-flow preventer (check valve),
or similar device is installed in the cold water line between the
water heater and the street main (or well). Excessive pressure
may develop due to the thermal expansion of heated water
causing premature tank failure or intermittent relief valve
operation. This type of failure is not covered by the limited
warranty. An expansion tank may be necessary in the cold water
supply to alleviate this situation, see fig. 1. Contact the local
plumbing authority.
If the temperature and pressure relief valve on the appliance
discharges periodically, this may be due to thermal expansion
in a closed water supply system. Contact the water supplier or
local plumbing inspector on how to correct the situation.
plug the temperature and pressure relief valve.
Do not
GAS CONNECTIONS
The minimum gas supply pressure is 4.5" W.C for natural gas
(11.0" W.C. for propane).
THE HEATER IS NOT INTENDED FOR OPERA TION A T HIGHER
THAN 14.0'' WA TER COLUMN SUPPL Y PRESSURE. EXPOSURE
TO HIGHER GAS SUPPL Y PRESSURE MAY CAUSE DAMAGE
TO THE CONTROL WHICH COULD RESULT IN FIRE OR
EXPLOSION.
improper testing of gas lines or emergency malfunction of the
supply system, the control must be checked for safe operation.
Make sure that the outside vents on the supply regulators and
the safety vent valves are protected against blockage. These
are parts of the gas supply system not the heater. Vent blockage
may occur during ice storms.
IT IS IMPORTANT TO GUARD AGAINST CONTROL FOULING
FROM CONTAMINANTS IN THE GAS W AYS. SUCH FOULING
MAY CAUSE IMPROPER OPERA TION, FIRE OR EXPLOSION.
All piping must comply with local codes and ordinances or with
the National Fuel Gas Code (ANSI Z223.1/ NFPA-54) whichever
applies. Copper and brass tubing and fittings (except tin lined
copper tubing) shall not be used.
REFER TO FIG. 1 FOR CONNECTION DETAILS. BEFORE
ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS
CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS
SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED DRIP LEG)
MUST BE INCORPORA TED IN THE PIPING, FIG . 1.
must be readily accessible. Install in accordance with
recommendations of serving gas supplier. Refer to the current
edition of National Fuel Gas Code, ANSI Z223.1/NFPA.
5
If overpressure has occurred such as through
The dirt leg
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve inlet. The
thermostat inlet has a pad for use with back up wrench.
Apply joint compounds (pipe dope) sparingly and only to the
male threads of pipe joints. Do not apply compound to the first
two threads. Use compounds resistant to the action of liquefied
petroleum gases. Do not use teflon tape on gas valve fittings.
DISCONNECT THE APPLIANCE AND ITS INDIVIDUAL SHUT
OFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM
DURING ANY SUPPLY PRESSURE TESTING EXCEEDING
1/2 PSI (3.5 kPa). GAS SUPPLY LINE MUST BE CAPPED
WHEN DISCONNECTED FROM THE HEATER. FOR TEST
PRESSURES AT 1/2 PSI (3.5 kPa) OR LESS, THE APPLIANCE
NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED
FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MAIN
MANUAL GAS V AL VE.
IMPORT ANT
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54, 7.3.4e and 7.8a,b,
as follows:
1. The exit terminals of a mechanical vent system shall be not
less than 7 feet above grade when located adjacent to public
walkways. (Figure. 3)
2. A venting system shall terminate at least 3 feet above any
forced air inlet located within 10 feet. (Figure 3)
3. The venting system shall terminate at least 4 feet below, 4
feet horizontally from or, 1 foot above any door, window or
gravity air inlet into any building.
The manufacturer also recommends that the vent termination
should not be installed closer than 3 feet from an inside
corner of an L shaped structure and not be less than 1 foot
above grade.
BEFORE PLACING THE HEA TER IN OPERA TION, CHECK FOR
GAS LEAKAGE. USE SOAP AND WA TER SOLUTION OR OTHER
MATERIAL ACCEPTABLE FOR THIS PURPOSE. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF
IGNITION TO LOCA TE GAS LEAKS.
RELIEF V ALVE (P)-FIG . 1
A NEW TEMPERATURE AND PRESSURE RELIEF VALVE
COMPLYING WITH THE ST ANDARD FOR RELIEF VA LVES AND
AUTOMATIC GAS SHUT OFF DEVICES FOR HOT WATER
SUPPL Y SYSTEMS, ANSI Z21.22 (CURRENT EDITION) MUST
BE INSTALLED IN THE HEATER IN THE MARKED OPENING
PROVIDED. THE V AL VE MUST BE OF A SIZE (INPUT RA TING)
THA T WILL BE ADEQUA TE FOR YOUR SIZE HEA TER.
Check the metal tag on the relief valve and compare it to the
heater’s rating plate. The pressure rating of relief valve must not
exceed the working pressure shown on the rating plate of the
heater. In addition the hourly Btu rated temperature steam
discharge capacity of the relief valve shall not be less than the
input rating of the heater.
THE RELIEF VALVE AND TANK. DO NOT PLUG THE RELIEF
V AL VE.
The drain line connected to this valve must not contain a reducing
coupling or other restriction and must terminate near a suitable
drain to prevent water damage during valve operation. The
discharge line shall be installed in a manner to allow complete
drainage of both the valve and line.
OR CAP THE END OF THE DRAIN LINE.
NO V ALVE IS TO BE PLACED BETWEEN
DO NOT THREAD, PLUG
VENTING
The vent shall terminate a minimum of 12'' above expected
snowfall level to prevent blockage of vent termination.
4. In cold climates, it is recommended that vent termination not
be mounted directly above or within 3 feet horizontally from an
oil tank vent or gas meter to avoid potential freeze-up from
condensation.
Plan the vent system layout so that proper clearances are
maintained from plumbing and wiring.
Vent pipes serving power vented appliances are classified by
building codes as “vent connectors”. Required clearances from
combustible materials must be provided in accordance with
information in this manual under LOCATION OF HEATER and
VENT TERMINAL INSTALLATIONS, and with the National Fuel
Gas Code and local codes.
IMPORT ANT
Plan the layout of the vent system from the vent termination to the
appliance considering all of the 90 degree and 45 degree elbows
plus the number of feet of pipe that would be needed to install
the total vent system. Make sure to include the 90 degree elbow
if required at the blower. Review the tables on page 9 to make
sure that the vent system is within the allowed vent configuration.
Multiple fittings, 90 or 45 degree, installed in close proximity to
each other could result in intermittent lockouts or prevent the
unit from firing. Plan the layout to locate the fittings as far apart
as possible.
CAUTION
Termination of the vent system with a device other than the
supplied type vent terminal could effect system performance
and result in a safety hazard. The 2 inch vent terminal is a tee
and the 3 inch vent terminal is a 45 degree elbow. Both vent
terminals have protective screens.
WARNING
NEVER OPERATE THE HEATER UNLESS IT IS VENTED TO
THE OUTDOORS AND HAS ADEQUA TE AIR SUPPLY TO A VOID
RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR
ASPHYXIATION.
Make sure the flue baffle and flue restrictor ring are properly
aligned and inserted on top of the flue. This can be checked
through the dilution air inlet of the blower.
VENT PIPE TERMINATION
NOTE: Before installing power venter determine place of vent
pipe termination. See figure 3 on page 7.
VENT TERMINAL INSTALLATION
1. After the point of termination has been determined, use the
cover plate as a template to mark the hole for the vent pipe to
insert through the wall.
AND PIPING INSIDE OF WALL.
2. If the Vent Terminal is being installed on the outside of a
finished wall, it may be easier to mark both the inside and
outside wall. Align the holes by drilling a hole through the
center of the template from the inside through to the outside.
The template can now be positioned on the outside wall using
the drilled hole as a centering point for the template.
6
BEWARE OF CONCEALED WIRING
WARNING
VENT HOOD(S) MAY BE
EXTREMEL Y HOT DURING
OPERA TION
FIGURE 3
3. A) MASONRY SIDE WALLS
Chisel an opening approximately one half inch larger than the
marked circle.
B) WOODEN SIDE WALLS
Drill a pilot hole approximately one quarter inch outside of the
marked circle. This pilot hole is used as a starting point for a
saws-all or sabre saw blade. Cut around the marked circle
staying approximately one quarter inch outside of the line. (This
will allow the vent pipe to easily slide through the opening. The
resulting gap will be covered up by the vent terminal cover
plates.) Repeat this step on inside wall if necessary.
This unit can vent through 2 or 3 inch nonmetallic pipe and fittings.
The vent pipe installation can be started from either the blower
discharge or the termination wall. Keep in mind the total vent system
(pipe and elbows) when installing the vent system. (SEE VENT
T ABLES AND FIGURES ON P AGES 9-10.)
SEQUENCE OF INST ALLATION
1. The Power Vent Models come with the blower assembly
installed.
2. After the unit is set in place, make sure the blower
assembly is still mounted securely. Also make sure there
is no damage to the blower.
3. Make sure there is no packing material in the discharge of
the blower or the intake of the dilution air restrictor. See
Fig. 5.
4. Make sure that the plastic tubing is still attached from the
air pressure switch to the port on the blower housing.
5. Make sure the ON/OFF switch is in the OFF position and
that the outer harness is connected from the blower control
box to the connector on the bottom side of the gas valve.
If the outer harness is not factory installed, make sure the
ON/OFF switch is in the OFF position and then connect
the outer harness from the blower control box to the
connector on the right side of the gas valve.
FIGURE 4
The vent terminal should be kept as close as possible to the outside
wall, but you need to allow at least 1.5 inches of pipe past the wall,
for the wall flange and vent terminal to mount on the pipe.
Before the vent terminal is installed, caulk (not supplied) around the
pipe on the exterior wall and install the wall flange (can be held to the
outside wall by placing some of the caulking on the back of the flange).
7
FIGURE 5
Figure 5 shows the optimal placement of the 3” to 2”
reducer; however, the vent can be reduced at any point in
the vent system as long as the 2” vent tables are followed.
Do not plug in power cord until vent system is completely
installed. The Power V ent operates on 110-120 Vac, therefore
a grounded outlet must be within reach of the six (6) foot
flexible power cord supplied with the unit (see fig. 1). The
power cord supplied may be used only where local codes
permit. If local codes do not permit the use of a flexible power
supply cord:
a.) Make sure the unit is unplugged from wall outlet. Remove
screws and open panel on front of control box.
d.) Splice field wiring into existing wiring using code
authorized method (wire nuts, etc.).
e.) Be certain that neutral and line connections are not
reversed when making these connections.
f.) Close panel on the side of control box, make sure that
access panel is secured shut.
b.) Cut the flexible power cord, leaving enough to be able to
make connections, then remove the strain relief fitting
from box.
c.) Install suitable conduit fitting in side of enclosure and
then follow (d.) and (e.) below.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN
SERVICING CONTROLS. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERA TION. VERIFY PROPER
OPERA TION AFTER SERVICING .
FIGURE 6
8
TABLE FOR VENT PIPE LENGTH
TWO (2) INCH DIAMETER PIPE
**Number of 90° Elbows **Number of 45° Elbows Minimum Pipe Maximum Pipe
One (1) None 2 F t. 30 Ft.
One (1) One (1) 1 Ft. 27.5 Ft.
Two (2) None 1 Ft. 25 Ft.
Two (2) One (1) 1 Ft. 22.5 Ft.
Three (3) None 1 F t. 20 Ft.
Three (3) One (1) 1 Ft. 17.5 Ft.
Four (4) None 1 F t. 15 Ft.
Four (4) One (1) 1 Ft. 12.5 Ft.
THREE (3) INCH DIAMETER PIPE
** Number of 90° Elbows **Number of 45° Elbows Minimum Pipe Maximum Pipe
One (1) None 2 F t. 75 Ft.
One (1) One (1) 2 Ft. 72.5 Ft.
Two (2) None 1 Ft. 70 Ft.
Two (2) One (1) 1 Ft. 67.5 Ft.
Three (3) None 1 F t. 65 Ft.
Three (3) One (1) 1 Ft. 62.5 Ft.
Four (4) None 1 F t. 60 Ft.
Four (4) One (1) 1 Ft. 57.5 Ft.
***Five (5) None 1 F t. 55 Ft.
***Five (5) One (1) 1 Ft. 52.5 Ft.
***Six (6) None 1 Ft . 50 Ft .
** One (1) 90° elbow is equal to two (2) 45° elbows.
*** It is not recommended that more than (4) 90° elbows be used, or a combination of three (3) 90° and two (2) 45° elbows, but as long
as the total length is less than in the chart above, the vent system is acceptable.
Note: For the two (2) and three (3) inch diameter vent pipes, one (1) 90° elbow is approximately the same as five (5) feet of the same diameter straight pipe.
INSTALLATION OF VENT SYSTEM
(Refer to Figures 3, 4, 5, 7 and 8 as guides).
1. Plan the route of the vent system. Layout the total vent system
to use minimum of vent pipe and elbows. The vent piping
should be vented downward away from the blower per the
required codes. If the vent piping is sloped level or upwards
away from the blower, then adequate means for draining and
disposing of the condensate needs to be made by the installer.
2. Refer to table above for allowable vent lengths. Nonmetallic
vent piping may be used if it has a “Heat Deflection
Temperature” (HDT@66psi) of at least 157 degrees F. Some
typical nonmetallic vent materials meeting this requirement
are PVC to ASTM D2665, CPVC to ASTM D2846, and ABS to
ASTM D2261. The cement used should be as recommended
by the vent pipe manufacturer. The vent terminal provided is
PVC to ASTM D2665 and is a standard 2 inch tee or a 3 inch
45 degree ell. If a material other than PVC is used for venting,
then an equivalent fitting of that material may be substituted if
the screen in the PVC terminal is removed and inserted into
the new fitting. For water heaters installed in locations with
high ambient temperatures (above 100 degrees F), it is
recommended that CPVC or ABS be used.
3. See the instructions on pages 10 through 12 for the proper
method of cutting and cementing the PVC pipe and fittings.
4. The vent piping should be connected to the blower with a
rubber adapter and secured with hose clamps. The adapter
and clamps are provided with the heater.
5. Even though the flue gas temperature leaving the blower is
between 140°F and 175°F, some installations will have water
condense in the vent piping. If this occurs, then adequate
means of draining and disposing of the condensate needs to
be made by the installer.
FIGURE 7
The vent pipe may be installed with a slight downward slope
to drain condensate away from the blower. The pipe may
slope 1/4 inch per five feet of pipe but not more than
1 1/2 inches in the total vent length.
The vent pipe should be properly supported and have
supports located no further apart than 5 feet on vertical runs
and 3 feet on horizontal runs. All pipe and fittings should be
joined by the proper procedures discussed on pages 10 and
11 under the heading: VENT PIPE PREPARATION.
9
VERTICAL VENT THROUGH ROOF
This unit is approved for venting through the roof with the type
vent terminal that is included with the unit. A proper flashing or
“BOOT” should be used to seal the pipe where it exits the roof.
The total vent system should not exceed that which is specified
in the table on page 9.
All of the pipe should be secured as per the instructions in the
“INSTALLA TION OF VENT SYSTEM” on p age 9.
VERTICAL VENT TERMINATION
RESTRICTIONS
1. Minimum of twelve (12) inches above the roof or twelve (12)
inches above the anticipated snow level. Provide proper
support for all pipe protruding through the roof.
C. Know the reputation of your manufacturer and their
products.
D. Know your own qualifications or those of your contractor.
The solvent welding technique of joining PVC and CPVC
pipe is a specialized skill just as any other pipe fitting
technique.
E. Closely supervise the installation and inspect the finished
job before start-up.
F. Contact the manufacturer, supplier, or competent
consulting agency if you have any questions about the
application or installation of PVC and CPVC pipe.
G. T ake the time and effort to do a professional job. Shortcut s
will only cause you problems and delays in start-up. By
far, the majority of failures in PVC and CPVC systems
are the result of shortcuts and/or improper joining
techniques.
2. SELECTION OF MATERIALS
• Cutting Device - Saw or Pipe Cutter
• Deburring T ool, Knife, File, or Beveling Machine (2" and above)
• Brush - Pure Bristle
• Rag - Cotton (Not Synthetic)
• Primer and Cleaner
• Solvent Cement - PVC for PVC Components and CPVC for
CPVC Components
• Containers - Metal or Glass to hold Primer and Cement. Select
the type of PVC or CPVC materials to be used on the basis of
their application with respect to chemical resistance, pressure
rating, temperature characteristics, etc.
• Insertion Tool - Helpful for larger diameter pipe and fittings
(6" and above).
FIGURE 8
2. Four (4) feet from or one (1) foot above any gable, dormer, or
other roof structure with access to interior of building (i.e.vent, window etc.).
3. Three (3) feet above any forced air inlet located within ten (10)
feet.
VENT PIPE PREPARATION
1. INITIAL PREPARA TION
A. Make sure the solvent cement you are planning to use is
designed for the specific application you are attempting.
B. Know the physical and chemical characteristics and
limitations of the PVC and CPVC piping materials that
you are about to use.
PRIMER
It is recommended that T etrahydrofuran (THF) be used to prep are
the surfaces of pipe and fittings for solvent welding. Do not use
water, rags, gasoline or any other substitutes for cleaning PVC
or CPVC surfaces. A chemical cleaner such as MEK may be
used.
CEMENT
The cement should be a bodied cement of approximately 500 to
1600 centipoise viscosity containing 10-20% (by weight) virgin
PVC material solvated with tetrahydrofuran (THF). Small
quantities of dimethyl formamide (DMF) may be included to act
as a retarding agent to extend curing time. Select the proper
cement; Schedule 40 cement should be used for Schedule 40
pipe. Never use all-purpose cements, commercial glues and
adhesives or ABS cement to join PVC or CPVC pipe and fittings.
SAFETY PRECAUTION: PRIMERS AND CEMENTS ARE
EXTREMELY FLAMMABLE, AND MUST NOT BE STORED OR
USED NEAR HEAT OR OPEN FLAME. ALSO, USE ONLY IN A
WELL-VENTILATED AREA.
APPLICAT ORS
Select a suitable pure bristle type paint brush. Use a proper
width brush or roller to apply the primer and cement (see chart
below). Speedy application of cement is important due to its fast
drying characteristics. IMPORTANT NOTE: A dauber type
applicator should only be used on pipe sizes 2" and below. For
larger diameter pipe, a brush or roller must be used.
10
RECOMMENDED BRUSH* SIZE FOR PRIMER
AND CEMENT APPLICA TIONS
Nominal Pipe Size Brush Width
(IPS) (INS.)
2 1-1/2
3 1-1/2 - 2-1/2
*USE ONLY NA TURAL BRISTLE
3. MAKING THE JOINT
A. Cutting
Pipe must be squarely cut to allow for the proper interfacing
of the pipe end and the fitting socket bottom. This can be
accomplished with a miter box saw or wheel type cutter. Wheel
type cutters are not generally recommended for larger
diameters since they tend to flare the corner of the pipe end.
If this type of cutter is used, the flare on the end must be
completely removed.
NOTE: Power saws should be specifically designed to cut plastic
pipe.
D . Inspection, cleaning, priming
Visually inspect the inside of the pipe and fitting sockets and
remove all dirt, grease or moisture with a clean dry rag. If
wiping fails to clean the surfaces, a chemical cleaner must
be used. Check for possible damage such as splits or cracks
and replace if necessary.
Depth-of-entry
Marking the depth of entry is a way to check if the pipe has
reached the bottom of the fitting socket in Step F. Measure
the fitting depth and mark this distance on the pipe O.D. You
may want to add several inches to the distance and make a
second mark as the primer and cement will most likely destroy
your first one.
Apply primer to the surface of the pipe and fitting socket with
a natural bristle brush (see chart on page 11). This process
softens and prepares the PVC or CPVC for the solvent
cementing step. Move quickly and without hesitation to the
cementing procedure while the surfaces are still wet with
primer.
E . Application of solvent cement
• Apply the solvent cement evenly and quickly around the
outside of the pipe at a width a little greater than the depth
of the fitting socket.
• Apply a light coat of cement evenly around the inside of the
fitting socket. Avoid puddling.
STEP A
B . Deburring
Use a knife, plastic pipe deburring tool, or file to remove burrs
from the end of small diameter pipe. Be sure to remove all
burrs from around the inside as well as the outside of the
pipe. A slight chamfer (bevel) of about 10°-15° should be
added to the end to permit easier insertion of the pipe into the
end of the fitting. Failure to chamfer the edge of the pipe may
remove cement from the fitting socket, causing the joint to
leak.
STEP B
• Apply a second coat of cement to the pipe end.
NOTE: Cans of cement and primer should be closed at all times
when not in use to prevent evaporation of chemicals and
hardening of cement. They are also very flammable and should
be kept away from heat or flame.
STEP E
F . Joint assembly
Working quickly, insert the pipe into the fitting socket bottom
and give the pipe or fitting a 1/4" turn to evenly distribute the
cement. Do not continue to rotate the pipe after it has hit the
bottom of the fitting socket. A good joint will have sufficient
cement to make a bead all the way around the outside of the
fitting hub. The fitting will have a tendency to slide back while
the cement is still wet so hold the joint together for about 15
seconds.
C . Test dry fit of the joint
Tapered fitting sockets are designed so that an interfaced fit
should occur when the pipe is inserted about 1/3 to 2/3 of the
way into the socket. Occasionally, when pipe fitting
dimensions are at the tolerance extremes, it will be possible
to fully insert dry pipe to the bottom of the fitting socket. When
this happens, a sufficient quantity of cement must be applied
to the joint to fill the gap between the pipe and fitting. The gap
must be filled to obtain a strong, leak-free joint.
STEP F
11
G . Cleanup and joint movement
Remove all excess cement from around the pipe and fitting
with a dry cotton rag. This must be done while the cement is
still soft.
The joint should not be disturbed immediately after the
cementing procedure, and sufficient time should be allowed
for proper curing of the joint. Exact drying time is difficult to
predict because it depends on variables such as temperature,
humidity and cement integrity. For more specific information,
you should contact your solvent cement manufacturer.
STEP G
T & P VALVE and PIPE INSULATION
Remove insulation for T & P Valve and pipe connections from
carton.
Fit pipe insulation over the in-coming cold water line and the hot
water line. Make sure that the insulation is against the top cover
of the heater.
Fit T & P valve insulation over valve. Make sure that the insulation
does not interfere with the lever of the T & P valve.
Secure all insulation using tape.
OPERATION
WARNING
NEVER OPERATE THE HEATER WITHOUT FIRST BEING
CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE
AND PRESSURE RELIEF VAL VE IS INST ALLED IN THE RELIEF
VALVE OPENING OF THE HEATER. DO NOT ATTEMPT TO
OPERATE HEA TER WITH COLD W A TER INLET V AL VE CLOSED.
TO OPERATE THE WATER HEATER
FILLING
1. Close the heater drain valve by turning handle clockwise
Fig. 1 (T)
2. Open a nearby hot water faucet to permit the air in the system
to escape.
3. Fully open the cold water inlet pipe valve (allowing the heater
and piping to be filled. Fig. 1(M)
4. Close the hot water faucet as water starts to flow from the
faucet.
5. The heater is ready to be operated.
12
FOR YOUR SAFETY READ BEFORE OPERA TING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss
of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH W ATER AND AIR PURGED FROM ALL LINES.
A. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights
the burner. Do
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
WHA T TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch;
do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
NOT try to light the burner by hand.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in the gas control
buttons. Never use tools. If the control buttons will
not push in, don’t try to repair them, call a qualified
service technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately contact a qualified
installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit! It
must be replaced!
OPERA TING INSTRUCTIONS
4. This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
1. STOP! Read the safety information above,
on this label.
2. Set the thermostat to the lowest setting by first
pressing the COOLER and HOTTER buttons
together and holding for 1 second. Then press the
COOLER
appears.
3. Turn the “ON/OFF” switch on the blower control box
to the “OFF” position.
button until the WARM indicator light
TO TURN OFF GAS TO APPLIANCE
5. Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B”
in the safety information above on this label. If
you don’t smell gas, go to the next step.
6. Turn on all electrical power to the appliance.
7. Set thermostat to desired setting by first pressing
the COOLER and HOTTER buttons
together and holding for 1 second. Then press
the HOTTER
8. If the appliance will not operate, follow the
instructions “TO TURN OFF GAS TO APPLIANCE”
and call your technician or gas supplier.
9. WATER TEMPERA TURE ADJUSTMENT
is approximately 120°F.
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING
button.
1. Set thermostat to the lowest setting by first pressing the COOLER and HOTTER buttons together
and holding for 1 second. Then press the COOLER
2. Set the ON/OFF switch on the blower control box to the “OFF” position.
3. Turn off all electric power to the appliance if service is to be performed.
button until the WARM indicator light appears.
13
TEMPERATURE REGULATION
T o avoid any unintentional changes in water temperature settings,
the control has a tamper resistant feature for changing the
temperature setting. To change the temperature setting follow
these instructions:
1. “Wake Up” the temperature indicators by holding down both
“COOLER” and “HOTTER” temperature adjustment buttons
at the same time for one second (See Figure 9). One or two of
the temperature indicators will light up. These indicators will
only remain on for 30 seconds if no further buttons are
pressed. After 30 seconds the control will go back to “Sleep”
mode.
2. Release both of the temperature adjustment buttons.
A. To decrease the temperature press and release the
“COOLER” button until the desired setting is reached.
WARNING
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT
WATER TEMPERATURES REQUIRED FOR AUTOMATIC
DISHWASHER AND LAUNDRY USE CAN CAUSE PAINFUL
SCALDING WITH POSSIBLE SERIOUS AND PERMANENT
INJURY. THE TEMPERATURE AT WHICH INJURY OCCURS
VARIES WITH THE PERSON'S AGE AND THE TIME OF
EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN,
AGED OR DISABLED PERSONS INCREASES THE HAZARDS
TO THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT
WA TER TAP OR TO DRAW THEIR OWN BATH WA TER. NEVER
LEAVE A CHILD OR DISABLED PERSON UNATTENDED IN A
BA THTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA
WHERE THE GENERAL PUBLIC DOES NOT HA VE ACCESS. IF
A SUITABLE AREA IS NOT A VAILABLE, A COVER SHOULD BE
INSTALLED OVER THE THERMOSTAT TO PREVENT
T AMPERING.
It is recommended that lower water temperatures be used to
avoid the risk of scalding. It is further recommended, in all cases,
that the water temperature be set for the lowest temperature
which satisfies your hot water needs. This will also provide the
most energy efficient operation of the water heater. The water
temperature setting was factory set at the lowest temperature;
Pressing the “COOLER”
pressing the “HOTTER”
button decreases temperature and
button increases the temperature.
B. To increase the temperature press and release the
“HOTTER” button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or
raise the temperature setting. The button must be pressed and
released for each temperature change desired.
SHOULD OVERHEA TING OCCUR OR THE GAS SUPPLY FAIL
TO SHUTOFF , TURN OFF THE MANUAL GAS CONTROL VAL VE
TO THE APPLIANCE. SEE FIGURE 1(G).
TEMPERATURE INDICA TORS
SETTING THE WATER HEATER TEMPERATURE AT 120°F
(APPROX. "
VALVE) WILL REDUCE THE RISK OF SCALDS
" MARK ON TEMPERATURE SETTING OF GAS
. Some states
require settings at specific lower temperatures.
Figure 9 shows the approximate water temperatures produced
at various thermostat settings. Short repeated heating cycles
caused by small hot water uses can cause temperatures at the
point of use to exceed the thermostat setting by up to 30°F (17ºC).
If you experience this type of use you should consider using
lower temperature settings to reduce scald hazards.
Valves for reducing the point-of-use temperature by mixing cold
and hot water are available. See figure 2. Also available are
inexpensive devices that attach to faucets to limit hot water
temperatures. Contact a licensed plumber or the local plumbing
authority.
TEMPERATURE ADJUSTMENT BUTTONS
Time to Produce
Display 2nd & 3rd Degree
Temperature Setting A B C Burns on Adult Skin
C - Flashing = approx. 160°F About 1/2 seconds
C = approx. 150°F About 1-1/2 seconds
B = approx. 140°F Less than 5 seconds
A = approx. 130°F About 30 seconds
= approx. 120°F More than 5 minutes
WARM = approx. 80°F - - - - - - - - - - - - - - -
FIGURE 9
14
WATER HEATING IGNITION SEQUENCE
(Make sure gas and electric power are connected properly)
1) The ignition control module is powered and monitors the
system, waiting for a call for heat from the thermostat.
2) The thermostat calls for heat by reading a resistance value
within a given range directly proportional to water
temperature.
3) The control Module:
a) Checks the pressure switch for an open circuit.
b) Energizes the blower.
c) Checks the pressure switch for a closed circuit to prove
draft.
d) Sends line voltage to the hot surface igniter with a
20 second warm up period.
e) Opens the gas valve and checks the sensing rod for
flame.
4) The burner heats the water to the desired thermostat setting.
a) The resistance in the thermostat rises to the value
selected by the temperature setting.
b) The control module closes the gas valve and 5 seconds
later, removes power from the blower.
5) Cycle is completed.
CONTROL SEQUENCE - HOT SURF ACE DIRECT IGNITION
Pre-purge 5 seconds.
HSI Warm-up 2 0 seconds.
Ignition Activation Period 4 seconds.
Flame Recognition Period 1 seco nd.
Ignition Trial 4 seconds.
Interpurge 5 seconds.
Post-purge 5 seconds.
Retries 2
Reset from Lockout 1 hr.
Flame Sensing (Nominal)
HSI Off/Run Mode 4.0µV DC
MAINTENANCE
WARNING
DISCONNECT FROM ELECTRICAL SUPPLY BEFORE
SERVICING UNIT .
FOR YOUR SAFETY, WATER HEATER SERVICE SHOULD BE
PERFORMED ONLY BY A QUALIFIED SERVICE TECHNICIAN.
READ THE GENERAL SAFETY INFORMA TION SECTION FIRST.
USERS OF THIS APPLIANCE SHOULD BE AWARE THAT GAS
COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE
GAS CARRYING COMPONENTS OF THIS APPLIANCE SHOULD
BE INSPECTED FOR PROPER OPERATION PERIODICALL Y BY
A QUALIFIED SERVICE TECHNICIAN.
MAIN BURNER -FIG. 1
Check main burner every 12 months for proper flame
characteristics. This is done by removing door(s) on heater, fig.
1. The main burner should provide complete combustion of
gas; ignite rapidly; give reasonably quiet operation; cause no
excessive flame lifting from burner ports. Make sure that the
flow of combustion and ventilation air is not blocked.
If proper flame characteristics are not evident, check for
accumulation of lint or other foreign material that restricts or
blocks the air openings in the heater or burner. Also check AIR
REQUIREMENTS.
WARNING
SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES
CORRECTION BEFORE FURTHER USE. Consult with a qualified
service technician.
Should the main burner or burner air openings require cleaning,
turn the blower switch to “OFF” position and allow the burner to
cool. Remove the burner and clean with a soft brush. Clean
main burner orifice with a suitable soft material.
HIGH TEMPERATURE LIMIT SWITCH
(Single-Use Type Energy Cut Off)
FIGURE 10
The thermostat has a built-in limit switch which will actuate in
case of excessive water temperatures. The heater cannot be
relit until the Gas Control Valve is replaced It is important that a
serviceman be called to determine the reason for limit operation
and thus avoid repeated thermostat replacement. Lower the
temperature adjustment setting on new control.
15
VENTING SYSTEM
• Turn off the gas and cold water inlet valve to the heater.
HA VE VENTING SYSTEM CHECKED EVERY SIX MONTHS FOR
OBSTRUCTIONS AND/OR DETERIORA TION IN VENT PIPING.
BLOWER ASSEMBLY MAINTENANCE
CAUTION
The air flow restrictor screen on the inlet side of the blower unit
should be checked periodically for any accumulation of dust and
lint. Any build up of dirt in the screen can result in insufficient
dilution air and excessive vent temperatures that could cause
heat damage to the PVC pipe or cause the thermal switch to
safely shut the unit down. Should this happen, the build up of the
lint/dirt needs to be cleaned.
The venter must be inspected four times a year. Points of
inspection are:
1. MOTOR - Motor must rotate freely .
2. WHEEL - Wheel must be clean of soot, ash, lint or any other
coating which inhibits either rotation or air flow. Remove all
foreign material from vent system before operating.
3. The pressure switch part inside the power venter must be
open and free from deposits of soot, carbon, etc.
For safety and satisfactory operation it is recommended that the
heater be checked once a year by a competent service person.
T & P VAL VE
At least once a year, the temperature and pressure relief valve
must be checked to ensure that it is in operating condition. Lift
the lever at the top of the valve several times until the valve seats
properly and operates freely.
• Open a nearby hot water faucet and the heater drain valve.
• BE CAREFUL TO GRASP THE DRAIN VALVE HANDLE SO
THAT THE HAND IS NOT EXPOSED TO HOT WATER. IF
DESIRED, A HOSE MAY BE CONNECTED TO THE DRAIN
VAL VE TO CARRY THE WA TER AW AY .
DANGER: The water MA Y BE HOT.
• The drain valve must be left open during the shutdown period.
• To restart heater, refer to the FILLING instructions under
OPERATION.
Periodically open the drain valve and allow the water to run until
it flows clean. This will help prevent sediment build-up in the
tank.
It is normal for lime and scale deposits to form within the tank.
Such deposits will not be removed by periodic draining. It is
necessary to chemically delime the affected parts in water areas
where such deposits are encountered. Deliming information
can be obtained from St ate W ater Heaters, 500 Lindahl Parkway,
Ashland City, TN 37015.
CONDENSATION
Water vapor can condense on the cooler surfaces of the tank
forming droplets, these drip into the fire or run out on the floor.
This is common at the time of startup after installation, during
periods of time when incoming water is very cold, or the heater
may be undersized for the requirements.
Droplets from the bottom of the flue may be due to corrosive
combustion products or improper vent. Check with your dealer
for more information.
DANGER
THE WATER PASSING OUT OF THE VALVE DURING THIS
CHECKING OPERATION MAY BE EXTREMELY HOT. AVOID
CONTACT AND DISCHARGE SAFELY TO PREVENT WATER
DAMAGE.
If temperature and pressure relief valve on the appliance
discharges periodically, this may be due to thermal expansion
in a closed water system. Contact the water supplier or local
plumbing inspector on how to correct this situation. DO NOT
PLUG the temperature and pressure relief valve.
DRAINING (T)-FIG. 1
If the heater is to be shut off and exposed to freezing
temperatures, it must be drained. Water, if left in the tank and
allowed to freeze, will damage the heater.
CATHODIC PROTECTION - ANODE (FIG. 1)
The anode rod is used to protect the tank from corrosion. Most
hot water tanks are equipped with an anode rod. The submerged
rod sacrifices itself to protect the tank. Instead of corroding the
tank, water ions attack and eat away the anode rod. This does
not affect the water's taste or color. The rod must be maintained
to keep the tank in operating condition.
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod
indicates high water conductivity and should be checked and/or
replaced more often than an anode rod that appears to be intact.
Replacement of a depleted anode rod can extend the life of your
water heater. Inspection should be conducted by a qualified
technician, and at a minimum should be checked annually after
the warranty period.
16
WARNING: DO NOT BY -P ASS ANY CONTROLS T O MAKE HEA TER OPERATE.
OPERA TE ONL Y AS WIRED FROM FACT ORY .
TROUBLE SHOOTING
Please check guidelines below. For your safety, water heater service should be performed only by a qualified service technician.
Read the GENERAL SAFETY INFORMA TION section first.
LED STA TUS
A B C
A B C
A B C
A B C
A B C
A B C
PROBLEM SOLUTION
An open earth ground circuit to the 1. Check that the earth ground connection is
ignition system. properly connected.
2. Check that the ground conductor on the
water heater is properly connected.
Wiring error or a high resistance to 1. Check for proper connection of line
earth ground. neutral and hot wires.
2. Check that the water heater is securely
connected to earth ground.
Pressure switch remained closed longer 1. Pressure switch wiring is incorrect.
than 5 seconds after the call for 2. Replace pressure switch.
heat began.
Pressure switch remained open longer 1. Pressure switch wiring is incorrect.
than 5 seconds after the combustion 2. Pressure switch tubing not connected
blower was energized. correctly.
3. Air intake or exhaust obstructed.
Error in the hot surface ignitor circuit. 1. Check that all wiring is correct and secure.
2. Replace hot surface ignitor.
System in lockout. 1. Gas supply is off or too low to operate.
2. Hot surface ignitor not positioned
correctly.
3. Low voltage to the water heater.
4. Electric polarity to unit is incorrect - test
and correct.
A B C
WA TER HEA TER CONTROL
A B C
A B C
A B C
A B C
A B C
A B C
Problem in the gas valve driver circuit. 1. Turn power to the water heater off for
10 seconds and the back on.
2. Replace gas control valve.
Problem with the internal circuit. 1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
Problem with the internal circuit. 1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
Flame signal sensed out of 1. Replace gas control valve.
proper sequence.
ECO activated. 1. Replace gas control valve.
One of the temperature adjust 1. Press and release each of the buttons
buttons stuck closed. once.
2. Replace gas control valve.
Water temperature sensor is 1. Check that all wiring is correct and secure.
either open or short circuited. 2. Replace gas control valve.
17
TROUBLE SHOOTING (Continued)
PROBLEM CAUSE SOLUTION
1) Blower will not run.
A) “ON/OFF” control switch turned off. Turn switch to the “ON” position.
B) Blower unplugged. Plug blower back into 115 Vac. outlet.
C) No power at outlet. Repair service to outlet.
D) Thermostat defective. Replace thermostat.
E) Control harness defective. Replace control harness.
F) High limit control circuit open. Replace thermostat.
NOT ENOUGH G) Blower motor defective. Replace Blower Assembly.
HOT WA TER Thermostat problems.
A) Thermostat set too low. Turn temperature control higher.
B) Thermostat or ECO defective. Replace thermostat.
Others
A) Heater undersized. Reduce hot water use.
B) Low gas pressure. Contact dealer.
C) Incoming water is unusually cold. Allow more time for heater to reheat.
D) Leaking hot water pipes or fixtures. Have plumber check and repair leaks.
A) Defective air flow restrictor. Take unit out of service immediately, call a
State Water Heaters service representative.
B) Not enough dilution air to mix with Proper dilution air must be provided for
VENT PIPE TOO HOT flue gases. combustion and dilution of flue temp.
(ABOVE 170°F) Refer to “INST ALLATION” section.
C) Dilution air too hot for mixing with Supply air is too hot. Check for heat sources
flue gases. around and/or blockage of dilution air intake.
D) Wrong burner orifice. Install correct orifice.
A) Dirt in burner ports Turn off heater and gas, clean burner head.
B) Combustion air path restricted. Check dilution air intake, exhaust venting, and
YELLOW FLAME air openings in bottom base pan for
obstructions or blockage.
C) Not enough dilution air for proper Check dilution air intake for obstructions
combustion. or blockage.
A) Water on the floor under heater. See “CONDENSATION” section.
CONDENSA TION B) Water dripping from blower assembly. Provide drip “TEE” to catch condensation,
see figure 1.
Improperly sealed, hot or cold supply Tighten threaded connections.
connections, relief valve, drain valve
W ATER LEAKS or thermostat threads.
Leakage from other appliances or water Inspect other appliances near water heater.
water lines.
Condensation of flue products. Refer to “CONDENSATION” section.
Thermal expansion in closed water Install thermal expansion tank (DO NOT plug
LEAKING T&P system. T&P valve).
Improperly seated valve. Check relief valve for proper operation
(DO NOT plug T&P valve).
HOT WA TER ODORS High sulfate or mineral content in Drain and flush heater thoroughly then refill.
(Refer to CATHODIC water supply.
PROTECTION Bacteria in water supply. Chlorinate water supply.
WA TER TOO HOT Thermostat set too high. Refer to HIGH TEMPERATURE REGULATION.
WA TER HEA TER SOUNDS Condensation dripping on burner. Refer to CONDENSATION above.
SIZZLING-RUMBLING Sediment at bottom of heater tank. Clean sediment from tank. Refer to DRAINING
instruction in Maintenance section of manual.
SOOTING Improper combustion. Refer to AIR REQUIREMENTS on p age 4.
HEATER LIGHTS Outlet polarity is reversed. Test polarity and correct.
BUT GOES OUT
IN 4-5 SECONDS
18
LIMITED RESIDENTIAL GAS WARRANTY
THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER
ONLY. If the glass lined tank in this water heater shall prove upon
examination by State W ater Heaters (the warrantor) to have leaked
during the warranty period in normal residential use, due to
natural corrosion from potable water therein, the warrantor will
furnish the ORIGINAL OWNER a replacement S tate water heater
of equivalent size and current model, or a replacement part for
any component part which fails in normal use, in accordance
with the warranty terms and conditions specified below. THE
STA TE W A TER HEATER REPLACEMENT MODEL OR P ART WILL
BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF
THE ORIGINAL WARRANTY. The warranty period will be
determined by the original installation date of the water heater.
PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION ARE
NECESSARY TO V ALIDA TE THIS W ARRANTY . This warranty is
not transferable and applies to models listed in Table 1.
TABLE 1
WARRANTY PERIOD
MODEL TANK
PR6 40 6 YEARS 2 YEARS
PR6 50 6 YEARS 2 YEARS
When the water heater has been used for other than single
family residential application: 1. The tank warranty shall be
reduced to 1 year. 2. The parts warranty shall be reduced to 1
year for all models. Returned parts which meet any of the
following conditions are not covered by this warranty: 1) improper
installation or removal; 2) damaged by other than normal wear;
3) replaced for cosmetic purposes; or 4) returned with defaced
date codes.
CONDITIONS AND EXCEPTIONS
This warranty shall apply only when the water heater is installed
and operated in accordance with: 1) all local fire codes and
plumbing codes, ordinances and regulations; 2) the printed
instructions provided with it; 3) good industry practices; and 4)
proper safety practices such as but not limited to a properly
sized drain pan if installed in an area where leakage from
connections of the tank would result in damage to the area
adjacent to the heater. In addition, a new temperature and
pressure relief valve, certified by the Canadian Standards
Association must have been properly installed and piped to the
nearest drain.
This warranty shall apply only when the heater is:
• owned by the original purchaser;
• used at temperatures not exceeding the maximum calibrated
setting of its thermostat;
• not subjected to excessive water pressure fluctuations and
not subject to an operating pressure greater than 150 P.S.I.;
• filled with potable water, free to circulate at all times and with
the tank free of damaging water sediment or scale deposits;
• used in a non-corrosive and non-contaminated atmosphere;
• used with factory approved anode(s) installed;
• in its original installation location;
• in the United States and its territories or possessions;
• sized in accordance with proper sizing techniques for
residential water heaters;
• bearing a rating plate which has not been altered, defaced or
removed except as required by the warrantor;
• used in an open system or in a closed system with a properly
sized and installed thermal expansion tank;
• fired at the factory rated input using the fuel stated in the face
of the rating plate;
• operated with the inner and outer combustion chamber doors
in place;
• maintained in accordance with the instructions printed in the
manual included with the heater.
Any accident to the water heater or any part thereof (including
freezing, fire, floods, or lightning), any misuse, abuse or alteration
of it, any operation of it in a modified form, or any attempt to
repair tank leaks or parts, will void this warranty.
SERVICE AND LABOR RESPONSIBILITY
UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL
PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART
THEREOF. THE OWNER IS RESPONSIBLE FOR ALL OTHER
COSTS. Such costs may include but are not limited to:
1
PARTS
2
a. Labor charges for service, removal, or reinstallation of the
water heater or part thereof.
b. Shipping and delivery charges for forwarding the new water
heater or replacement part from the nearest distributor and
returning the claimed defective heater or part to such distributor
except in the state of California where such charges are the
manufacturer’s responsibility.
c. All cost necessary or incidental for handling and
administrative charges, and for any materials and/or permits
required for installation of the replacement heater or part.
LIMITATION ON IMPLIED WARRANTIES
Implied warranties, including any warranty of merchantability
imposed on the sale of this heater under state law are limited to
one year duration for the heater or any of its parts. Some states
do not allow limitations on how long an implied warranty lasts,
so the above limitations may not apply to you.
CLAIM PROCEDURE
Any claim under this warranty should be initiated with the dealer
who sold the heater, or with any other dealer handling the
warrantor’s products. If this is not practical, the owner should
contact: St ate Water Heaters, 500 Lindahl Parkway, Ashland City ,
TN 37015.
The warrantor will only honor replacement with identical or
similar water heater or parts thereof which are manufactured or
distributed by the warrantor.
Dealer replacements are made subject to in-warranty validation
by warrantor.
PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION
DATES ARE REQUIRED TO SUPPORT WARRANTY FOR
CLAIM FROM ORIGINAL OWNER. THIS FORM DOES NOT
CONSTITUTE PROOF-OF-PURCHASE OR PROOF-OFINSTALLATION.
DISCLAIMERS
NO EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN
BEHALF OF THE WARRANTOR WITH RESPECT TO THE
MERCHANTABILITY OF THE HEA TER OR THE INSTALLA TION,
OPERATION, REP AIR OR REPLACEMENT OF THE HEA TER OR
PARTS. THE WARRANTOR SHALL NOT BE RESPONSIBLE
FOR WATER DAMAGE, LOSS OF USE OF THE UNIT,
INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL
PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE
WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS
WARRANTY OR OTHER WISE FOR DAMAGE TO ANY PERSONS
OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND
WHETHER ARISING IN CONTRACT OR IN TORT.
Some states do not allow the limitation or exclusion of incidental
or consequential damages, so the above limitation or exclusion
may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Fill out and keep with water heater.
IMPORT ANT INFORMATION
Model Number____________________________________________
Serial Number_____________________________________________
Installation Information:
Date Installed _____________________________________________
Company’s Name _________________________________________
Street or P.O. Box _________________________________________
City, State, and Zip Code ___________________________________
Phone Number _______________Plumber’s Name_______________
19
500 LINDAHL P ARKW A Y
ASHLAND CITY, TN 37015
www.statewaterheaters.com
20
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