Vertex GP6 Instruction Manual

RESIDENTIAL GAS WATER HEATERS

www.statewaterheaters.com

Instruction Manual

POWER VENTED GAS MODELS W/HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

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 0406 P ART NO. 197425-000

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

1

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 .

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.

IMPORT ANT DEFINITIONS

• 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 of water heaters, 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 .

• 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 SAFETY

3

GENERAL SAFETY

4

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE...........................2

GENERAL SAFETY ............................................................. 3-4

TABLE OF CONTENTS...........................................................5

INTRODUCTION .....................................................................5

Preparing for the Installation ............................................5

TYPICAL INST ALLATION .................................................... 6-7

LOCATING THE NEW WATER HEATER .......................... 8-10

Facts to Consider About Location ................................ 8-9

Insulation Blankets ...........................................................9

Combustion Air and V entilation for Appliances

Located in Unconfined Spaces.........................................9

Combustion Air and V entilation for Appliances

Located in Confined Spaces ...................................... 9-10

INST ALLING THE WATER HEATER................................ 11-23

Chemical V apor Corrosion .............................................11

Water Piping..............................................................11-12

Temperature-Pressure Relief Valve ...............................12

Gas Piping......................................................................13

Sediment Traps ..............................................................14

Filling the Water Heater .................................................14

Vent Pipe Assembly .......................................................14

Venting ...........................................................................14

Vent Pipe Termination ....................................................15

Planning the Vent System ........................................ 15-16

Condensate ....................................................................16

Blower Assembly Installation.................................... 16-17

Installation of Vent System ....................................... 17-19

Vent Attenuation Assembly Installation Instructions .......20-21

Vent Pipe Preparation .............................................. 22-23

LIGHTING & OPERA TING LABEL ........................................24

TEMPERATURE REGULATION............................................25

FOR YOUR INFORMA TION ..................................................26

Start Up Conditions

Smoke/Odor ...........................................................26

Thermal Expansion.................................................26

Strange Sounds......................................................26

Operational Conditions...................................................26

Smelly Water ..........................................................26

“Air” in Hot Water Faucets......................................26

High Temperature Shut Off System........................26

PERIODIC MAINTENANCE ............................................ 27-29

Venting System Inspection.............................................27

Burner Operation and Inspection ...................................27

Burner Cleaning .............................................................27

Housekeeping .......................................................... 27-28

Anode Rod Inspection .................................................... 28

Temperature-Pressure Relief Valve Operation ..............28

Draining ..........................................................................28

Service ...........................................................................29

LEAKAGE CHECKPOINTS ...................................................29

REP AIR PARTS .....................................................................30

TROUBLESHOOTING ..................................................... 31-32

NOTES .......................................................................... 33-34

WARRANTY ..........................................................................35

INTRODUCTION

Thank Yo u 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

• UL - Underwriters Laboratories Inc.

This gas-fired water heater is design certified by Underwriters
Laboratories Inc. under American National Standard/CSA Standard
for Gas Water Heaters ANSI Z21.10.3 • CSA 4.3 (current edition).

PREP ARING FOR THE INST ALLATION

1. Read the “General Safety” section, p age 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 INST ALL OR OPERATE THE W A TER HEATER.

2. 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 and the National Electrical Code, NFP A 70. These
publications are available from The National Fire Protection
Association, 1 Batterymarch Park, Quincy, M A 02269.

3. The water heater when installed must be grounded in accordance
with the local codes, or in the absence of local codes: the National
Electrical Code. NFP A 70.

4. 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.

5. 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.

6. 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.

7. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: St ate Plumbing
Code and 248-CMR 5.00.

8. Complies with SCAQMD rule #1146 and districts having equivalent
NOx requirements.

5

TYPICAL INSTALLA TION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe
B Anode
C Hot Water Outlet
D Outlet (120 VAC)
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
O Inlet Dip Tube
P Temperature & Pressure Relief Valve
Q Rating Plate
R Insulation
S Vent Terminal
T Drain Valve

U Igniter And Main Burner

W Drain Pan

X Control

Y Control Harness*
AA Motor & Blower
CC Condensate Fitting

(4 Places Shown)**
D D Plastic Top
E E On/Off Switch

REPLACEMENT P ARTS 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.

FF Exhaust Tee

GG Elbow

HH Bushing

II Nipple

JJ Condensate Tee

KK Hose Barb

LL Plug

MM Vent Pipe Assembly #1

NN Vent Pipe Assembly #2

OO Vent Pipe Assembly #3

PP Side Recirculation Loop

Inlet***

QQ Side Recirculation Loop

Outlet*** (not shown)

RR Vent Attenuation

Assembly (V AA) (Optional)

CONDENSATE ASSEMBLY

* CAUTION HARNESS HAS 120 VAC. IN OPERATION.

** See "PLANNING THE VENT SYSTEM", "CONDENSATE" and "BLOWER

ASSEMBLY INSTALLA TION" for more information.

*** The side recirculation loop connections may not be used as the primary

water inlet and outlet connections. For your convenience, plugs are
installed in these fittings at the factory. Remove these plugs if needed for
your specific installation. Otherwise (as with all connections) check for
leaks while filling the tank with water and after completing the installation.

(U) NA TURAL GAS MAIN BURNER

WITH IGNITER ASSEMBLY

SIDE VIEW

TEMPERATURE INDICATORS

VACUUM RELIEF

VALVE

*INSTAL L P ER

LOCAL CODES

FIGURE 1

6

(X)

TEMPERATURE ADJUSTMENT BUTTONS

TYPICAL INSTALLA TION

MIXING VALVE USAGE

FIGURE 2.

This appliance has been design certified as complying with American
National Standard/CSA S tandard for water heaters and is considered
suitable for:

Water (Potable) Heating and Space Heating: All models are
considered suitable for water (potable) heating and space heating.

HOTTER WA TER CAN SCALD:

Water heaters are intended to produce hot water . W ater 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 V alve, 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 “T emperature
Regulation” section in this manual, see Figure 26.

7

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCA TION

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 terminal or
location to which the water heater vent piping is going to be connected,
and as centralized with the water piping system as possible.

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

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" (5.1
cm) greater that the water heater dimensions and must be piped to
an adequate drain. The pan must not restrict combustion air flow.

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. 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.

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 hot surface
igniter or main burner. The resulting flashback and fire can cause
death or serious burns to anyone in the area.

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

This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
appliance extending beyond the full width and depth of the appliance
by at least 3" (7.6 cm) in any direction, or if the appliance is installed

8

in an alcove or closet, the entire floor must be covered by the panel.
Failure to heed this warning may result in a fire hazard.

Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5.5" (14.0 cm) from the front
and 12" (30.5 cm) from the top. (Standard clearance.) If clearances stated
on the heater differ from standard clearances, install water heater
according to clearances stated on the heater.

Adequate clearance 24" (61.0 cm) for servicing this appliance should be
considered before installation, such as changing the anodes, etc.

A minimum clearance of 5.5" (14.0 cm) 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.

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 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.

INSULA TION BLANKETS

Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the Energy Policy Act standards with respect to insulation and
standby loss requirements, making an insulation blanket unnecessary .

Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For 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.

FIGURE 4.

A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area
such as a closet, unless you provide air as shown in the “Locating
The New Water Heater” section. 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.

FIGURE 5.

• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
Do not cover the outer door, thermostat or temperature & pressure

•
relief valve.
Do not allow insulation to come within 2" (5.1 cm) 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.

COMBUSTION AIR AND VENTILA TION FOR
APPLIANCES LOCA TED IN UNCONFINED SP ACES

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 cubic meters per kW) of the
aggregate input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconfined space.

In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of tight construction (for example, weather
stripping, heavily insulated, caulked, vapor barrier, etc.), additional air
may need to be provided using the methods described in “Combustion
Air and Ventilation for Appliances Located in Confined Spaces.”

COMBUSTION AIR AND VENTILA TION FOR
APPLIANCES LOCA TED IN CONFINED SP ACES

CONFINED SPACE is a space whose volume is less than 50 cubic

feet per 1,000 Btu per hour (4.8 cm per kW) of the aggregate input
rating of all appliances installed in that space.

When drawing combustion 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 WITHIN 12 INCHES OF THE
ENCLOSURE BOTTOM. Each opening shall have a free area of one

9

square inch per 1000 Btu/hr 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 and ventilation 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 Btu/hr of 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 Btu/hr of the total input
of all appliances in the enclosure.

A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 5 and 6)
The confined space shall be provided with two permanent openings

communicating directly with an additional room(s) of sufficient volume
so that the combined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utilization equipment installed
in the combined space shall be considered in making this determination.
Each opening shall have a minimum free area of one square inch per
1,000 Btu per hour (22 cm

equipment in the confined space, but not less than 100 square inches
(645 cm

2

). One opening shall commence within 12 inches

2

/kW) of the total input rating of all gas utilization

(31 cm) of the top and one commencing within 12 inches (31 cm) of
the bottom of the enclosures.

2. When communicating with the outdoors through vertical ducts, each
opening shall have a minimum free area of 1 square inch per 4,000
Btu per hour (5.5 cm2/kW) of total input rating of all equipment in the
enclosure, see Figure 8.

3. When communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1 square
inch per 2,000 Btu per hour (11 cm

2

/kW)) of total input rating of

all equipment in the enclosure, see Figure 9.

FIGURE 6.

B. ALL AIR FROM OUTDOORS: (See Figures 7, 8 and 9)

The confined space shall be provided with two permanent openings,

one commencing within 12 inches (31 cm) of the top and one
commencing within 12 inches (31 cm) from the bottom of the
enclosure. The openings shall communicate directly , or by ducts,
with the outdoors or spaces (crawl or attic) that freely communicate
with the outdoors.

1. When directly communicating with the outdoors, each opening shall
have a minimum free area of 1 square inch per 4,000 Btu per hour

2

(5.5 cm

/kW) of total input rating of all equipment in the enclosure,

see Figure 7.

FIGURE 8.

4. When ducts are used, they shall be of the same cross-sectional
area as the free area of the openings to which they connect.
The minimum short side dimension of rectangular air ducts shall
not be less than 3 inches (7.6 cm), see Figure 9.

FIGURE 9.

5. Louvers and Grilles: In calculating free area, consideration shall be
given to the blocking effect of louvers, grilles or screens protecting
openings. Screens used shall not be smaller than 1/4 inch (6.4 mm)
mesh. If the free area through a design of louver or grille is known, it
should be used in calculating the size opening required to provide the
free area specified. If the design and free area is not known, it may be
assumed that wood louvers will be 20-25 percent free area and metal
louvers and grilles will have 60-75 percent free area. Louvers and grilles
shall be fixed in the open position or interlocked with the equipment so
that they are opened automatically during equipment operation.

FIGURE 7.

6. Special Conditions Created by Mechanical Exhausting or Fireplaces:
operation of exhaust fans, ventilation systems, clothes dryers or
fireplaces may create conditions requiring special attention to avoid
unsatisfactory operation of installed gas utilization equipment.

10

INSTALLING THE NEW WATER HEATER

CHEMICAL V APOR CORROSION

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF
AIR FOR COMBUSTION CONT AINS CERTAIN CHEMICAL VAPORS. SUCH
CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIA TION.

Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium and
sodium chloride (water softener salt), waxes, and process chemicals
are typical compounds which are potentially corrosive.

Do not store products of this sort near the heater. Also, air which is
brought in contact with the heater should not contain any of these
chemicals. If necessary, uncontaminated air should be obtained from
remote or outside sources. The limited warranty is voided when failure
of water heater is due to a corrosive atmosphere. (See limited warranty
for complete terms and conditions).

WA TER PIPING

Water supply systems may , because of such events as high line pressure,
frequent cut-offs, the effects of water hammer among others, have
installed devices such as pressure reducing valves, check valves, back
flow preventers, etc. to control these types of problems. When these
devices are not equipped with an internal by-pass, and no other measures
are taken, the devices cause the water system to be closed. As water is
heated, it expands (thermal expansion) and closed systems do not allow
for the expansion of heated water.

The water within the water heater tank expands as it is heated and increases
the pressure of the water system. If the relieving point of the water heater’s
temperature-pressure relief valve is reached, the valve will relieve the
excess pressure. The temperature-pressure relief valve is not intended
for the constant relief of thermal expansion. This is an unacceptable
condition and must be corrected.

It is recommended that any devices installed which could create a closed
system have a by-pass and/or the system have an expansion tank to
relieve the pressure built by thermal expansion in the water system.
Expansion tanks are available for ordering through a local plumbing
contractor.

assistance in controlling these situations.

NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe.

All gas 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.

Contact the local water supplier and/or a service agency for

HOTTER WA TER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing, cleaning and other sanitizing needs can scald and permanently
injure you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly , children, the
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, see Figure 2. Valves for reducing
point of use temperature by mixing cold and hot water are also available:

Consult a Qualified Installer or Service Agency . Follow manufacturer’s
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the “T emperature Regulation” section
in this manual.

This water heater shall not be connected to any heating systems or
component(s) used with a non-potable water heating appliance.

All piping components connected to this unit for space heating applications
shall be suitable for use with potable water.

Toxic chemicals, such as those used for boiler treatment shall not be
introduced into this system.

When the system requires water for space heating at temperatures higher
than required for domestic water purposes, a tempering valve must be
installed. Please refer to Figure 2 for suggested piping arrangement.

FIGURE 10.

11

Figure 10 shows the typical attachment of the water piping to the
water heater. The water heater is equipped with 3/4 inch NPT
water connections.

NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the water heater connections. Do not
solder the water lines directly to the water heater connections.
It will harm the dip tube and damage the tank.

T & P Valve and Pipe Insulation (if supplied)

Remove insulation for T & P valve and pipe connections from carton.

FIGURE 11.

Fit pipe insulation over the incoming 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.

The valve must be marked with a maximum set pressure not to exceed
the marked hydrostatic working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity not less than the
water heater input rate as shown on the model rating plate.

For safe operation of the water heater, the relief valve must not be
removed from its designated opening nor plugged.

The temperature-pressure relief valve must be installed directly into
the fitting of the water heater designed for the relief valve. Position
the valve downward and provide tubing so that any discharge will exit
only within 6 inches (15.2 cm) above, or at any distance below the
structural floor. Be certain that no contact is made with any live
electrical part. The discharge opening must not be blocked or reduced
in size under any circumstances. Excessive length, over 30 feet (9.14
m), or use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve, see Figures 10 or 14.

No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect tubing directly to discharge drain unless
a 6" (15.2 cm) air gap is provided. To prevent bodily injury , hazard to
life, or property damage, the relief valve must be allowed to discharge
water in quantities should circumstances demand. If the discharge
pipe is not connected to a drain or other suitable means, the water
flow may cause property damage.

Secure all insulation using tape.

TEMPERA TURE-PRESSURE RELIEF VALV E

This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.

The valve is certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment
of materials as meeting the requirements for Relief Valves and
Automatic Gas Shut-off Devices for Hot Water Supply Systems, ANSI
Z21.22 • CSA 4.4, and the code requirements of ASME.

If replaced, the valve must meet the requirements of local codes, but
not less than a combination temperature and pressure relief valve
certified as indicated in the above paragraph.

The Discharge Pipe:

•Shall not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.

•Shall not be plugged or blocked.

•Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.

•Shall terminate at an adequate drain.

•Shall not have any valve between the relief valve and tank.

The temperature-pressure relief valve must be manually operated at least
once a year. Caution should be taken to ensure that (1) no one is in front
of or around the outlet of the temperature-pressure relief valve discharge
line, and (2) the water manually discharged will not cause any bodily
injury or property damage because the water may be extremely hot.

If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to
the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.

12

GAS PIPING

Make sure the gas supplied is the same type listed on the model rating
plate. The inlet gas pressure must not exceed 14 inch water column (3.5
kPa) for natural and propane gas (L.P.). The minimum inlet gas pressure
shown on the rating plate is that which will permit firing at rated input.

All gas 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.

If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a fire
or explosion from leaking gas.

When installed at elevations above 2,000 feet (610 meters) for standard
models or 4,500 feet (1,370m) for high altitude models, input rating should
be reduced at the rate of 4 percent for each 1,000 feet (305 meters)

above sea level which requires replacement of the burner orifice in
accordance with National Fuel Gas Code ANSI Z223.1/NFP A 54. Contact
your local gas supplier for further information.

Failure to replace the standard orifice with a high altitude orifice when
installed could result in improper and inefficient operation of the
appliance, producing carbon monoxide gas in excess of safe limits,
which could result in serious injury or death. Contact your gas supplier
for any specific changes which may be required in your area.

Use pipe joint compound or teflon tape marked as being resistant to
the action of petroleum [Propane (L.P.)] gases.

The appliance and its gas connection must be leak tested before
placing the appliance in operation.

If the main gas line Shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.

A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code ANSI Z223.1/NFPA
54 and your gas supplier concerning pipe size.

There must be:

• A readily accessible manual shut off valve in the gas supply line
serving the water heater, and

• A drip leg (sediment trap) ahead of the gas control valve to help
prevent dirt and foreign materials from entering the gas control valve.

• A flexible gas connector or a ground joint union between the shut
off valve and control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the water
heater. Use a soapy water solution, not a match or open flame.
Rinse off soapy solution and wipe dry.

The appliance and its individual Shut-off valve shall be disconnected
from the gas supply piping system during any pressure testing of
that system at test pressures in excess of 1/2 pound per square
inch (3.5 kPa). It shall be isolated from the gas supply piping system
by closing its individual manual Shut-off valve during any pressure
testing of the gas supply piping system at test pressures equal to or
less than 1/2 pound per square inch (3.5 kPa).

Connecting the gas piping to the gas control valve of the water heater can be
accomplished by either of the two methods shown in Figures 12 and 13.

FIGURE 12. GAS PIPING WITH

FLEXIBLE CONNECTOR.

FIGURE 13. GAS PIPING WITH ALL

BLACK IRON PIPE TO GAS CONTROL.

13

SEDIMENT TRAPS

A sediment trap shall be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The
sediment trap shall be either a tee fitting with a capped nipple in the
bottom outlet or other device recognized as an effective sediment
trap. If a tee fitting is used, it shall be installed in conformance with
one of the methods of installation shown in Figures 12 and 13.

Contaminants in the gas lines may cause improper operation of the
gas control valve that may result in fire or explosion. 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 drip leg
(sometimes called a sediment trap) must be incorporated in the
piping. The drip leg must be readily accessible. Install in accordance
with the “Gas Piping” section. Refer to the current edition of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Never use this water heater unless it is completely full of water. T o prevent
damage to the tank, the tank must be filled with water . Water must flow
from the hot water faucet before turning “ON” gas to the water heater.

To fill the water heater with water:

1. Close the water heater drain valve by turning the handle to the right
(clockwise). The drain valve is on the lower front of the water heater.

2. Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open when
the water heater is in use.

3. To insure complete filling of the t ank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow is
obtained. This will let air out of the water heater and the piping.

4. Check all water piping and connections for leaks. Repair as needed.

VENT PIPE ASSEMBLY

There are three parts of the vent pipe assembly that connect the water
heater exhaust (located on the lower back side of the water heater) to
the inlet of the blower assembly (mounted on top of the water heater) as
shown in Figure 1. These parts will need to be assembled according to
the instructions in the VENT PIPE PREPARA TION section of this manual.
These PVC parts should be assembled with ASTM D-2564 grade cement.

Assemble Vent Pipe Assemblies #1, #2 and #3 (See Figure 1) prior
to cementing. The preferred orientation of Vent Pipe Assembly #1
(Condensate U-Assembly) is shown in Figure 16. However this
assembly may be rotated to a different orientation as needed for the
specific installation requirements. Note the rotational orientation of
each part by marking a line several inches long across the joints.
The long tube of Vent Pipe Assembly #2 should be approximately
vertical. If it is found that either of the two pieces of pipe in Vent Pipe
Assembly #2 are too long for proper fit-up, then remove as little
material as possible to improve the fit-up. Keep in mind that the
pipes will insert slightly further into the elbows when cement is applied
as it acts as a lubricating agent. The vertical distance from the bottom
of the Condensate U-Assembly to the floor that supports the water
heater should be approximately 0.25" (See Figure 16). Disassemble
the parts and cement back together using the alignment marks. A fter
the cement dries, attach the assembly to the blower and the water

heater exhaust using the supplied rubber boots and hose clamps.

FIGURE 14.

FILLING THE WA TER HEATER

A condensate trap is incorporated in the bottom of this vent pipe assembly .
See the CONDENSA TE section of this manual for further det ails.

VENTING

14

VENT HOOD(S) MAY BE

WARNING

EXTREMELY HOT

DURING OPERATION.

FIGURE 15

VENT PIPE TERMINA TION

The first step is to determine where the vent pipe will terminate.
See Figures 15, 20 and 21. The vent may terminate through a
sidewall as shown in Figure 20 or through the roof as shown in
Figure 21.

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, 12.9.1 through 12.9.4.

Instructions on proper installation through a sidewall are provided
in Figure 15.

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 LOCATING THE NEW
WATER HEATER and INSTALLING THE WATER HEATER,
and with the National Fuel Gas Code and local codes.

PLANNING THE VENT SYSTEM

Plan the route of the vent system from the discharge of the blower
to the planned location of the vent terminal.

1. Layout the total vent system to use a minimum of vent pipe and
elbows.

2. This water heater is capable of venting the flue gases the
equivalent of twenty-five (25) feet of 2 inch pipe, sixty-five (65)
feet of 3 inch pipe, or one-hundred twenty-eight (128) feet of 4
inch pipe as listed in Table 1.

TABLE 1

Number of 2" Maximum 3" Maximum 4" Maximum

90° Elbows Pipe (Feet) Pipe (Feet) Pipe (Feet)

1 20 60 120
215 55112
3 10 50 104
4-- 4596
5-- 4088
6-- 3580

The minimum vent lengths for each of the pipe sizes is one 90° on
top of the unit plus 2' of straight pipe and the appropriate termination.

NOTE: The equivalent feet of pipe listed above are exclusive of
the termination. That is, the termination, with an installed screen,
is assumed to be in the system and the remainder of the system
must not exceed the lengths discussed above.

3. The blower discharge adapter is made to accept only straight
sections of 2" pipe. To start, a minimum of 2 inches of 2" pipe
must be attached to the blower discharge (See figure 17).

If using 2" inch vent pipe:

A minimum of 2 inches must be attached to the blower before
the first elbow. After the first elbow add the additional venting
required for the installation. The total system cannot exceed
the lengths discussed above, where each elbow is equal to 5
feet of straight pipe.

If using 3" or 4" inch vent pipe:

Two inches of pipe must be attached to the blower discharge before
adding a reducer to acquire the desired pipe diameter. An appropriately
sized 45 degree elbow (supplied locally-a schedule 40 DWV) vent
terminal must be obtained with an equivalent screen (supplied in vent
kit). The total system cannot exceed the equivalent pipe lengths

15

discussed above where each elbow is equal to 5 feet of straight pipe
(3" vent pipe) or 8 feet of straight pipe (4" vent pipe).

NOTE: This unit can be vented using only PVC (Class 160, ASTM D­2241; Schedule 40, ASTM D-1785; or Cellular Core Schedule 40
DWV , ASTM F-891), CPVC (Schedule 40 /ASTM F-441), or ABS
(ASTM D-2661) pipe. The fittings, other than the
should be equivalent to PVC-DWV fittings meeting ASTM D-2665
(Use CPVC fittings, ASTM F-438 for CPVC pipe and ABS fittings,
ASTM D-2661/3311 for ABS pipe). If CPVC or ABS pipe and fittings
are used, then the proper cement must be used for all joints, including
joining the pipe to the T ermination (PVC Material). If local codes do
not allow the use of the PVC termination when 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.

PVC Materials should use ASTM D-2564 Grade Cement; CPVC
Materials should use ASTM F-493 Grade Cement and ABS
Materials should use ASTM D-2235 Grade Cement.

If the water heater is being installed as a replacement for an existing
power vented heater in pre-existing venting, a thorough inspection
of the existing venting system must be performed prior to any
installation work. Verify that the correct material as detailed above
has been used, and that the minimum or maximum vent lengths
and terminal location as detailed in this manual have been met.
Carefully inspect the entire venting system for any signs of cracks
or fractures, particularly at the joints between elbows and other
fittings and the straight runs of vent pipe. Check the system for
signs of sagging or other stresses in the joints as a result of
misalignment of any components in the system. If any of these
conditions are found, they must be corrected in accordance with
the venting instructions in this manual before completing the
installation and putting the water heater into service.

NOTE: A. For water heaters in locations with high ambient
temperatures (above 100°F) it is recommended that CPVC or
ABS pipe and fittings be used. B. A 22.5 degree elbow (2" vent
pipe) or a 45 degree elbow (3" and 4" vent pipe) with an installed
screen VENT TERMINAL

must be used in all cases.

TERMINATION

the condensate drain does not create a slippery condition which could
lead to personal injury.

The condensate trap may be primed by filling the CONDENSATE
U-ASSEMBLY with tap water using the supplied hose while the water
heater is not operating. The system is fully primed when the hose is
lowered below the hose clamp on the side of the water heater and
water begins to flow out of the hose. In most installations the water
heater will self-prime the condensate trap during the first full heat­up cycle. If a sound of air bubbling through water (gurgling) is heard
while the blower is operating after the first heat-up cycle, then turn
the unit off and contact your plumber or service representative.

If these instructions are not followed, the condensate build-up will
block the exhaust outlet, which will cause improper operation.

There will be some installations where condensate will be formed

4.
in the horizontal runs of the vent system. This condensate will
run into the condensate boot attached to the blower and out the
fitting. The water heater is shipped with condensate hose that
attaches to the fitting on the condensate boot. No other Tee or
fitting is required. See Figures 17, 20 and 21.

CONDENSA TE

This water heater is a condensing unit and requires a drain to be
located in close proximity to allow the condensate to drain safely. The
condensate drains from the unit at the exhaust tee located at the
bottom of the unit (see figure 16) and from two places on the blower
assembly (see figure 17). Condensate from this water heater is mildly
acidic. Please note that some local codes require that condensate is
treated by using a pH neutralizing filter prior to disposal.

NOTE: It is important that the condensate hose on the bottom of the
unit is not installed elevated above the clamp that is secured to the side
of the jacket, see figure 16. This must be true for the entire length of the
hose from the clamp to the exit into an appropriate drain. If these
instructions are not followed or if the condensate hose is blocked, water
will spill from the condensate trap. As with every water heater installation,
a drain pan should be used to prevent water damage to the surrounding
area. If necessary, a condensate pump with an incorporated reservoir
may be used to pump the water to an appropriate drain. To avoid
condensate spillage, select a pump with an overflow switch.

Caution must be used to ensure that the drain is free and clear of
debris and will not allow backflow through the condensate hose.
Consideration must be given to avoid freezing of the condensate
lines which could result in excessive build up of condensate inside
the water heater. Waterproof heat tape may be required to prevent
freezing of the condensate lines. Please ensure that the outlet of

CONDENSATE SYSTEM - FIGURE 16

Condensate is likely to form in the venting system attached to this water
heater. The vent pipe should be sloped downward away from the blower
assembly (not less than 1/8" (3.2 mm) nor greater than 1/2" (12.7 mm)
per foot maximum). If the vent piping is vented level or sloped upwards
away from the blower assembly, then adequate means for draining
and disposing of the condensate needs to be made by the installer. In
either case, a 3/8" drain hose should be connected to the built-in drain
port. Prior to operating the water heater, make sure the removable cap

is installed on the second drain port (See Figure 17).

BLOWER ASSEMBL Y INSTALLA TION

1. This power vented water heater comes 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 that one of the drain ports

16

of the rubber boot vent adapter is capped off. Lastly , make sure
there is no damage to the blower.

3. Condensate drains from two locations on the blower assembly as
shown in figure 17. A condensate hose must be secured to form a
"trap" as shown in figure 17 for these condensate drain connections.
These two hoses may be connected together. The hose(s) should
be routed to a suitable drain. A fitting that may be used to join the
two hoses from the blower assembly is included in a supplied kit.

FIGURE 17.

4. Make sure there is no packing material in the inlet or discharge
of the blower.

5. Make sure that the plastic tubing is still attached from the air
pressure switch to the port on the blower housing. Make sure
the plastic tubing is not folded anywhere between the pressure
switch and the blower housing.

6. 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.

7. 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
bottom side of the gas valve.

F . Ground heater properly . This water heater must be grounded in

accordance with the National Electrical Code NFP A 70 and/or
local codes. These must be followed in all cases.

The water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding
conductor must be run with the circuit conductors and
connected to the equipment grounding terminal or lead on
the water heater, see Figure 19.

G . Close the panel on the control box. Make sure that the access

panel is secured shut.

9. The blower discharge boot is made to accept only straight sections
of 2" pipe. T o st art off with an elbow , a short section of the furnished
pipe, a minimum of 2 inches, must be cut and glued into the end of
the elbow that will mount on the discharge boot.

INST ALLA TION OF VENT SYSTEM

Before beginning installation of piping system thoroughly read the
section of this manual VENT PIPE PREPARATION.

If you are installing your system so that it vents through roof, please
refer to section titled INSTALLA TION OF VERTICAL VENT SYSTEM.

VENT TERMINAL INSTALLA TION, SIDEW ALL

1. Install the vent terminal by using the cover plate as a template to
mark the hole for the vent pipe to pass through the wall. BEWARE
OF CONCEALED WIRING AND PIPING INSIDE THE WALL.

2. If the Vent T erminal is being inst alled 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.

3. A) MASONRY SIDE WALLS
Chisel an opening approximately one half inch larger than the
marked circle.

8. Do not plug in power cord until vent system is completely installed.
The Power Vent operates on 1 1 0-1 20 Vac. therefore a grounded
outlet must be within reach of the 6 foot (1.8 m) flexible power
cord supplied with the vent (See Figure 1). The power cord
supplied may be used on a unit only where local codes permit.
If local codes do not permit use of flexible power supply cord:

A. Make sure the unit is unplugged from the wall outlet. Remove

the plastic top cap. Remove screws and open panel on the
front of the control box on the blower.

B. Cut the flexible power cord, leaving enough to be able to make

connections. Remove the strain relief fitting from the box.

C. Install a suitable conduit fitting inside the enclosure.

D. Splice field wiring into existing wiring using code authorized

method (wire nuts, etc).

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 to easily slide
through the opening. The resulting gap will be covered up by the

Vent T erminal cover plate.) Repeat this step on inside wall if necessary.
SEQUENCE OF INSTALLATIONS, FIGURE 18
Cut a length of PVC pipe about 3.5 inches longer than the wall thickness at

the opening. Glue the vent terminal to this section of pipe. Slide the wall
plate over the pipe to stop against the vent terminal. Place a bead of caulking
(not supplied) around the gap between the pipe and cover plate. Apply
enough to fill some of the gap between the pipe and wall. Place some of
the caulking on the back of the plate to hold it against the wall after installation.
If the vent pipe is installed up to the wall, with a coupling on the end against
the wall opening, the pipe with the vent terminal can be prepared for gluing
before inserting through the wall. Slide the pipe through the wall and insert
into the coupling on the other side of the wall, making sure that the vent
terminal ends up pointed in the correct position, see Figure 18.

E. Be certain that neutral and line connections are not reversed

when making these connections.

VENT TERMINATION - FIGURE 18.

17

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

POWER VENT WIRING SCHEMATIC - FIGURE 19.

18

INST ALLATION OF VENT SYSTEM, SIDEWALL

With the route of the venting system and selection of materials completed,
as discussed in the section of this manual titled PLANNING THE VENT
SYSTEM, the through the wall vent terminal in place and the first section
of piping, up to first elbow, installed at the blower it is time to complete
the installation of the venting system for the sidewall installation.

Provide support for all pipe protruding through the roof. All piping
should be properly secured. The vent system piping should be
supported every 5 feet of vertical run and every 3 feet of horizontal
run. All piping and fittings must be joined by the proper procedures
as described under: VENT PIPE PREPARATION.

FIGURE 20

Before completing the installation of the venting system be sure to read
the sections of this manual discussing the proper method of cutting
and cementing PVC pipe and fittings: VENT PIPE PREPARATION.

It is recommended that the completion of the venting system start at
the blower assembly and run to the coupling on the inside wall of
the vent terminal, Figure18.

The vent system piping should be supported every 5 feet of vertical run
and every 3 feet of horizontal run. All piping and fittings must be joined by
the proper procedures as described under: VENT PIPE PREP ARATION.

INST ALLATION OF VERTICAL VENT SYSTEM

A proper flashing or "BOOT" should be used to seal the pipe where
it exits the roof. The total vent system should not exceed the
equivalent feet of pipe as listed in Table 1.

FIGURE 21

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 and as listed below:

1. Vent Termination must extend a minimum of 18 inches above roof
or 18 inches above the anticipated snow level to prevent blockage
of the vent termination, as shown in Figures 20 and 21.

2. The venting system shall terminate at least four (4) feet from or
one (1) foot above any gable, dormer or other roof structure with
building interior access; i.e., vent, window, etc.

3. The venting system shall terminate three (3) feet above any
forced air inlet located within ten feet.

19

VENT ATTENU ATION ASSEMBLY
INSTALLATI ON I NSTRUCTIONS

support the VAA and the surrounding vent pipe could create a hazardous
situation. DO NOT puncture any surface of the V AA.

The Vent Attenuation Assembly (V AA) is designed to provide a reduction
in fan noise created in the blower wheel. This installation of this V AA is
optional. Review directions thoroughly prior to installing the new V AA.
Please contact the manufacturer of the water heater as shown in the
instruction manual with any questions or for additional product support.

VENT ATTENUATION ASSEMBLY KIT PARTS LIST

The kit consists of the following items. If a part is missing, use the
contact information in the instruction manual to acquire missing
component(s).

• vent attenuation assembly

• flexible tubing

• hose barb

• hex plug (installed on V AA)

• instruction sheet

VENT ATTENUATION A SSEMBLY INSTALLATION

The V AA is designed for both vertical and horizontal installations. The
vertical installation does not require the additional hose barb and flexible
tubing. However, the horizontal inst allation will require the hose barb and
flexible tubing to release condensate buildup from the V AA. See instructions
and diagrams that follow for a more detailed description.

5. Confirm that the hex plug is securely installed in the 1/2" fitting
found on the center of the V AA pipe. It is imperative that the plug
is secure and air tight to prevent any combustion gases escaping
into the room. If the plug is not securely tightened, remove and
reinstall using Teflon tape on the threads. Once installed along
with the rest of the vent configuration, make sure to operate the
unit through at least one heat up cycle to ensure there is no leakage
around the plug or any joints of the VAA or vent pipe system.

FIGURE 22: Typical Vertical Installation

Horizontal VAA Inst allations

1. The VAA is designed to accept two inch PVC pipe into the adapters on
both ends. The V AA can be installed to the piping from either side (there
is no specific inlet or outlet). For optimum performance, install VAA as
close as possible to the blower assembly .

Vertical VAA Inst allations (Recommended)

1. The VAA is designed to accept two inch PVC pipe into the adapters
on both ends. The VAA can be installed to the piping from either side
(there is no specific inlet or outlet). For optimum performance, install
VAA as close as possible to the blower assembly.

2. Use standard PVC cement (not included with kit) and glue the two
inch PVC pipe coming from the blower into the V AA.

3. Perform the same sequence on the PVC pipe coming from the
exhaust side (vent terminal side) of the VAA.

4. Make sure the VAA and vent pipe is supported securely to a permanent
fixture (stud or wall). Use standard support straps (not supplied with
kit) that may be found at a local hardware store. Failure to properly

2. Use standard PVC cement (not included with kit) and glue the two
inch PVC pipe coming from the blower into the VAA. Make sure
the 1/2" fitting is on the bottom side of the V AA. This will be used
to run the condensate hose to a suitable drain. See typical vent
installation in Figure 23.

3. Perform the same sequence on the PVC pipe coming from the
exhaust side (vent terminal side) of the V AA.

4. Make sure the VAA and vent pipe is supported securely to a permanent
fixture (stud or wall). Use standard support straps (not supplied with
kit) that may be found at a local hardware store. Failure to properly
support the VAA and the surrounding vent pipe could create a hazardous
situation. DO NOT puncture any surface of theV AA.

5. Remove hex plug from the center pipe of the VAA. Locate the
hose barb and install into the 1/2" fitting on the center of the V AA.
Using Teflon tape on the threads, install hose barb into 1/2" fitting
securely . It is imperative that the hose barb is secure and tight to
prevent any combustion gases escaping into the room.

6. Locate flexible tubing. Slide one end of tube over the hose barb
located on the center pipe of the VAA. The ridges on the hose
barb should prevent the tube from sliding off, however, to ensure
there are no leaks and possible dislocation from hose barb, use a
wire tie or hose clamp (not supplied with kit) and secure.

7. T ake the other end of the flexible tubing and form an 8 inch diameter
circle approximately 3 feet down from the hose barb located in
the V AA. To ensure that the circle (loop) maintains its shape, use
two wire ties (not supplied with kit) to secure it.

20

8. Take the end of the tube at the bottom of the floor and route it to a
suitable drain. This will provide an area where the condensate can
drain without affecting the area around the appliance.

9. Once installed along with the rest of the vent configuration,
make sure to operate the unit through at least one heat up
cycle to ensure there is no leakage around the hose barb or
any joints of the VA A or vent pipe system.

FIGURE 23: Typical Horizontal Installation

Installation for VAA with 3 & 4 inch Pipe for Vertical Vent

Some applications may require the use of 3 or 4 inch vent pipe for
longer vent lengths. Please refer to the Figure 24 as you review
these instructions. Refer back to the vertical V AA installation steps but
with the following changes to the vent construction.

3 inch vent (Vertical VAA Installations)

The VA A is designed to accommodate only 2 inch vent pipe. The inst aller
must use 2 inch vent pipe between the blower assembly and the inlet
into the V AA. On the outlet side of the VAA, a short run of 2 inch vent
pipe is required. Each of the short pieces of 2 inch pipe entering and
exiting the V AA must not exceed 6 inches in length. From this point on, a
2 inch to 3 inch adapter may be used. From the 2 inch to 3 inch adapter,
the installer may use up to 65 equivalent feet of pipe. See Figure 24 for
typical installation.

4 inch vent (Vertical VAA Installations)

The V AA is designed to accommodate only 2 inch vent pipe. The installer
must use 2 inch vent pipe between the blower assembly and the inlet
into the V AA. On the outlet side of the VAA, a short run of 2 inch vent
pipe is required. Each of the short pieces of 2 inch pipe entering and
exiting the V AA must not exceed 6 inches in length. From this point on,
a 2 inch to 4 inch adapter may be used. From the 2 inch to 4 inch
adapter, the installer may use up to 128 equivalent feet of pipe. See
Figure 24 for typical installation.

FIGURE 24: Typical Installation for Vertical Vent with 3 or 4 inch Pipe

Installation of VAA with 3 & 4 inch Pipe for Horizontal V ent

Some applications may require the use of 3 or 4 inch vent pipe for longer
vent lengths. Please refer to the Figure 25 as you review these instructions.
Refer back to the horizontal VAA installation step s but with the following
changes to the vent construction.

3 inch vent (Horizontal VAA Installations)

The VA A is designed to accommodate only 2 inch vent pipe. The installer
must use 2 inch vent pipe between the blower assembly and the inlet
into the V AA. On the outlet side of the VAA, a short run of 2 inch vent
pipe is required. From this point on, a 2 inch to 3 inch adapter may be
used. From the 2 inch to 3 inch adapter, the installer may use up to 52
equivalent feet of pipe. This is 8 equivalent feet less than the original 60
equivalent feet specified with one elbow due to the 2 inch elbow instead
of a 3 inch elbow required for the vent from the blower to the inlet of the
VAA. See Figure 25 for typical inst allation.

4 inch vent (Horizontal VAA Installations)

The VAA is designed to accommodate only 2 inch vent pipe. The installer
must use 2 inch vent pipe between the blower assembly and the inlet into
the VAA. On the outlet side of the V AA a short run of 2 inch vent pipe is
required. From this point on, a 2 inch to 4 inch adapter may be used. From the
2 inch to 4 inch adapter, the installer may use up to 102 equivalent feet of
pipe. This is 18 equivalent feet less than the original 120 equivalent feet
specified with one elbow due to the 2 inch elbow instead of a 4 inch elbow
required for the vent from the blower to the inlet of the VAA. See Figure 25
for typical installation.

Remember to operate the unit for at least one heat cycle to ensure
there are no air leaks in the vent joints of the VAA and the vent pipe
system. Air leaks will allow flue gas by-products to disseminate
into the room creating an unsafe environment and could cause
illness, asphyxiation and/or even death.

Remember to operate the unit for at least one heat cycle to
ensure there are no air leaks in the vent joints of the VAA
and the vent pipe system. Air leaks will allow flue gas by­products to disseminate into the room creating an unsafe
environment and could cause illness, asphyxiation and/or
even death.

FIGURE 25: Typical Installation for Horizontal Vent with 3 or 4 inch

21

VENT PIPE PREP ARA TION

PRIMER

1. INITIAL PREP ARA 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.
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 MA TERIALS

• Cutting Device - Saw or Pipe Cutter

• Deburring Tool, 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

It is recommended that Tetrahydrofuran (THF) be used to prepare
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 all­purpose cements, commercial glues and adhesives or ABS cement
to join PVC or CPVC pipe and fittings.

APPLICATORS

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. IMPORT ANT 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.

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

• 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
inches (15.2 cm) and above.

*USE ONL Y NATURAL 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.

STEP A

22

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

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.

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 .

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.

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. 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.

• Apply a second coat of cement to the pipe end.

STEP F

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 cont act your
solvent cement manufacturer.

STEP G

23

FOR YOUR SAFETY READ BEFORE OPERATING

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 WATER 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 NOT try to light the burner by hand.

B. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric switch;
Do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.

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

C. Use only your hand to 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 holding for 1 second. Then press the COOLER

button until the WARM indicator light appears.

3. Set the “ON/OFF” switch on the blower control box to

the “OFF” position.

and HOTTER buttons together

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 holding for 1 second. Then press the HOTTER

button.

8. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your
technician or gas supplier.

9. WA TER TEMPERA TURE ADJUSTMENT

is approximately 120°F.

and HOTTER buttons together

CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.

WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING

1. 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

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.

24

TEMPERATURE REGULATION

Any water heater’s intended purpose is to heat water. Hot water is needed
for cleansing, cleaning, and sanitizing (bodies, dishes, clothing).
Untempered hot water can present a scald hazard. Depending on the time
element, and the people involved (adults, children, elderly , infirm, etc.)
scalding may occur at different temperatures.

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.

Figure 26 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 (17°C). 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.

The water temperature setting was factory set at the lowest temperature;
Pressing the “COOLER”

the “HOTTER”

button increases the temperature.

button decreases temperature and pressing

Setting the water heater temperature at 120°F (49°C) (Approx. “
mark on temperature setting of gas valve) will reduce the risks of
scalds. Some states require settings at specific lower temperatures.

To 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 26. 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.

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.

”

HOT 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, see Figure 2. Follow manufacturer’s instructions for installation of
the valves. Before changing the factory setting on the thermostat, read the
“T emperature Regulation” section in this manual, see Figure 26.

Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended in
a bathtub or shower.

The water heater should be located in an area where the general
public does not have access. If a suitable area is not available, a cover
should be installed over the thermostat to prevent tampering.

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

Time to Produce

Display 2nd and 3rd Degree

T emperature Setting A B C Burns on Adult Skin

C-Flashing = approx. 160°F (71°C) About 1/2 seconds
C = approx. 150°F (66°C) About 1-1/2 seconds
B = approx. 140°F (60°C) Less than 5 seconds
A = approx. 130°F (54°C) About 30 seconds
= approx. 120°F (49°C) More than 5 minutes
WARM = approx. 80°F (27°C)

- - - - - - - - - - - - -

FIGURE 26.

25

FOR YOUR INFORMATION

ST ART UP CONDITIONS

SMOKE/ODOR

It is not uncommon to experience a small amount of smoke and
odor during the initial start-up. This is due to burning off of oil from
metal parts, and will disappear in a short while.

THERMAL EXP ANSION

Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among
others, have installed devices such as pressure reducing valves,
check valves, back flow preventers, etc. to control these types of
problems. When these devices are not equipped with an internal
by-pass, and no other measures are taken, the devices cause the
water system to be closed. As water is heated, it expands (thermal
expansion) and closed systems do not allow for the expansion of
heated water.

conditions will cause a reaction between this rod and the water. The
most common complaint associated with the anode rod is one of a
“rotten egg smell” in the hot water. The smell is a result of four factors
which must all be present for the odor to develop:

a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated within the

water heater (this harmless bacteria is nontoxic to humans).

d. An excess of active hydrogen in the tank. This is caused by the

corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material,
and then chlorinating the water heater tank and all water lines. Contact
the local water heater supplier or service agency for further information
concerning an Anode Replacement Kit and this chlorination treatment.

If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that chlorination or aeration
of the water supply be considered to eliminate the water problem.

Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.

“AIR” IN HOT WATER FAUCETS

The water within the water tank expands as it is heated and
increases the pressure of the water system. If the relieving point
of the water heater’s temperature-pressure relief valve is
reached, the valve will release the excess pressure. The

temperature-pressure relief valve is not intended for the
constant relief of thermal expansion. This is an unacceptable

condition and must be corrected. It is recommended that any
devices installed which could create a closed system have a
by-pass and/or the system have an expansion tank or device to
relieve the pressure built by thermal expansion in the water
system. Expansion tanks are available for ordering through a
local plumbing contractor. Cont act the local water heater supplier
or service agency for assistance in controlling these situations.

STRANGE SOUNDS

Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered normal.
See “Condensate” in this section.

OPERA TIONAL CONDITIONS

SMELL Y WA TER

In each water heater there is installed at least one anode rod (see
parts section) for corrosion protection of the tank. Certain water

HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. T o prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances which
are connected to the hot water system are used (such as a
dishwasher or washing machine). If hydrogen gas is present, there
will probably be an unusual sound similar to air escaping through
the pipe as the hot water faucet is opened. There must be no
smoking or open flame near the faucet at the time it is open.

HIGH WATER TEMPERATURE SHUT OFF SYSTEM

This water heater is equipped with an automatic gas shut-off system.
This system works when high water temperatures are present. Turn
“OFF” the entire gas supply to the water heater. The high temperature
shut-off is built into the gas control valve. It is non-resettable. If the
high temperature shut-off activates, the gas control valve must be
replaced. Contact your gas supplier or service agency.

26

PERIODIC MAINTENANCE

VENTING SYSTEM INSPECTION

At least once a year a visual inspection should be made of the venting
system. You should look for:

1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.

2. Damage or deterioration which could cause improper venting or
leakage of combustion products.

Be sure the vent piping is properly connected to prevent escape of
dangerous flue gasses which could cause deadly asphyxiation.

characteristics and ignition sequences. This can be done by
removing the Outer Door and viewing the main burner operation
through the Viewport on the Inner Door, see Figure 1. The main
burner should provide complete combustion of gas, ignite rapidly,
give reasonably quiet operation, and cause no excessive flame
lifting from the burner ports. If the proper flame characteristics are
not evident (see Figure 27), make sure that the flow of combustion
and ventilation air is not blocked.

You should also check for sooting. Soot is not normal and will impair
proper combustion. A visual inspection of the main burner and HSI igniter
assembly should also be done at least once a year, see Figure 27.

Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until rep airs
are made, because failure to correct the cause of the sooting can
result in a fire causing death, serious injury, or property damage.

FIGURE 27.

BURNER CLEANING

In the event your burner or burner air openings require cleaning,
turn the blower switch to the “OFF” position and allow the burner
to cool. Call a service agency to remove and clean the burner and
correct the problem that required the burner to be cleaned.

Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.

Chemical vapor corrosion of the flue and vent system may occur if
air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes, bleach and process chemicals are typical
compounds which are potentially corrosive.

If after inspection of the vent system you found sooting or deterioration,
something is wrong. Call the local gas utility to correct the problem
and clean or replace the flue and venting before resuming operation
of the water heater.

BURNER OPERA TION AND INSPECTION

Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions

DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a qualified installer or service agency to replace a flooded
water heater. Do not attempt to

At least once a year a visual inspection should be made of the
main burner and the hot surface igniter assembly for proper flame

repair the unit! It must be replaced!

which can cause

HOUSEKEEPING

Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.

27

INSTALLED IN SUITABLE AREA: T o insure sufficient ventilation and
combustion air supply, proper clearances from the water heater must
be maintained. See “Locating the New Water Heater” section.
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent to
the water heater which can cause a fire.

When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of the
temperature-pressure relief valve discharge line, and (2) that the
water discharge will not cause any property damage, as the water
may be extremely hot, see Figure 28.

ANODE ROD INSPECTION

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.

TEMPERA TURE-PRESSURE
RELIEF VAL VE OPERA TION

If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to
the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.

If the temperature-pressure relief valve on the appliance weeps or
discharges periodically, this may be due to thermal exp ansion. Y ou
may have a check valve installed in the water line or a water meter
with a check valve. Consult your local water supplier or service
agency for further information. Do not plug the temperature­pressure relief valve.

DRAINING

The water heater should be drained if being shut down during
freezing temperatures. Also periodic draining and cleaning of
sediment from the tank may be necessary.

The temperature-pressure relief valve must be manually operated
at least once a year.

FIGURE 28.

1. Set the blower switch to the “OFF” position.

2. CLOSE the cold water inlet valve to the water heater.

3. OPEN a nearby hot water faucet and leave open to allow for
draining.

4. Connect a hose to the drain valve and terminate to an adequate
drain.

5. OPEN the water heater drain valve to allow for tank draining.

NOTE: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.

6. CLOSE the drain valve.

7. Follow instructions in the “Filling The Water Heater” section.

8. Follow the lighting instructions on the label or see “Lighting
Instructions” in this manual to restart the water heater.

28

SERVICE

If a condition persists or you are uncertain about the operation of
the water heater contact a service agency.

If you are not thoroughly familiar with gas codes, your water heater,
and safety practices, contact your gas supplier or qualified installer
to check the water heater.

Use this guide to check a “Leaking” water heater. Many
suspected “Leakers” are not leaking tanks. Often the source of

the water can be found and corrected.

LEAKAGE CHECKPOINTS

B

D

C

Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.

Never use this water heater unless it is completely filled with water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.

A *Condensation may be seen on pipes in humid weather or pipe

connections may be leaking.

B. *The anode rod fitting may be leaking.

C. Small amounts of water from temperature-pressure relief valve

may be due to thermal expansion or high water pressure in your
area.

D. *The temperature-pressure relief valve may be leaking at the

tank fitting.

E. Water from a drain valve may be due to the valve being slightly

opened.

F. *The drain valve may be leaking at the tank fitting.

F

G

E

G . Combustion products contain water vapor which can condense

on the cooler surfaces of the tank. Droplets form and drip onto
the burner or run on the floor. This is common at the time of
start-up after installation and when incoming water is cold.

H. Water in the water heater bottom or on the floor may be

from condensation, loose connections, or the relief valve.
DO NOT replace the water heater until a full inspection of
all possible water sources is made and necessary
corrective steps taken.

Leakage from other appliances, water lines, or ground seepage
should also be checked.

* T o check where threaded portion enters tank, insert cotton swab

between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.

29

Key No. Part Description

1 Outer Door
2 Aluminum Anode
3 Intellivent Control
4 Plastic Top
5 Blower Assembly
6 Switch and Harness Assembly
7 T&P Valve
8 Drain Valve
9 Wiring Harness

10 Aluminum Anode Outlet

11 Vent Pipe Assembly #1
12 Vent Pipe Assembly #2
13 Vent Pipe Assembly #3
14 Inlet Tube
15 Pipe Nipple
16 Burner Tube Assembly
17 Hot Surface Igniter
18 Burner Head Assembly
19 Embossed Inner Door
20 Insulation - Inner Door
21 Insulation - Viewport
22 Window - Observation
23 Viewport
24 Nut - Serrated Hex Flange
25 Screw - Sheet Metal, # 8-15
26 Orifice - Burner
27 Vent Kit Assembly
28 Wall Plate 2”
29 Wall Plate 3”
30 Screen and Vent Terminal Assembly
31 Instruction Tag-Wire Screen F/E 3”
32 Instruction Tag-Wire Screen F/E 4”
33 Instruction Sheet
34 Wire Screen 3”
35 Wire Screen 4”
36 Wall Plate 4”
37 Flexible Tubing
38 Reducing Hose Barb Tee

* Not Shown.
* * Optional

REPAIR P ARTS LIST

13

12

16

24

5

2

10

11

18

17

16

25

4

14

15

6

7

9

3

8

1

26

20

Now that you have purchased this water heater, should a need ever
exist for repair parts or service, simply contact the company it was
purchased from or direct from the manufacturer listed on the rating
plate on the water heater.

Be sure to provide all pertinent facts when you call or visit.

Selling prices will be furnished on request or parts will be
shipped at prevailing prices and you will be billed accordingly .

The model number of your Gas Water Heater will be found on the
rating place located above the gas control valve.

WHEN ORDERING REPAIR P ARTS, AL WA YS GIVE THE FOLLOWING
INFORMATION:

• MODEL NUMBER

• TYPE GAS (NATURAL OR PROPANE (L.P.)

• SERIAL NUMBER

• PART DESCRIPTION

THIS IS A REPAIR PARTS LIST , NOT A PACKING LIST . PAR TS ARE
NOT DRAWN T O SCALE.

30

23

27 28

34

29

31

33

24

22

35

36

25

21

19

38

32
30

37

TROUBLESHOOTING GUIDELINESTROUBLESHOOTING GUIDELINES

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 INFORMATION section first.

LED ST ATUS

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 igniter circuit. 1 . Check that all wiring is correct and secure.

2. Replace hot surface igniter.

System in lockout. 1. Gas supply is off or too low to operate.

2. Hot surface igniter not positioned
correctly.

3. Low voltage to the water heater.

4. Electric polarity to unit is incorrect - test
and correct.

A B
C

WATER HEATER 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.

31

TROUBLESHOOTING GUIDELINESTROUBLESHOOTING GUIDELINES

These guidelines should be utilized by a qualified service agent.

PROBLEM CAUSE SOLUTION

NOT ENOUGH HOT WATER

VENT PIPE TOO HOT (ABOVE 170° F)

YELLOW FLA ME

CONDENSATION

WATER LEAKS

LEAKING T & P

HOT WATER ODORS

(refer to cathodic protection)

WATER TOO HOT

WATER HEATER SOUNDS

SIZZLING - RUMBLING Sediment at bo t tom of heater tank .

SOOTING Improper combustion. Refer to Air Requirements on Page 4.

BURNER WILL NOT STAY LIT –

GOES OUT 4-5 SECONDS

VENT GAS ODORS

1.) Bl ow er wi ll not run.
a. “ON/OFF” control switch turned off. Turn switch to the “ON” positi on.
b. Blower unplugged. Plug blower back into 115 VAC outlet.
c. No powe r at outlet. Repair s er v i c e to outlet.
d. Therm ostat defective. R e place therm os tat.
e. Control harness defective. Replace control harness.
f. High limit control circuit open. Replace thermostat.
g. Blower motor defective. Replace blower assembly.

2.) Ther m os tat problems
a. Thermostat set too low. Adjust temperature control higher.
b. Thermostat or ECO defective. Replace thermostat.

3.) Others
a. Heater undersized. Reduce hot water use.
b. Low gas pressure. Contact dealer.
c. Incoming water is usually cold. Allow more time for heater to rehe at.
d. Leaking hot water pipes of fixtures. Have plumber check and repair leaks.
e. Heater not lit or thermostat not on. Refer to LIGHTING INSTRUCTIONS.
Wrong bur ner orifice. Install correct orifice.
Dirt in burner ports . Turn of f heater and gas, clean burner head .

Combustion air path restricted.
Water on the floor under heater. See CONDENSATION section.
Wate r dripping from blower assembl y.
Improperly sealed, hot or cold supply

connections, relief valve, drain valve or
thermost at threads.
Leak ag e f rom other appliances or water line s. Inspect oth er ap pliances near wat er heater.
Condensation of flue products. Refer to CONDENSATION section.

Thermal expansion in closed water system.
Improperly sealed valve.

High sulfate or mineral content in water
supply.
Bacteria in water supply. Chlorinate water supply.

Thermostat set too high.
Condensation dripping on burner. Refer to CONDENSATION above.

Outl et po larity is reve r s ed. Test polarity and co r r ec t .
High ambient room temperature. Contact a service agency to determine cause.

Combustion air path restricted.
Defe c t i ve gas valve. Replace gas valve.

Lack of air supply.
Improper ly installed vent piping.
Downdraft
Poor Co mb ustion

Check exhaust venting and air openings in
bottom base pan for obstructions or blockage.

Provide drip “TEE” to catch condensation, see
Figure 1.
Check for leaks at all condensate points. See
Figure 1. Also see LEAK CHECKPOINTS
section.

Install thermal expansion ta nk (Do no t plug
T&P valve).
Check relief valve for proper operation (Do
not plug T&P valve).

Drain an d fl ush heater thoroughly then refill.

Refer to TEMPERATURE REGULATION
section.

Clean sediment from tank. Refer to
DRAINING.

Check exhaust venting and air openings in
bottom base pan for obstructions or blockage.

Shut off water heater immediately and contact
a service agency to determine cause.

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NOTES:

33

NOTES:

34

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
(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 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 WA TER HEATER REPLACEMENT MODEL OR PART
WILL BE W ARRANTED FOR ONLY THE UNEXPIRED POR TION 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 VALIDATE THIS
WARRANTY. This warranty is not transferable.

WARRANTY PERIOD

Product Line TANK

GP6 50 YTVIT 6 YEARS 6 YEARS

When the water heater has been used for other than
residential application: 1. The Tank warranty shall be reduced to 3 years
on 10 year models and 1 year on 6 and 8 year models. 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.

1

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:
a. Labor charges for service, removal, or reinstallation of the water

heater or part thereof.

2

PARTS

single family

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.

LIMIT ATION 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 st ates 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 product s.

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 PROOF­OF-PURCHASE OR PROOF-OF-INST ALLATION.

DISCLAIMERS

NO EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF
OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY
OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR
REPLACEMENT OF THE HEA TER OR PARTS. THE WARRANTOR SHALL
NOT BE RESPONSIBLE FOR WA TER DAMAGE, LOSS OF USE OF THE
UNIT , INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPER TY ,
OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL
NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE 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. Should governmental
regulations or industry standards prohibit the Manufacturer from furnishing
a comparable model replacement under this warranty , the Owner will be
furnished with the closest comparable water heater meeting the current
governmental regulations and industry standards. A supplementary fee
may be assessed to cover the additional cost associated with the changes
made to meet applicable regulations and standards.

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_______________

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