Westinghouse WGRTLP199, WGRTNG199 Installation Manual

Residential

Tankless

Water Heater

INSTALLATION

START-UP

MAINTENANCE

PARTS

Models*

WGRTNG199

WGRTLP199

NOTICE: Westionghouse reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

The surfaces of these products contacted by consumable water contain less than 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.

IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER WATER HEATER.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any water heater.

Do not touch any electrical 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. Installation and service must be provided by a qualified installer, service agency, or the gas supplier.

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The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

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

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

NOTICE	SAFETY INSTRUCTIONS
NOTICE is used to address practices not related to personal	SAFETY INSTRUCTIONS (or equivalent) signs indicate specific
injury.	safety related instructions or procedures.
NOTE: Contains additional information important to a procedure.
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FOREWORD

This manual is intended to be used in conjunction with other literature provided with the water heater. This includes all related control information. It is important that this manual, all other documents included with this system, and additional publications including the National Fuel Gas Code, ANSI Z223.1-2002, be reviewed in their entirety before beginning any work.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The Authority Having Jurisdiction may be a federal, state, local government, or individual such as a fire chief, fire marshal, chief of a fire prevention bureau, labor department or health department, building official or electrical inspector, or others having statutory authority. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ.

NOTE: Westinghouse reserves the right to modify product technical specifications and components without prior notice.

FOR THE INSTALLER

This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.

This appliance must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the water heater, and with local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code, ANSI Z223.1-2002.

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INSTALLATIONS MUST COMPLY WITH:

Local, state, provincial, and national codes, laws, regulations and ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

In Canada – CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

Code for the installation of Heat Producing Appliances (latest version), from American Insurance Association, 85 John Street, New York, NY 11038.

The latest version of the National Electrical Code, NFPA No. 70.

NOTE: The gas manifold and controls met safe lighting and other performance criteria when the water heater underwent tests specified in ANSI Z21.10.3 – latest edition.

TABLE OF CONTENTS
PART 1 – ITEMS SHIPPED WITH THE WATER HEATER .........................................................................................................	6
PART 2 – SAFETY REGULATIONS ...........................................................................................................................................	6
A. OPERATION AND INSTALLATION WARNINGS .......................................................................................................................	6
C. IMPROPER COMBUSTION .......................................................................................................................................................	8
D. GAS............................................................................................................................................................................................	8
E. WHEN SERVICING THE WATER HEATER ..............................................................................................................................	8
F. WATER QUALITY.......................................................................................................................................................................	8
G. FREEZE PROTECTION.............................................................................................................................................................	8
PART 3 – TECHNICAL SPECIFICATIONS .................................................................................................................................	9
PART 4 – PREPARE WATER HEATER LOCATION ................................................................................................................	11
A. BEFORE LOCATING THE WATER HEATER ..........................................................................................................................	12
B. LEVELING ................................................................................................................................................................................	13
C. CLEARANCES FOR SERVICE ACCESS ................................................................................................................................	13
D. RESIDENTIAL GARAGE INSTALLATION ...............................................................................................................................	13
E. EXHAUST VENT AND INTAKE PIPE.......................................................................................................................................	13
F. PREVENT COMBUSTION AIR CONTAMINATION..................................................................................................................	14
G. REMOVING A WATER HEATER FROM A COMMON VENT SYSTEM ..................................................................................	14
H. UNCRATING THE WATER HEATER.......................................................................................................................................	15
I. WALL-MOUNTING THE WATER HEATER ...............................................................................................................................	15
PART 5 – VENTING...................................................................................................................................................................	16
A. INTAKE PIPE AND EXHAUST VENT GUIDELINES ................................................................................................................	16
B. APPROVED VENT MATERIALS ..............................................................................................................................................	18
C. ALLOWED SCHEDULE 40 VENT LENGTHS (PVC, CPVC, PP).............................................................................................	18
D. TIGHTENING WATER HEATER COLLAR TO EXHAUST VENT AND INTAKE PIPE.............................................................	19
E. VENT TERMINATION ..............................................................................................................................................................	19
1. Two Pipe Roof and Sidewall Vent Terminations .....................................................................................................................	19
2. Direct Vent, Optional Horizontal and Vertical Vent Kits .........................................................................................................	20
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3. Screen Installation.....................................................................................................................................................................	20
PART 6 – INSTALL THE CONDENSATE DRAIN .....................................................................................................................	21
PART 7 – GAS PIPING..............................................................................................................................................................	21
A. GAS PIPE SIZING TABLES .....................................................................................................................................................	21
1. Gas Pipe Sizing..........................................................................................................................................................................	21
2. Natural Gas Pipe Sizing ............................................................................................................................................................	21
3. LP (Liquid Propane) Gas Pipe Sizing.......................................................................................................................................	22
B. GAS CONNECTION REQUIREMENTS ...................................................................................................................................	22
C. ADJUSTING GAS PRESSURE AT THE WATER HEATER .....................................................................................................	24
PART 8 – WATER PIPING ........................................................................................................................................................	24
A. GENERAL PLUMBING CONNECTION GUIDELINES .............................................................................................................	24
B. INSTALL A BACKFLOW PREVENTER....................................................................................................................................	24
C. PIPING THE WATER HEATER................................................................................................................................................	24
D. PIPING DIAGRAM....................................................................................................................................................................	25
E. PRESSURE RELIEF VALVE ....................................................................................................................................................	25
PART 9 – CONNECT ELECTRICAL POWER / INITIAL STARTUP .........................................................................................	26
A. WIRING INFORMATION ..........................................................................................................................................................	26
B. DIP SWITCHES........................................................................................................................................................................	27
PART 10 – OPERATING SYSTEM INSTRUCTIONS................................................................................................................	32
A. CONTROL PANEL ...................................................................................................................................................................	32
B. LCD DISPLAY DESCRIPTIONS ..............................................................................................................................................	32
C. START-UP SEQUENCE ..........................................................................................................................................................	32
D. CHANGING THE DHW SET-POINT ........................................................................................................................................	33
E. CHANGING THE TEMPERATURE INDICATOR .....................................................................................................................	33
G. STATUS DISPLAY MODE .......................................................................................................................................................	33
H. INSTALLER MODE ..................................................................................................................................................................	34
F. ERROR MODE .........................................................................................................................................................................	35
G. ERROR TREE ANALYSIS .......................................................................................................................................................	38
1. FLAME DETECTION...................................................................................................................................................................	38
2. GAS DETECTION .......................................................................................................................................................................	39
3. AIR PRESSURE SWITCH...........................................................................................................................................................	39
4. Inlet / DHW / Operating Temperature SENSORS.....................................................................................................................	39
PART 11 – FINAL INSTALLATION CHECKLIST .....................................................................................................................	40
PART 12 – TROUBLESHOOTING ............................................................................................................................................	41
PART 13 – MAINTENANCE PROCEDURES ............................................................................................................................	42
REPLACEMENT PARTS ................................................................................................................................................................	47
Limited Warranty for Residential Tankless Water Heaters ........................................................................................................	49
MAINTENANCE REPORT ..............................................................................................................................................................	51
MAINTENANCE NOTES.................................................................................................................................................................	55
CUSTOMER INSTALLATION RECORD FORM .............................................................................................................................	56

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PART 1 – ITEMS SHIPPED WITH THE WATER HEATER

	ITEM	DESCRIPTION		QUANTITY
	Residential Tankless Water
	Heater		1
	WGRTNG199
	WGRTLP199
	Quick Reference Guide, User,			1 Each
	and Installation Manuals
	Condensate Hose		1
	Anchors and Wall Mounting		4
	Bracket
	Spare Parts Kit		1
	(Gaskets and O-Rings)
	Vent Screens (3”)			2 Screens
		OPTIONAL PARTS (Not Included)
	150 PSI Pressure Relief Valve		1
	Tankless Isolation Valves		2
	Vent Screens (2” Mesh)			2 Screens

Table 1 – Items Included with the Water Heater

PART 2 – SAFETY REGULATIONS

A. OPERATION AND INSTALLATION WARNINGS

To avoid serious injury or death, read, understand, and follow all the precautions listed here.

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Vapors from flammable liquids will explode and can cause a fire, resulting in personal injury or death. The water heater has a burner that can come on at any time and ignite vapors. DO NOT use or store flammable liquids around the water heater.

Improper venting can cause a build-up of carbon monoxide. Breathing carbon monoxide can result in brain damage or death. DO NOT operate the water heater unless it is properly vented to the outside and has an adequate fresh air supply for safe operation. Inspect the exterior exhaust gas outlet port and fresh air inlet port on a regular basis to ensure they are functioning properly.

A concentration of carbon monoxide as small as .04% (400 parts per million) in the air can be fatal. When making high fire or low fire adjustments, CO levels must be monitored using a flue gas analyzer such that a CO level of no more than 150 ppm is exceeded at any time during operation.

Adjusting the “low fire offset” or the “main flow restrictor” in small increments can result in a significant increase in CO concentration. To avoid serious injury or death, DO NOT make any adjustments to the gas valve without monitoring the exhaust gases with a fully functional and calibrated flue gas analyzer.

This water heater must be installed by a licensed plumber, licensed gas fitter, and/or professional service technician. Improper installation and/or operation can cause a potentially hazardous situation, which, if not avoided, could result in serious injury or death, and will void the warranty.

Westinghouse cannot anticipate every circumstance that might involve a potential hazard. Each installation has its own specialized characteristics, requirements, and possible hazards. Therefore, all possible incidents are not included in these warnings. Proper and safe installation, operation, and service are the responsibility of the professional service technician.

Proper care of the water heater is the user’s responsibility. Ensure the user carefully reads and understands the User’s Information

Manual before operating and maintaining the water heater.

Make sure the user knows the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve if the water heater is subjected to fire, overheating, flood, physical damage, or any other damaging condition that might affect the operation of the unit. Have the water heater checked by a qualified technician before resuming operation.

Do not power up the unit unless the gas and water supply valves are fully opened. Make sure the fresh air intake port and exhaust gas port are open and functional.

No one but a professional service technician should attempt to install, service, or repair this water heater. There are no serviceable parts which can be changed by the user / owner. User / Owner: Contact the original professional service technician if the water heater needs repair or maintenance. If the original technician is unavailable, ask your gas supplier for a list of qualified service providers.

Keep the area around the water heater clean and free of all materials that can burn. DO NOT store or place gasoline, oils, spray paint, or other flammable products near the water heater.

DO NOT use spray paint, hair spray, or any other flammable spray near the water heater or near the exterior fresh air intake port. DO NOT place any items in or around the exterior exhaust gas outlet port and/or fresh air inlet port that could restrict or block the flow in or out of the vent system.

DO NOT store or place newspapers, laundry, or other combustible items near the water heater or the exterior exhaust gas outlet and/or fresh air inlet port.

The owner should inspect the system monthly for damage, water stains, signs of rust, corrosion, and exhaust vent and air intake blockage. If inspection of the unit shows signs of damage, the water heater should be shut off until the problem is repaired by a qualified technician.

After installation, all water heater safety devices should be tested.

This water heater is certified for indoor installations only. The water heater consists of gas ignition system components which must be protected from water (dripping, spraying, etc.) during operation and service. Carefully consider installation location and the placement of critical components (circulators, condensate neutralizers, etc.) before installing the water heater.

DO NOT allow children to operate this unit. DO NOT use this unit if it does not appear to be operating correctly. A qualified technician should service and inspect the water heater annually.

The water heater temperature is factory set to 125oF (51.7oC). To avoid scalding, always check the temperature of the hot water before bathing, showering, washing, etc. DO NOT adjust the water temperature while the water heater is being used by other persons.

NOTICE

If the water heater is exposed to the following, do not operate until all corrective steps have been made by a qualified service technician:

1.FIRE

2.DAMAGE

3.WATER

DO NOT alter or modify the water heater or water heater controls. This can be dangerous and WILL VOID the warranty.

This water heater is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong receptacle. DO NOT remove the ground plug from the plug.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

This water heater provides a overheat shutdown limit. In the event the water heater water exceeds the set point of the control limit, the cutoff will trip and the water heater will shut down. Certain local codes require additional temperature limits. In addition, certain types of systems may operate at temperatures below the minimum set point of the limit provided with the water heater. Contact Westinghouse for additional overheat controls.

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NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the water heater rating label.

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualified service technician. The appliance MUST BE replaced if it has been submerged. Attempting to operate an appliance that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a fire and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged appliance could result in property damage, severe personal injury, or death.

NOTE: Appliance damage due to flood or submersion is considered an Act of God, and IS NOT covered under product warranty.

Be sure to disconnect electrical power before opening water heater cabinet or performing service. Label all wires while performing service to ensure proper re-wiring of the water heater. Wiring errors can cause improper or dangerous operation. Failure to do so could result in an electrical shock, improper water heater operation, property damage, serious personal injury, or death.

C. IMPROPER COMBUSTION

Do not obstruct the flow of combustion and ventilating air. Adequate air must be provided for safe operation. Failure to keep the exhaust vent and intake pipe clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

D. GAS

Should overheating or gas supply fail to shut off, do not turn off or disconnect electrical supply to the circulator. Instead, shut off the gas supply at a location external to the appliance.

E. WHEN SERVICING THE WATER HEATER

To avoid electric shock, disconnect electrical supply before performing maintenance.

To avoid severe burns, allow water heater to cool.

Do not use petroleum-based cleaning or sealing compounds in a water heater system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.

Do not use “homemade cures” or “patent medicines”. Substantial property damage, damage to water heater, and/or serious personal injury may result.

Always verify proper operation after servicing the water heater.

F. WATER QUALITY

Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in Table 2. If your water contains contaminants higher than outlined by EPA, then water treatment is recommended and additional maintenance may be required. If you suspect that your water is contaminated in any way, discontinue use of the water heater and contact an authorized technician or licensed professional.

Contaminant	Maximum Allowable Level
Total Hardness	200 mg/l (12 grains/gallon)
Aluminum	0.05 to 0.2 mg/l
Chloride	250 mg/l
Copper	1 mg/l
Iron	0.3 mg/l
Manganese	0.05 mg/l
pH	6.5-8.5
Sulfate	205 mg/l
Total Dissolved Solids (TDS)	500 mg/l
Zinc	205 mg/l
Table 2 – Water Quality Specifications

G. FREEZE PROTECTION

Consider water heater piping and installation when determining water heater location.

NOTE: Damages resulting from incorrect installation or from use of products not approved by Westinghouse ARE NOT covered by warranty.

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PART 3 – TECHNICAL SPECIFICATIONS

	MODEL				WGRTNG199 / WGRTLP199
	Installation				Indoor, Wall Hung, Fully Condensing
	Minimum / Maximum Input (Btu/Hr)				19,900 / 199,000
			35oF Rise		11 Gal
	Hot Water Capacity		45oF Rise		8.5 Gal
			77oF Rise		5 Gal
	Flue System				Sealed Combustion Direct Vent
	Vent Run				2” (15 feet), 3” (100 feet), Schedule 40 PVC, CPVC, PP
	Weight (lbs)				88
	Orifice Size		NG		.374” (9.5 mm)
			LP		Consult Factory
	Gas Supply Pressure		NG		3.5” to 14” WC
			LP		3.5” to 14” WC
	Manifold Pressure		Min (3”)		NG: -0.01” / LP: -0.11” WC
			Max (3”)		NG: -0.05” / LP: -0.06” WC
			Main Supply		120V 60 Hz
	Power Supply		Maximum Power		135W
			Consumption
				Temperature
				Ambient Temperature Range: 33 – 104oF (0.6 – 40oC)
				Operating Relative Humidity: Up to 90% at 140oF (40oC)
				Shipping and Storage Temperature Range: -4 – 176oF (-20 – 80oC)
	General Operating Conditions			Input Ratings
				Power Supply and Communication (CN4): 14V DC
				Product Approvals and Requirements
					EMC: 89/336/EEC
					LVD: 73/23/EEC)
	Ignition System				Direct Electronic Ignition / Automatic Flame Sensing
	Burner System				Single Orifice Premixed Fuel Modulation Metal Fiber Infrared
	Gas Valve System				Air Ratio Valve
	Minimum Flow Rate				0.5 GPM
	Internal Pipe Material				Stainless Steel
	Dimensions				W 17.3” – H 27.6” – D 14.8”
	Sub Heat Exchanger Water Capacity (DHW)				Under 2 Gallons
	Main Controller / Control Panel				P-920C / GTH-9500C
	Water Pressure				Min 15 – Max 150 PSI
			Cold Water Inlet /		¾” NPT
	Connection Sizes		Hot Water Outlet
			Gas Inlet		¾” NPT
			Cabinet		Cold Rolled Carbon Steel
	Materials		Heat Exchanger		Primary Heat Exchanger: Stainless Steel
					Secondary Heat Exchanger: Stainless Steel
				Flame Rod, Burner Overheat Cut Off Device 302oF (150oC), Gas Leak Detector,
	Safety Devices			Flue High Limit Switch 149oF (65oC), Water Temperature High Limit Switch 199oF
				(93oC), Freeze Protection Ceramic Heater (Turns on at 41oF / 5oC, Turns off at
					59oF / 15oC)
	Table 3 – Technical Specifications

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Figure 1 – Specifications and Dimensions

	DESCRIPTION	DIAMETER
A	Exhaust Outlet Pipe	3”
B	Air Intake	3”
C	Gas Inlet	¾”
D	DHW Outlet Adapter	¾”
E	DHW Inlet Adapter	¾”
F	Condensate Adapter	½”
G	DHW Inlet Filter	N/A

Table 4 – Adapter Specifications

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Figure 2 – Components

NUMBER	COMPONENT DESCRIPTION	NUMBER	COMPONENT DESCRIPTION
1	Exhaust Vent Adapter	19	Exhaust Duct
2	Air Inlet Pipe	20	Gas Valve
3	AGM (Air Gas Mixer)	21	Gas Inlet Pipe 2
4	Ignition Transformer	22	BLDC Fan
5	Igniter	23	Air Intake Pipe Adapter
6	Flame Detection Sensor	24	Gas Inlet Adapter
7	Primary Heat Exchanger Assembly	25	Freeze Protector
8	Hot Water Outlet	26	DHW Outlet Adapter
9	Mixing Valve	27	Condensate Trap
10	Air Pressure Switch	28	Cold Water Inlet Adapter
11	N/A	29	Cold Water Inlet Filter
12	Manual Power Switch	30	Control Panel
13	Water Adjustment Valve	31	Operating Temperature Sensor
14	Main Controller	32	High Limit Overheat Switch
15	Secondary Heat Exchanger Assembly	33	Ceramic Heater
16	Gas Inlet Pipe 1	34	DHW Sensor
17	Flame Sight Glass	35	Condensate Trap Hose
18	Burner Case	36	Burner Overheat Switch

Table 5 – Component List

PART 4 – PREPARE WATER HEATER LOCATION

Carefully consider installation when determining water heater location. Please read the entire manual before attempting installation. Failure to properly take factors such as water heater venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

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A. BEFORE LOCATING THE WATER HEATER

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the water heater installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death.

Failure of water heater or components due to incorrect operating conditions IS NOT covered by product warranty.

1.Installation Area (Mechanical Room) Operating Conditions

Ensure ambient temperatures are higher than 32oF/0oC and lower than 104oF/40oC.

Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual.

Avoid continuously high levels of humidity

Never close existing ventilation openings

The service life of the water heater’s exposed metallic surfaces, such as the cabinet, as well as internal surfaces, such as the heat exchanger, are directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of the heat exchanger and other water heater components. In these environments, water heaters must not be installed using direct vent systems which draw outdoor air for combustion. Such water heaters must be installed using room air for combustion. Indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.

This water heater is certified for indoor installations only. Do not install the water heater outdoors. Failure to install this water heater indoors could result in substantial property damage, severe personal injury, or death.

2.Check for nearby connections to:

System water piping

Venting connections

Gas supply piping

Electrical power

Condensate drain

Locate the water heater where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower floors of the building. The water heater should be located near a floor drain, or installed in proximity to an adequately drained drain pan. Westinghouse WILL NOT be held liable for leakage damages.

To conserve water and energy, insulate all water piping, especially the hot and recirculation water lines.

3. Check area around water heater. Remove any combustible materials, gasoline, and other flammable liquids.

Failure to keep water heater area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

4.Gas control system components must be protected from dripping water during operation and service.

5.If the water heater is to replace an existing water heater, check for and correct any existing system problems, such as:

System leaks

Location that could cause the system and water heater to freeze and leak.

Incorrectly-sized expansion tank

Do not connect the water heater to any heating systems or components that have been previously used for non-potable applications.

Do not introduce toxic chemicals, such as antifreeze or water heater treatments, into the water heater or any piping meant for potable water purposes.

Ensure that all piping and components connected to the water heater are suitable for potable water applications.

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Do not use this water heater for space heating applications.

Circulators suitable for DHW applications must be used.

6. Clean and flush system when reinstalling a water heater.

NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the water heater model and serial number.

B. LEVELING

In order for the condensate to properly flow out of the collection system, the water heater must be installed level.

C. CLEARANCES FOR SERVICE ACCESS

See Table 6 for recommended service clearances. If these minimum clearances are not provided, it may not be possible to service the water heater without removing it from the space.

Space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the water heater. The water heater cover must be securely fastened to prevent it from drawing air from the water heater room. This is particularly important if the water heater is in a room with other appliances. Failure to comply with the above could result in substantial property damage, severe personal injury, or death.

MINIMUM CLEARANCES

	Installation Clearances from Non-Combustibles / Combustibles				Recommended Service and Proper Operation Clearances
	Top		9 in. (228.6 mm)		9 in. (228.6 mm)
	Back		5/8 in. (15.9 mm)		5/8 in. (15.9 mm)
					24 in. (609.6 mm) or more (Front of Water heater)
	Front		6 in. (152.4 mm)		(A combustible door or removable panel is acceptable front
					clearance.)
	Right Side		3 in. (76.2 mm)		3 in. (76.2 mm)
	Left Side
	Bottom		12 in. (304.8 mm)		12 in. (304.8 mm)

Table 6 – Minimum Installation and Service Clearances

NOTE: The exhaust vent piping for this direct vented appliance is approved for zero clearance to combustible construction.

NOTE: If the water heater is installed in a narrow space or corner, ensure that there is sufficient space for service and maintenance access. There should be easy access to the gas and water lines and internal components for future service. A combustible door or removable panel is acceptable front clearance.

D. RESIDENTIAL GARAGE INSTALLATION

If the water heater is located in a residential garage, per ANSI Z223.1:

Mount the bottom of the water heater a minimum of 18” above the floor of the garage, to ensure the burner and ignition devices are well off the floor.

Locate or protect the water heater so it cannot be damaged by a moving vehicle.

E. EXHAUST VENT AND INTAKE PIPE

Vents must be properly supported. The water heater exhaust and intake connections are not designed to carry heavy weight. Vent support brackets must be within 1’ of the water heater and the balance at 4’ intervals. Venting must be readily accessible for visual inspection for the first 3’ from the water heater.

You must also install air intake piping from outdoors to the water heater flue adaptor. The resultant installation is categorized as direct vent (sealed combustion).

NOTE: To prevent combustion air contamination, see Table 7 in this section when considering exhaust vent and intake pipe termination.

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Exhaust vent and intake pipe may be vented vertically through the roof or out a side wall. Venting methods are detailed in the Venting Section. Do not attempt installation using any other means. Be sure to locate the water heater so exhaust vent and intake piping can be routed through the building and properly terminated. Exhaust vent and intake piping lengths, routing, and termination method must comply with methods and limits given in the venting section.

F. PREVENT COMBUSTION AIR CONTAMINATION

Install intake piping for the water heater as described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.

Ensure that the intake air will not contain any of the contaminants below. For example, do not pipe intake near a swimming pool. Avoid areas subject to exhaust fumes from laundry facilities. These areas always contain contaminants. Contaminated air will damage the water heater, resulting in possible substantial property damage, severe personal injury, or death.

PRODUCTS TO AVOID	AREAS LIKELY TO HAVE CONTAMINANTS
Spray cans containing fluorocarbons	Dry cleaning/laundry areas and establishments
Permanent wave solutions	Swimming pools
Chlorinated waxes/cleaners	Metal fabrication plants
Chlorine-based swimming pool chemicals	Beauty shops
Calcium chloride used for thawing	Refrigeration repair shops
Sodium chloride used for water softening	Photo processing plants
Refrigerant leaks	Auto body shops
Paint or varnish removers	Plastic manufacturing plants
Hydrochloric or Muriatic acid	Furniture refinishing areas and establishments
Cements and glues	New building construction
Antistatic fabric softeners used in clothes dryers	Remodeling areas
Chlorine-type bleaches, laundry detergents, and cleaning solvents	Garages and workshops
Adhesives used to fasten building products
Table 7

NOTE: DAMAGE TO THE WATER HEATER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to the limited warranty for complete terms and conditions).

G. REMOVING A WATER HEATER FROM A COMMON VENT

SYSTEM

Do not install the water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

When removing an existing water heater, the following steps must be followed.

1.Seal any unused openings in the common venting system.

2.Visually inspect the venting system for proper size and horizontal pitch to

	determine if there is blockage, leakage, corrosion or other deficiencies that	Figure 3 - CO Warning Label
	could cause an unsafe condition.

3.If practical, close all building doors, windows and all doors between the common venting system and other spaces in the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer exhaust fan. Close all fireplace dampers.

4.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

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5.Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette.

6.After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use.

7.Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code, ANSI Z 223.1.

H. UNCRATING THE WATER HEATER

UNCRATING WATER HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Cold weather handling – If water heater has been stored in a very cold location (below 0oF) before installation, handle with care until the plastic components come to room temperature.

Remove all sides of the shipping crate to allow the water heater to be lifted into its installation location.

I. WALL-MOUNTING THE WATER HEATER

The water heater must be installed on a wall that can bear its weight (more than 88 lbs. when fully plumbed and full of water). Installing the water heater on a wall which cannot support its weight could result in property damage, personal injury, or death.

The water heater may be installed on any suitable internal wall (suitable sound-proofing may be required when installing onto a stud partition wall).

This water heater is too heavy for one person to lift. It is highly recommended to install the water heater with two people. Use caution as to not drop the water heater, which could damage the water heater and cause property damage and/or severe personal injury. Verify that the water heater is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the water heater could result in substantial property damage, severe personal injury, or death.

This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the water heater could result in substantial property damage, severe personal injury, or death.

POSITIONING THE WATER HEATER ON THE WALL

1.Attach the wall bracket on the location where you want to install the water heater. Ensure it is level and on stud (16” centers) before proceeding.

2.Mark the four drill holes with a pencil or marker. Remove the wall bracket.

3.Drill four (4) holes using a 5/32 drill bit at the marked hole locations.

4.Mount the wall bracket to the wall with the four (4) included anchor bolts. Ensure the mounted bracket is level. See Figure 4A.

5.Align the heater bracket grooves on the back of the water heater with the tongues on the wall bracket and hang the water heater on the bracket. See Figure 4B.

Figure 4 – Wall Mounting the Water Heater

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PART 5 – VENTING

Vent this water heater in accordance with these instructions. Failure to do so will result in property damage, severe personal injury, or death.

DO NOT mix vent systems or materials unless specifically told to do so in this manual.

DO NOT thermally insulate the exhaust vent or intake pipes.

DO NOT use an electric damper, vent damper, or draft hood with this water heater.

DO NOT locate the exhaust vent or intake pipe terminations where exposed to prevailing winds.

Moisture will be produced by the exhaust vent. Take precautions when determining exhaust vent termination. Moisture may fall from the vent termination to the ground and turn to ice in freezing conditions. Moisture or ice can produce a hazardous condition.

Exhaust condensate is acidic, and could deteriorate the surface below the exhaust vent termination. Ensure this surface is in good repair (sealed, painted, etc.) to prevent deterioration.

Failure to follow these instructions could result in property damage, severe personal injury, or death.

A. INTAKE PIPE AND EXHAUST VENT GUIDELINES

1.Vent system must be installed in accordance with local codes, or, in absence of local codes, the National Fuel Gas Code, ANSI Z223.1 / NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

2.For installation in Canada, installer supplied plastic vent piping must comply with CAN/CGA B149.1 and be certified to the Standard for Type BH Gas Venting Systems, ULC-S636. Components of this listed system must not be interchanged with other vent systems or unlisted pipes or fittings. All plastic components and specified primers and glues must be from a single system manufacturer and must not be intermixed with another system manufacturer’s products. Clean and dry all applicable surfaces before applying cement.

3.This water heater is designed to be installed as a direct vent (sealed combustion) type. Combustion air must be supplied directly from the outdoors to the burner, and the flue (exhaust) gases should be vented directly to the outdoors through the wall or roof.

4.This water heater uses 2” or 3” diameter pipe for exhaust vent and intake pipe. It is important to ensure an airtight seal from the water heater collar to the

vent terminations. It is EXTREMELY IMPORTANT that the maximum allowed combined venting lengths are not exceeded. See Table 9 for a list of Approved Vent Materials and Table 10 for Approved Vent Lengths.

5.Do not install venting system components on the exterior of the building except as specifically required by these instructions.

Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.

Maintain the correct clearance and orientation between the exhaust vent and intake pipe terminals.

The exhaust vent and air intake terminals must be at the same height and their center lines must be spaced apart 1 foot minimum.

The bottom of the exhaust vent and intake pipe terminals must be at least 1 foot above the normal snow accumulation level. In no case should these terminals be installed less than 1 foot above normal snow accumulation level.

Do not install the exhaust vent terminals directly above windows or doors.

Intake pipe terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools.

For sidewall venting, the minimum horizontal distance between adjacent exhaust vent terminations is 1 foot. It is recommended this distance be greater than 1 foot to better avoid frost damage to building surfaces.

For roof venting, minimum horizontal distance between any adjacent exhaust vent termination is 1 foot.

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space.

Remove all burrs and debris from joints and fittings.

When using PVC or CPVC pipe, all joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC and ASTM F493 for CPVC pipe.

NOTE: DO NOT CEMENT POLYPROPYLENE PIPE.

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Ensure the vent is located where it will not be exposed to prevailing winds.

In all roof venting applications, exhaust discharge must point away from the pitch of the roof.

To prevent water leakage, install adequate roof flashing where the pipe enters the roof.

Do not locate vent over public walkways, driveways, or parking lots. Condensate could drip and freeze, resulting in a slip hazard or damage to vehicles and machinery.

Due to potential moisture build-up, sidewall venting may not be the preferred venting option. To save time and cost, carefully consider venting installation and location.

Horizontal lengths of exhaust vent must slope back towards the water heater not less than ¼" per foot to allow condensate to drain from the vent pipe.

The exhaust vent must terminate where vapors cannot make accidental contact with people or pets, or damage shrubs or plants.

In vacant chimney applications, install and seal a rain cap over existing chimney openings.

All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

Do not use the water heater to support any piping.

Figure 5 – Vent Termination Detail

				DESCRIPTION		US			CANADA
	A			Clearance above grade, veranda, porch, deck, or balcony		1 foot			1 foot
	B			Clearance to window or door that may be opened		1 foot			3 feet
	C			Clearance to permanently closed window	*			*
				Vertical clearance to ventilated soffit located above the
	D		terminal within a horizontal distance of 2 feet from the center		*			*
				line of the terminal
	E			Clearance to unventilated soffit	*			*
	F			Clearance to outside corner	*			*
	G			Clearance to inside corner	*			*
	H			Clearance to each side of center line extended above meter	*				3 feet with a height 15 feet
				/ regulator assembly					above meter / regulator assembly
	I			Clearance to service regulator vent outlet	*				3 feet
	J			Clearance to non-mechanical air supply inlet to building or		1 foot			3 feet
				the combustion air inlet to any other appliance
	K			Clearance to a mechanical air supply inlet		3 feet above if within 10 feet			6 feet
						horizontally
	L			Clearance above paved sidewalk or driveway located	*				7 feet
	M			Clearance under veranda, porch, deck, or balcony	*				1 foot

Table 8 – Vent Termination Clearances - *NOTE: For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA-B 149.1, please use clearances in accordance with local installation codes and the requirements of the gas supplier.

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