Installation Guide

TABLE OF CONTENTS
TABLE OF CONTENTS 2
SAFE INSTALLATION, USE AND SERVICE 3
GENERAL SAFETY 4
INTRODUCTION 6
Qualifi ed Installer Or Service Agency . . . . . . . . . . . . 6
Preparing For The Installation. . . . . . . . . . . . . . . . . . 6
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS 7
TYPICAL INSTALLATION 9
Get To Know Your Water Heater - Gas Models
(List Referencing Figures 1-7). . . . . . . . . . . . . . . . . . 9
Replacement Parts And Deliming Products . . . . . . 10
Combo Heating Inlet And Outlet Side Taps. . . . . . . 10
Water Piping - Mixing Valve Usage. . . . . . . . . . . . . .11
Mixing Valves
Water Heater Operation . . . . . . . . . . . . . . . . . . . . . 12
Electrical Requirements & Wiring Diagram. . . . . . . 13
SAFETY LOCKOUTS 14
High Limit Controls (Energy Cut Off). . . . . . . . . . . . 14
Thermostat/Water Temperature
Blower High Limit Switch
Blower Air Pressure Switch. . . . . . . . . . . . . . . . . . . 14
Flammable Vapor Sensor . . . . . . . . . . . . . . . . . . . . 14
LOCATING THE NEW WATER HEATER 15
Facts To Consider About The Location . . . . . . . . . . 15
Storage Of Flammable Liquids . . . . . . . . . . . . . . . . 15
Clearances to combustibles
Floors with carpeting
Clearance for servicing
Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unconfi ned Space. . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unusually Tight Construction . . . . . . . . . . . . . . . . . 17
Confi ned Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Direct Vent Appliances . . . . . . . . . . . . . . . . . . . . . . 18
Exhaust Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fresh Air Openings For Confi ned Spaces. . . . . . . . 18
Chemical Vapor Corrosion . . . . . . . . . . . . . . . . . . . 19
INSTALLING THE NEW WATER HEATER 20
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Space Heating And Potable Water Systems. . . . . . 20
Combo Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
System Requirements
Installation
Closed Water Systems . . . . . . . . . . . . . . . . . . . . . . 22
Thermal Expansion. . . . . . . . . . . . . . . . . . . . . . . . . 22
Temperature-Pressure Relief Valve. . . . . . . . . . . . . 23
T&P valve discharge pipe requirements:
Temperature-Pressure Relief Valve and
Pipe Insulation
High Altitude Installation . . . . . . . . . . . . . . . . . . . . . 24
Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Sediment Traps/Dirt Leg . . . . . . . . . . . . . . . . . . . . . 25
Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 26
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Termination Clearances Sidewall Power Vent. . . . . 27
Blower Assembly Installation. . . . . . . . . . . . . . . . . . 28
Installation Of Vent System. . . . . . . . . . . . . . . . . . . 28
Planning The Vent System . . . . . . . . . . . . . . . . . . . 28
High Ambient Temperature Installations . . . . . . . . . 28
Polypropylene Vent Systems . . . . . . . . . . . . . . . . . 29
Condensate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Important Notes and Warnings
Venting terminations and sizing
Vent screen installation
Calculating Equivalent Feet
Venting instructions
Vent pipe connection to blower
Different coupling installations according
to vent sizes
Blower Exhaust Direction . . . . . . . . . . . . . . . . . . . . 35
Vent Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . 35
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 38
LIGHTING INSTRUCTIONS 39
OPERATING THE TEMPERATURE
CONTROL SYSTEM 40
Gas Control Valve/Thermostat . . . . . . . . . . . . . . . . 41
FOR YOUR INFORMATION 42
Start Up Conditions. . . . . . . . . . . . . . . . . . . . . . . . . 42
Condensate
Thermal expansion
Closed water systems
Smoke/odor
Strange sounds
Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 42
Smelly water
“Air” In Hot-Water Faucets . . . . . . . . . . . . . . . . . . . 43
PERIODIC MAINTENANCE 44
General Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Venting System Inspection . . . . . . . . . . . . . . . . . . . 44
Blower Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 44
Cleaning The Blower. . . . . . . . . . . . . . . . . . . . . . . . 44
Burner Operation And Inspection . . . . . . . . . . . . . . 45
Combustion Chamber And Burner Cleaning. . . . . . 46
Housekeeping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Anode Rod Inspection. . . . . . . . . . . . . . . . . . . . . . . 46
Anode Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removing Anode Rod:
Installing Anode Rod:
Temperature-Pressure Relief Valve Test. . . . . . . . . 47
Draining And Flushing. . . . . . . . . . . . . . . . . . . . . . . 48
To drain the water heater storage tank:
To fl ush the water heater storage tank:
LEAKAGE CHECKPOINTS 49
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REFERENCE PARTS LISTING 50
TROUBLESHOOTING GUIDELINES 52
Resetting The Heater Control . . . . . . . . . . . . . . . . . 54
Lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Soft Lockout
Hard Lockout
Ignition State And Timing . . . . . . . . . . . . . . . . . . . . 55
System Status And Error Codes . . . . . . . . . . . . . . . 55
LIMITED WARRANTY 58
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