Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES • For Your Safety • AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE . . . . . . . . . . . 3 GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Qualified Installer Or Service Agency . . . . . . . . . . . . 6 Preparing For The Installation . . . . . . . . . . . . . . . . . . 6 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7 TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . .
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.
GENERAL SAFETY 4 www.americanwaterheater.
GENERAL SAFETY DANGER WARNING Breathing Hazard - Carbon Monoxide Gas • Install vent system in accordance with codes. • Do not operate water heater if flood damaged. • For operation above 10,100’, a high altitude orifice must be installed. • Do not operate if soot buildup is present. • Do not obstruct water heater air intake with insulating jacket. FLAMMBLE Flammable Vapors • Do not obstruct blower air intake. • Do not place chemical vapor emitting products near water heater.
INTRODUCTION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations found in this Installation and Operating manual: • CSA - Canadian Standards Association • ANSI - American National Standards Institute • NFPA - National Fire Protection Association • ASME - American Society of Mechanical Engineers • UL - Underwriters Laboratories Inc. • AHRI - Air Conditioning, Heating and Refrigeration Institute.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but n
INSTALLATION GRAPHIC: GAS-FIRED POTABLE WATER HEATING/SPACE HEATING SYSTEM • If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following graphic during installation and during modifications to the water supply system. TYPICAL MIXING VALVE INSTALLATION COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM EXPANSION TANK TEMPERED WATER TO FIXTURES (MUST MEET TEMPS LISTED IN MASS.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5) 1 Termination Elbow with Rodent Screen 2 *Vent Pipe 3 *Vent Pipe Elbow (long radius) 4 Sound Suppressor (Tee fitting) 5 *Union (Di-electric water connection) 6 Cold-Water Inlet Nipple/Diptube 7 **Combo Heating System Supply Outlet (Optional) 8 T&P Valve 9 * Discharge Pipe 10 **Combo Heating System Return Inlet (Optional) 11 Gas Control Valve/Thermostat (Honeywell) 12 Gas Valve Electronic Control Module And Cover (
Natural gas and Propane main burner with igniter assembly for 40k and 45k Btu/hr models 18 Vacuum relief valve install per local codes (not supplied with heater). 36 37 35 38 39 40 41 43 42 Figure 3 Natural gas and Propane (LP) main burner with igniter assembly for 58k, 62k, 72k and 76k Btu/hr models 36 Flare Nut †† 37 35 38 Figure 6 Notes: * Items not supplied with the water heater. ** The side recirculation loop connections may not be used as the primary water inlet and outlet connections.
WATER PIPING - MIXING VALVE USAGE Mixing Valves DANGER Water temperature over 125°F can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. HOT BURN Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures.
Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm and the physically/mentally disabled. Table 1 (published by U.S. Government Memorandum, 1978) shows the approximate time-to-burn relationship for normal adult skin.
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. ELECTRICAL REQUIREMENTS & WIRING DIAGRAM WARNING Electric Shock Hazard Disconnect power before servicing. NOTE: REFER TO THE “INSTALLATION CHECKLIST” BEFORE OPERATING THIS HEATER. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
SAFETY LOCKOUTS This water heater has several lockout features designed to prevent the heater from operating in unsafe conditions. HIGH LIMIT CONTROLS (ENERGY CUT OFF) Thermostat/Water Temperature This feature is a part of the gas control valve/thermostat (see Figure 1, item 10) and limits the maximum water temperature. In the event of the water overheating, this safety feature shuts off the fuel supply to the burner.
LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION 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.
Clearances To Combustibles Minimum clearances between water heater and combustibles are 0” at the sides and rear, 5.5” from the front and 12” from top (standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater (see Figure 12). Floors With Carpeting This water heater must not be installed directly on carpeting.
Important Notes and Warnings • This heater is certified to be installed using Schedule • • • • • 40 PVC or CPVC or polypropylene plastic vent material. Only use approved material. All venting material and components must be joined with the approved primer/ cleaner and solvent cement. Do not common vent this heater with any other appliance. During operation the plastic piping will expand as it heats up and contract as it cools down. This is normal for this type of venting.
INSTALLING THE NEW WATER HEATER WATER PIPING DANGER Water temperature over 125°F can cause severe burns instantly resulting in severe injury or death. Children, the elderly and the disabled and are at highest risk of scald injury. Feel water before bathing or showering. HOT BURN Temperature limiting devices such as mixing must be installed when required by codes and to ensure safe temperatures at fixtures. The water supply pressure should not exceed 80 psi.
COMBO HEATING This section serves as a guide for the installation and use of “Combo” heating systems utilizing a domestic water heater that has been specifically approved for such use. It is written for those knowledgeable in the required trades and professionals involved in the design and installation of Combo Heating Systems. It is the responsibility of the installer/designer to follow all applicable codes to ensure the effectiveness and safety of the installation.
CLOSED WATER SYSTEMS Water supply systems may, because of code requirements or such conditions as high line pressure, among others, have installed devices such as pressure-reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system. THERMAL EXPANSION As water is heated, it expands (thermal expansion). In a closed system, the volume of water will increase.
TEMPERATURE-PRESSURE RELIEF VALVE WARNING Explosion Hazard • Temperature-pressure relief valve must comply with ANSI Z21.22-CSA4.4 and ASME code. • Properly sized temperaturepressure relief valve must be installed in opening provided. • Do not plug, block, or cap the discharge line. • Failure to follow this warning can result in excessive tank pressure, serious injury or death.
Note: The purpose of a temperature-pressure relief valve is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see “Closed Water Systems” and “Thermal Expansion” sections.
model rating plate. The inlet gas pressure must not exceed 14” w.c. for natural gas and propane gas. 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. Copper or brass tubing and fittings (except tin lined copper tubing) should not be used.
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. FILLING THE WATER HEATER CAUTION Property Damage Hazard SHUT-OFF VALVE HOT-WATER OUTLET COLDWATER INLET UNION • Avoid water heater damage. • Fill tank with water before operating. • Do not insert the power cord into the electrical receptacle until the heater has been fully installed.
VENTING WARNING CAUTION Improper Installation, use and service may result in property damage. Breathing Hazard - Carbon Monoxide Gas • Install water heater in accordance with the instruction manual and NFPA 54. This unit includes an air intake terminal and an exhaust vent terminal. • To avoid injury, combustion and ventilation air must be taken from outdoors. • Do not place chemical vapor emitting products near water heater.
TERMINATION CLEARANCES (SIDEWALL) R RNE E CO INSIDDETAIL V Vent terminal X Air supply inlet G Area where is not permitted V A D E V B B V C D FIXE D SE CLO V L V B E ERABL OP F V B B D FIXE ED LOS BLE C RA OPE V B V I M V X X K J A Gas meter / regulator Figure 20 Vent terminal clearances for “Power Direct Vent” installations.
Side Wall Vent Terminal Installation Important: When terminating the vent on a side wall, the following specifications pertaining to terminal location must be followed (see Figure 21). 1. The air intake terminal and the exhaust vent terminal must terminate on the same exterior wall. 2. The vertical centerline of the air intake terminal must be located at a minimum of 8” and not more than 24” from the vertical centerline of the exhaust vent terminal. 3.
ORIENTATION OF EXHAUST PIPING AND COMBUSTION AIR PIPING RELATIVE TO EACH OTHER MAY BE VERTICAL (AS SHOWN) OR AT ANY OTHER ANGLE TO SUIT THE INSTALLATION. STRAP (FIELD SUPPLIED) PIPE NIPPLE (USE WITH ELBOW) 90° ELBOW (SEE LOCAL CODES) COMBUSTION AIR EXHAUST SLOPE 1/4” OVER 5’ 1” MAXIMUM COMBUSTION AIR WALL SCREEN INSIDE ELBOW (FIELD SUPPLIED) Figure 24 NOTE: IF AN ELBOW IS REQUIRED BY LOCAL CODES INSTALL SCREEN IN ELBOW INSTEAD OF CONCENTRIC VENT EXHAUST. VENT DIA.
Vent Pipe Termination This water heater includes one (1) pair of more restrictive Vent Termination Screens and one (1) pair of less restrictive Vent Termination Screens. For safety and optimum efficiency performance, ensure the correct Vent Termination Screen is installed for the vent length in your installation. Note: Before installing the Power Direct Vent Water Heater, it is recommended that the location of the pipe terminations (air intake and exhaust vent) be determined.
Venting Terminations And Sizing • Refer to Table 3 for vent pipe materials and sizing. If the installation requires a vent riser, suitable drainage must be provided to ensure condensation does not accumulate (see Figure 35). Termination through a roof is shown Figure 22. Vent Screen Installation Installed in the vent termination elbow, the vent screen is required to keep foreign objects, rodents and small birds from entering the venting system.
• Insertion Tool - Helpful for larger diameter pipe and Vent Pipe Material This heater is certified to be installed using Schedule 40 PVC or CPVC or polypropylene or ABS plastic vent material for the exhaust. The combustion air intake material may be PVC, ABS, CPVC or polypropylene. Check local codes to determine which materials are allowed in your area and only use approved material. All venting material and components must be joined with the approved primer/ cleaner and solvent cement.
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. IMPORTANT NOTE: A dauber type applicator should only be used on pipe sizes 2” and below. For larger diameter pipe, a brush or roller must be used. B. Deburring Use a knife, plastic pipe deburring tool, or file to remove burrs from the end of small diameter pipe.
E. Application of solvent cement • Apply solvent cement evenly and quickly around outside of 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. WARNING Fire Hazard • Cans of cement and primer should be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement.
Vent Pipe Installation The following guidelines should be followed when installing the air intake and exhaust vent system: • Venting should be as direct as possible with a minimum number of pipe fittings. • Vent diameter must not be reduced unless specifically noted in the installation instructions. • Support all horizontal pipe runs every 4’ and all vertical pipe runs every 5’ or according to local codes or venting manufacturer’s instructions.
BLOWER ASSEMBLY INSTALLATION 1. This power vented water heater comes with blower assembly installed. 2. After unit is set in place, make sure blower assembly is still mounted securely. Make sure there is no damage to blower. 3. Make sure there is no packing material in the inlet or discharge of the blower. 4. Make sure that the plastic tubing is still attached from the air pressure switch to the port on the blower motor housing.
Coupling Installations According To Vent Sizes 2” INLET PIPE 2” VENT PIPE 2”-3” ADAPTER (SUPPLIED) 2” RUBBER COUPLING (SUPPLIED) 3” PIPE (SUPPLIED) 3” INLET PIPE 3” VENT PIPE 3” RUBBER COUPLING (SUPPLIED) BLOWER AIR DUCT ADAPTER BLOWER AIR DUCT ADAPTER CONFIGURATION FOR 40 AND 50 GALLON (LO-INPUT) HEATERS CONNECTED TO 2" VENTING. CONFIGURATION FOR HI-INPUT HEATERS CONNECTED TO 3” VENTING. (OPTIONAL CONFIGURATION FOR LO-INPUT HEATERS CONNECTED TO 3” VENTING.
SOUND SUPPRESSOR Included with this water heater is a Tee fitting configured as a sound suppressor. Depending on the configuration of the water heater this will be either a 2” or a 3” fitting. The sound suppressor can be fitted to the venting near the blower assembly or used as the exhaust termination (see Figure 41 thru Figure 44). Side Wall Vent Installation The preferred location for the Sound Suppressor is 12” away from the blower as shown in Figure 41 and Figure 42 and serves as the first 90° elbow.
INSTALLATION CHECKLIST Note: Use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Water Heater Location Centrally located with the water piping system. Located as close to gas piping and vent pipe system as possible. Located indoors and in a vertical position. Protected from freezing temperatures. Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor.
LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner viewport is not missing or damaged. Make sure the tank is completely filled with water before operating the water heater. The gas control valve/thermostat has an “On/Off Switch” and must be turned on before the water heater is operational. Check the label on the front of the water heater near the gas control valve/thermostat for the correct gas.
OPERATING THE TEMPERATURE CONTROL SYSTEM 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.
GAS CONTROL VALVE/THERMOSTAT 130°F ON/OFF SWITCH TEMPERATURE SETTING DIAL 140°F 150°F 120°F 110°F 155°F 70°F Figure 45 Approximate Temperature Temperature Dial Setting °F Time to induce a 2nd and 3rd Degree burn to adult skin VERY HOT 155 Less than 1 second C 150 About 1.5 seconds B 140 Less than 5 seconds A 130 More than 30 seconds HOT 120 More than 5 minutes LOW 110 Normal shower temp VAC 70 N/A Table 5 Note: The temperatures indicated are approximate.
FOR YOUR INFORMATION START UP CONDITIONS Condensate Whenever the water heater is filled with cold water, some condensate will form while the burner is ON. A water heater may appear to be leaking when in fact the water is condensate. This usually happens when: a. A new water heater is filled with cold water for the first time. b. Burning gas produces water vapor in water heaters, particularly high efficiency models where flue temperatures are lower. c.
PERIODIC MAINTENANCE GENERAL UPKEEP Make it a habit to look around the heater, the vent piping, and the hot and cold water pipes. Do not allow any material to be piled up against the heater. Do not place any object on top of the vent pipes. Every 3 - 6 months or as necessary: • Clean lint from blower, top of heater. Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapo rs.
BLUE TIPS LIGHT BLUE INNER CONES ARE SATISFACTORY INCORRECT FLAME LAZY YELLOW CORRECT FLAME SOFT BLUE Figure 47 COMBUSTION CHAMBER AND BURNER CLEANING In the event your burner or burner air openings require cleaning, Call your service agency to remove and clean the burner and correct the problem that required the burner to be cleaned.
DRAINING AND FLUSHING Periodic draining and cleaning of sediment from the tank maybe necessary. It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. See “Typical Installation” section in this manual for location of the water heater components described below. DANGER • Burn hazard. • Hot water discharge.
ANODE ROD MAINTENANCE Each water heater contains at least one anode rod, which will slowly deplete (due to electrolysis) prolonging the life of the water heater by protecting the glass-lined tank from corrosion. Adverse water quality, hotter water temperatures, high hot water usage, hydronic heating devices, and water softening methods can increase the rate of anode rod depletion. Once the anode rod is depleted, the tank will start to corrode, eventually developing a leak.
LEAKAGE CHECKPOINTS SERVICE If a condition persists or you are uncertain about the operation of the water heater contact a service agency. 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. 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.
REFERENCE PARTS LISTING Replacement parts may be ordered through your plumber or the local distributor. When ordering replacement parts, always have the following information ready: 1. Model, Serial and Product number 2. Type of gas 3. Item number 4.
Natural gas and Propane (LP) main burner with igniter assembly for 40k and 45k Btu/hr models Flare Nut †† Shown with Junction Box Cover removed for clarity. 36 † 30 37 28 29 44 49 35 38 39 45 48 47 40 46 41 43 Figure 56 42 Figure 54 Notes: * Items not supplied with the water heater. ** The side recirculation loop connections may not be used as the primary water inlet and outlet connections. See “Combo Heating Inlet And Outlet Side Taps”. *** Caution harness has 120 VAC In operation.
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service agent. LOCKOUTS Soft Lockout • Occurs when a system safety device trips to break the sequence of operation. The control will try to start the system in a timed basis but will not reinstate operation until the failure is corrected. Hard Lockout • Occurs when the main controller fails and must be replaced. RESETTING THE HEATER CONTROL • Soft lockouts as diagnosed by the system error codes require the gas control to be reset.
SYSTEM STATUS AND ERROR CODES The micro-controller inside the gas control monitors the ignition sequence, temperature settings, and overall operation of the heater. If any of these parameters does not operate properly the controller will shut down the water heater, diagnose the failure and flash an error code. The table below lists the System Status Codes for the Honeywell control. Refer to it and to the “Ignition State And Timing” to diagnose the problem before attempting corrective action.
CORRECTIVE ACTIONS See the table below for corrective actions corresponding to the Corrective Action Number in the “System Status And Error Codes” section above. If following those corrective actions does not resolve the error, refer to “Other Symptoms“ table later in this manual. Corrective Action Number Corrective Action 1 Normal operation, no action necessary. 2 Normal operation, no action necessary. 3 1. Flame rod not properly seated in flame, reposition rod. 2.
Corrective Action Number Corrective Action 8 1. Gas supply is turned off or gas pressure is too low. Ensure supply pressure and manifold gas pressures are within requirements. Manifold pressure is nonadjustable, if gas supply pressure proves correct and manifold pressure is off by more than 0.3” WC replace the control. 2. Low supply voltage - should be 115 - 125 VAC 3. Ensure flame sensor is making good contact with the burner flame and flame is steady. 4.
OTHER SYMPTOMS Problem Insufficient Hot Water Water Is Too Hot Slow Hot Water Recovery Drip From Relief Valve Smelly Water Condensation Possible Cause(S) 1. 2. 3. 4. 5. 6. 7. Thermostat set too low Leaking faucets/Wasted hot water Wrong piping connections Water heater too small Sediment or lime in tank Long runs of exposed piping Hot-water piping in outside wall 54 1. 2. 3. 4. 5. 6. 7.
NOTES 328767-001 www.americanwaterheater.
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