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instruction manual residential gas water heaters power vented gas models with hot surface ignition not for use in manufactured mobile homes 500 tennessee waltz parkway ashland city tn 37015 www.statewaterheaters.com gama certification applies to all residential gas water heaters with capacities of 20 to 100 gallons with input rating of 75,000 btu/hr or less an odorant is added to the gas used by this water heater · for your safety · 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 1208 1 315466-000

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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 the california safe drinking water and toxic enforcement act requires the governor of california to publish a list of substances known to the state of california to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances warning this product contains a chemical known to the state of california to cause cancer birth defects or other reproductive harm this appliance can cause low-level exposure to some of the substances included in the act important 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 and use of flammable vapor ignition resistant 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

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general safety 3

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table of contents safe installation use and service 2 general safety 3 table of contents 4 introduction 4 preparing for the new installation 4 installation requirements for the commonwealth of massachusetts 5 typical installation 6-7 locating the new water heater 8 facts to consider about location 8-9 insulation blankets 9 combustion air and ventilation for appliances located in unconfined spaces 9 combustion air and ventilation for appliances located in confined spaces 9-10 installing the water heater 11 water piping 11-12 temperature-pressure relief valve 12 gas piping 13 sediment traps 14 blower assembly installation 14 vent pipe connection to blower assembly 15 venting and installation 15-16 lighting operating label 21 temperature regulation 22 for your information 23 start up conditions 23 condensate 23 smoke/odor 23 thermal expansion 23 strange sounds 23 operational conditions 23 smelly water 23 air in hot water faucets 23 high temperature shut off system 23 periodic maintenance 24 venting system inspection 24 burner inspection 24 burner cleaning 24 housekeeping 24-25 anode rod inspection 25 temperature-pressure relief valve operation 25 draining 25 drain valve washer replacement 25-26 service 26 leakage checkpoints 26 repair parts 27 troubleshooting 28-30 warranty 31 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 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 z21.10.1 · csa 4.1 current edition 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 nfpa 70 these publications are available from the national fire protection association 1 batterymarch park quincy ma 02269 3 the water heater when installed must be grounded in accordance with the local codes or in the absence of local codes in the united states the national electrical code ansi/nfpa 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 state plumbing code and 248-cmr 5.00 for more information see next page 8 complies with scaqmd rule #1121 and districts having equivalent nox requirements 4 preparing for the installation 1 read the general safety section page 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 install or operate the water heater.

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installation requirements for the 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 not limited to decks and porches the following requirements shall be satisfied installation of carbon monoxide detectors at the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed in addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the sidewall horizontal vented gas fueled equipment it shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors in the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level in the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed approved carbon monoxide detectors each carbon monoxide detector as required in accordance with the above provisions shall comply with nfpa 720 and be ansi/ul 2034 listed and csa certified signage a metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment the sign shall read in print size no less than one-half 1/2 inch in size gas vent directly below keep clear of all obstructions inspection the state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 cmr 5.082 a 1 through 4 exemptions the following equipment is exempt from 248 cmr 5.082 a1 through 4 1 the equipment listed in chapter 10 entitled equipment not required to be vented in the most current edition of nfpa 54 as adopted by the board and 2 product approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes manufacturer requirements gas equipment venting system provided when the manufacturer of product approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 detailed instructions for the installation of the venting system design or the venting system components and 2 a complete parts list for the venting system design or venting system manufacturer requirements gas equipment venting system not provided when the manufacturer of a product approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 the referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 the special venting systems shall be product approved by the board and the instructions for that system shall include a parts list and detailed installation instructions a copy of all installation instructions for all product approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation 5

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typical installation get to know your water heater gas models abcdefghjklm vent pipe­exhaust vent terminal vent adapter-rubber boot blower assembly cold water inlet inlet water shut-off valve union inlet dip tube anode hot water outlet outlet receptacle 115 vac temperature-pressure relief valve nopqrstuvwxy flue flue baffle assembly insulation control harness rating plate gas supply manual gas shut-off valve ground joint union drip leg sediment trap drain valve gas control valve drain pan z aa bb cc dd ee ff air intake screen base pan inner door outer door hsi burner assembly air intake screen blower assembly fv sensor/bracket assembly 40k 50k models only fv sensor/bracket assembly 55k 62.5k models only all piping materials to be supplied by customers located under the blower assembly natural hot surface igniter main burner hot surface ignitor sensor propane hot surface igniter main burner hot surface ignitor sensor gas control valve-thermostat caution 115 vac in control harness and inside outer door temperature indicators temperature adjustment buttons gas models with hot surface ignition 2 3 or 4 pvc vent capability figure 1 6

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typical installation mixing valve usage figure 2 this appliance has been design certified as complying with american national standard/csa standard 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 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 should 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 temperature regulation section in this manual see figure 19 7

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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 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 figure 3 also the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle 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 this water is equipped with a fv sensor for detecting the presence of flammable vapors see figure 3 when the sensor detects those vapors the unit will shut down and not operate should this happen please refer to the troubleshooting guide on pages 28-30 even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance 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 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 8 minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear 5 12.7 cm from the front

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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 for servicing this appliance should be considered before installation such as changing the anodes etc a minimum clearance of 5 12.7 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 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 insulation 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 national appliance energy conversation 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 · do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood · 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 ventilation for appliances located in unconfined spaces 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 figure 5 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 9 combustion air and ventilation for appliances located in confined spaces 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.

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chemical vapor corrosion of the flue blower assembly 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 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 rooms 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 cm2/kw of the total input rating of all gas utilization equipment in the confined space but not less than 100 square inches 645 cm2 one opening shall commence within 12 inches 31 cm of the top and one commencing within 12 inches 31 cm of the bottom of the enclosures 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 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 5.5 cm2/kw of total input rating of all equipment in the enclosure see figure 7 5 alternatively a single permanent opening may be used when communicating directly with the outdoors or with spaces that freely communicate with the outdoors the opening shall have a minimum free area of 1 square inch per 3,000 btu per hour 8.3 cm2/kw of total input rating of all equipment in enclosure see figure 9a figure 9a 6 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 7 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 figure 7 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 cm2/kw of total input rating of all equipment in the enclosure see figure 9.

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installing the new water heater water piping thermal expansion as water is heated it expands thermal expansion in a closed system the volume of water will grow as the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion thermal expansion can cause premature tank failure leakage this type of failure is not covered under the limited warranty thermal expansion can also cause intermittent temperature-pressure relief valve operation water discharged from the valve due to excessive pressure build up the temperature-pressure relief valve is not intended for the constant relief of thermal expansion this condition is not covered under the limited warranty a properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion contact a local plumbing service agency to have a thermal expansion tank installed 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 hotter 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 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 should 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 temperature regulation section in this manual this water heater shall not be connected to any heating systems or components 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 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 11 figure 10.

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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 cold water inlet connection do not solder the cold water supply line directly to the cold water inlet 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 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 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 secure all insulation using tape 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 temperature-pressure relief valve 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 for hot water supply systems ansi z21.22 · csa 4.4 and the code requirements of asme 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 if replaced the valve must meet the requirements of local codes but not continues to release water immediately close the cold water inlet less than a combination temperature and pressure relief valve certified to the water heater follow the draining instructions and replace the temperature-pressure relief valve with a new one as indicated in the above paragraph 12

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gas piping when installed at elevations above 7,700 feet 2,347 meters 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 nfpa 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 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 14 inches water column 3.5 kpa the damage to the gas control valve could result in a fire or explosion from leaking gas 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 figure 12 gas piping with flexible connector 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 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 14 inches water column 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 13 figure 13 gas piping with all black iron pipe to gas control valve.

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sediment traps 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 tank 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 blower assembly installation 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 sequence of installation 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 and the air intake screen of the blower assembly is installed in the dilution air opening also make sure the drain port of the rubber boot vent adapter is capped off lastly make sure there is no damage to the blower 3 make sure there is no packing material in the discharge of the blower or the intake of the dilution air restrictor see figure 15 4 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 5 make sure the on/off switch is in the off position and that the outer harness is connected from the blower control box to the connector on the bottom side of the gas control valve 6 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 control valve 7 this water heater is a polarity sensitive appliance and will not operate if the power supply polarity is reversed the power supply or outlet providing power to this water heater must be wired properly correct polarity 8 do not plug in power cord until vent system is completely installed this powered vent heater operates on 110-120 vac therefore a grounded outlet must be within reach of the six 6 foot 1.8 m flexible power cord supplied with the unit see figure 1 the power cord supplied may be used only where local codes permit if local codes do not permit the use of a flexible power supply cord a make sure the unit is unplugged from wall outlet remove screws and open panel on front of control box b cut the flexible power cord leaving enough to be able to make connections the remove the strain relief fitting from box c install suitable conduit fitting in side of enclosure and then follow d and e below d splice field wiring into existing wiring using code authorized method wire nuts etc e be certain that neutral and live connections are not reversed when making these connections f close panel on the side of control box make sure that access panel is secured shut 14 figure 14 filling the water heater never use this water heater unless it is completely full of 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.

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p. 15

vent connections to blower assembly figure 15 shows the optimal placement of the 2 to 3 or 3 to 4 reducer however the vent can be reduced at any point in the vent system as long as the maximum and minimum vent length requirements are met venting and installation plan the layout of the vent system from the vent termination to the water heater considering all of the 90° and 45° elbows plus the number of feet of pipe that would be needed to install the total vent system the water heater must be vented to the outdoors as described in these instructions do not connect this water heater to an existing vent or chimney it must be vented separately from all other appliances nonmetallic vent may be used if it has heat deflection temperature hdt@66 psi or 455 kpa of at least 157°f or 69°c typical nonmetallic vent materials meeting this requirement are pvc schedule 40 astm d-1785 coex cellular core schedule 40 astm f-441 cpvc schedule 40 astm d-2846 abs schedule 40 astm d-2661 the fittings other than the supplied vent termination should be equivalent to the following pvc schedule 40 dwv astm d-2665 cpvc schedule 40 dwv astm f-438 abs schedule 40 dwv astm d-2661 the cement used should be as recommended by the vent pipe manufacturer see the instructions on pages 18 and 19 for the proper method of cutting and cementing the pvc pipe and fittings 15 figure 15.

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