POWERED DIRECT VENT GAS WATER HEATER A Spanish language version of these instructions is available by contacting the company listed on the rating plate. La version espanola de estas instrucciones se puede obtener al escribirle a la fabrica cuyo nombre aparece en la placa de especificaciones. INSTALLATION AND OPERATING INSTRUCTION MANUAL WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.
CONGRATULATIONS! You have just purchased one of the finest water heaters on the market today! This installation, operation and instruction manual will explain in detail the installation and maintenance of your new Powered Direct Vent Gas Water Heater. We strongly recommend that you contact a plumbing professional for the installation of this water heater. We require that you carefully read this manual, as well as the enclosed warranty, and refer to it when questions arise.
TABLE OF CONTENTS GENERAL INFORMATION ................................................................. Page 4 INSTALLATION. .................................................................................. Locating the Water Heater .......................................................... Minimum Clearances ................................................................... Venting .......................................................................................... Specifications for 75 Gal.
GENERAL INFORMATION This gas-fired water heater’s design is certified by CSA International under the American National Standard Z21.10.1 and CSA 4.1-M, most current editions at the time of manufacture. This is a category III water heater. This water heater must be installed in accordance with local codes or, in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1-Latest Edition) and/or in Canada CAN/CGA B149 Installation Codes (Latest Editions).
General Information continued- Make sure that you check the rating plate and combination gas control on the water heater to be certain that the type of gas being supplied corresponds with the marking on the rating plate and combination gas control. A sacrificial anode is used to extend tank life. The removal of this anode, except for inspection and/or replacement, will nullify the warranty.
Installation (Locating the Water Heater) continued- Water heater corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Examples of some typical compounds that are potentially corrosive are: spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals.
Installation (Locating the Water Heater) continued- WARNING DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU ARE NOT CERTAIN OF THE FOLLOWING: Liquefied petroleum gases/propane gas and natural gas have an odorant added by the gas supplier that aids in the detection of the gas. Most people recognize this odor as a “sulfur” or “rotten egg” smell. Other conditions, such as “odorant fade” can cause the odorant to diminish in intensity, or “fade”, and not be as readily detectable.
Minimum Clearances WARNING Failure to adhere to these installation and operating instructions may create a hazard to life and property and will nullify the warranty. This installation must allow access to the front of the water heater and adequate clearance must be provided for servicing and operating this water heater. The water heater may be installed on either a combustible or non-combustible floor.
Venting continued- A= Clearance above grade, veranda, porch, deck or balcony B= Clearance to window or door that may be opened Canadian Installations1 US Installations2 12 inches (30 cm) 6 in. (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in. (30 cm) for appliances > 10,000 Btuh (3 kW) and ≤100,000 Btuh (30 kW), 36 in. (91 cm) for appliances >100,000 Btuh (30 kW)) 12 inches (30 cm) 4 ft (1.
Venting continued- NOTICE In locations where sustained outside air temperatures are below freezing, it is possible for the vent terminations to accumulate ice build-up due to adverse local climate conditions (prevailing wind direction, wind speed, termination orientation, etc.). The optional concentric vent terminal is more resistant to this ice build-up.
Venting continued- NOTICE For installations in Canada, field supplied vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard For Type BH, Class II, 65°C, Gas Venting Systems, ULC S636. Components of this listed system shall not be interchanged with other vent systems or unlisted pipe/fittings.
Venting System Condensation Condensate formation does not occur in all installations of power direct vented water heaters, but should be protected against on installations where condensation can form in the venting system.
Venting continued- Table 2 lists the venting distances allowed with 4” (10.2 cm) diameter vent pipe. When venting with 4” (10.2 cm) vent pipe, use a 4” (10.2 cm) to 3” (7.6 cm) reducer to exit through the building wall with 3” (7.6 cm) vent pipe. Use the 3” (7.6 cm) vent terminal supplied with the water heater to terminate on the outside of the building. If the length of 3” (7.6 cm) vent pipe needed to go through the wall is greater than 14” (35.5 cm), use 4” (10.
Venting continued- TABLE 2 -VENT CONNECTOR LENGTHS FOR 4” (10.2 cm) DIAMETER VENT PIPE Maximum straight # of 90 Length ft. (m) Terminating Elbows (excl. 75 gal. vent term.) Through the Wall Through the Wall Through the Wall Through the Wall Through the Wall Through the Roof Through the Roof Through the Roof Through the Roof Through the Roof 1 2 3 4 5 0 1 2 3 4 95 (29.0) 90 (27.4) 85 (25.9) 80 (24.4) 75 (22.9) 100 (30.5) 95 (29.0) 90 (27.4) 85 (25.9) 80 (24.4) Min straight Length ft. (m) 10 (3.
Venting continued- THROUGH THE WALL VENTING: (HORIZONTAL VENTING WITH STANDARD VENT TERMINALS). Cut two 3 1/2 in. (8.9 cm) diameter holes in the wall at the point where the vent connector is going to pass through the wall. Use the proper cement to secure the 90° vent terminal provided with the water heater to the vent connector. The distance between the edges of the 90° vent terminal and the exterior wall (see Figure 3) must be 1 in. (2.5 cm). The exhaust and intake must not be less than 16” (40.
Venting continuedVent terminal configurations for through the wall venting. When venting through the wall, the exhaust terminal must exit the structure at a minimum distance of 16” (40.6 cm) from the intake terminal. The exhaust terminal must not be located below the intake terminal for any reason (see figure 4a below for examples of acceptable vent terminal configurations).
Venting continued- Figure 4c IMPORTANT When using the vent terminal configuration shown in 4c the extra elbows must be accounted for in the total vent length see Table 3 or Table 4.
Venting continued- THROUGH THE WALL VENTING: (HORIZONTAL VENTING WITH CONCENTRIC VENT). Cut one 4 5/8 in. (11.7 cm) diameter hole in the wall at the point where the vent connector is going to pass through the wall. Use the proper cement to secure the vent terminal to the vent connector. Use the proper cement and assembly procedures to secure the vent connector joints between the terminal and the blower outlet. Provide support brackets for every 5 feet (1.5 m) of horizontal vent.
Venting continued- It is acceptable to install a 90 degree elbow on IPEX concentric vent terminations use with this power direct vent water heater (see Figure 5b). A short length of appropriate diameter vent pipe should be used to transition from the vent terminal to the 90 degree elbow. Approved venting materials along with primers and cements are listed at the beginning of this venting section.
Venting continued- 3” VENT INSTALLATION 4” VENT INSTALLATION Figure 6 NOTE: For installations requiring both horizontal and vertical runs, the following rule must be followed: Total length of straight pipe (both horizontally and vertically) must not exceed the maximum equivalent length listed in these instructions.
Venting continued- THROUGH THE ROOF VENTING: (VERTICAL VENTING CONCENTRIC VENT TERMINAL): Cut the necessary holes through the roof and ceiling and install the vent connector as shown in Figure 7. Make sure that the installation meets the local codes and/or the National Fuel Gas Code ANSI Z223.1 (Latest Edition) or CAN/CGA B149 installation code (latest edition). A condensate kit must be installed when venting through the roof.
Venting continued- THROUGH THE WALL VENTING WITH LOW GROUND CLEARANCE: When venting cannot exit through the wall at a height greater than or equal to 12” (30.5 cm) above the ground, or anticipated snow level, the installation must be modified as shown below (see Figure 8). Refer to Table 3 for maximum venting lengths using 3” (7.6 cm) vent pipe or Table 4 for maximum lengths using 4” (10.2 cm) vent pipe. The exhaust and intake terminals must not be less than 16 in. (40.6 cm) apart (see figure 4a).
Venting continued- TABLE 3 3” (7.6 cm) VENT CONNECTOR LENGTHS FROM INSIDE WALL FOR LOW GROUND CLEARANCE INSTALLATIONS Max Straight Min # of Elbows Length ft. (m) straight Terminating (excl. vent term.) Length 75 gal. ft. (m) (2) 90 Elbows with (1) 40 (12.2) 1 5 (1.5) 90 Elbow (2) 90 Elbows with (1) 35 (10.7) 2 5 (1.5) 90 Elbow (2) 90 Elbows with (1) 30 (9.1) 3 5 (1.5) 90 Elbow (2) 90 Elbows with (1) 25 (7.6) 4 5 (1.5) 90 Elbow TABLE 4 4” (10.
VENT PIPE PREPARATION AND JOINING Most failures in vent systems result from improper preparation and joining of pipe and fittings. The guidelines below must be followed when installing the venting system. If you have any question about the application or installation of the venting system, contact the vent pipe manufacturer, supplier, or your plumbing professional. 1) Specific cleaners, solvents, primers and cements are available for PVC, CPVC, and ABS pipe.
Water Connections Note: BEFORE PROCEEDING WITH THE INSTALLATION, CLOSE THE MAIN WATER SUPPLY VALVE. After shutting off the main water supply, open a faucet to relieve the water line pressure to prevent any water from leaking out of the pipes while making the water connections to the water heater. After the pressure has been relieved, close the faucet. The COLD water inlet and HOT water outlet are identified on the top of the water heater.
Water Connections continued- WARNING For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements of the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, A
Water Connections continued- WARNING Hydrogen gas can be produced in an operating water heater that has not had water drawn from the tank for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable. To prevent the possibility of injury under these conditions, we recommend the hot water faucet to be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system.
Gas Connections WARNING Prior to connecting the gas supply line to a gas fired water heater, ensure that the gas supply line does not have moisture/water or dirt/scale inside the gas line. Commonly this check is done at the lowest point in the gas distribution system prior to gas burning appliances. The gas supply lines must meet all requirements of the National Fuel Gas Code (ANSI Z223.1-Latest Edition), or in Canada CAN/CGA B149.1 Natural Gas Installation Code (Latest Edition) or CAN/CGA B149.
Gas Connections continued- CAUTION The water heater and individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of 1/2 psi (3.5 kPa). The water heater must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply system at test pressures equal to or less than 1/2 psi (3.5 kPa).
Wiring Diagram Figure 9 30
GENERAL OPERATION WARNING Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent-air intake system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent-air intake system.
Lighting and Shutdown instructions 32
Thermostat Adjustment The thermostat dial is adjusted to its lowest setting when shipped from the factory. When adjusting the thermostat, it should be remembered that lower temperature settings are more energy efficient. To adjust the thermostat turn the dial clockwise until the minimum acceptable temperature is set. It is suggested that the starting point setting not exceed the 120°F (49°C) or “HOT” setting on the thermostat.
Burner Flame Check Steel Burner: These models are equipped with self-adjusting air mixture and do not have an adjustable air shutter (See Figure 11). At periodic intervals a visual check of the main burner and pilot flames should be made to determine if they are burning properly. The main burner flame should light smoothly from the pilot. Figure 11 WARNING Do not run out of propane gas. Damage to the water heater may occur.
MAINTENANCE WARNING Water heaters are heat producing appliances. To avoid damage or injury there must be no materials stored against the water heater or vent-air intake system, and proper care must be taken to avoid unnecessary contact (especially by children) with the water heater and vent-air intake system.
Maintenance continued- 5. Annually remove the inner door and main burner assembly to clean orifices and related parts of any dirt or other foreign material. Inspect the burner ports for obstructions or debris and clean with a wire brush as needed. Wire brush and/or vacuum clean the combustion chamber as needed to remove scale deposits and debris. NOTE: It is imperative for proper operation of the water heater that the inner door be replaced in the original location.
Maintenance continued- WARNING When lifting lever of the combination temperature and pressure relief valve, hot water will be released under pressure. Be careful that any released water does not result in bodily injury or property damage. WARNING Do not run out of propane gas. Damage to the water heater may occur. 6. At least once a year, check the combination temperature and pressure relief valve to insure that the valve has not become encrusted with lime.
Maintenance continued- CAUTION FOR YOUR SAFETY, DO NOT ATTEMPT REPAIR OF COMBINATION GAS CONTROL, BURNERS OR GAS PIPING. REFER REPAIRS TO A QUALIFIED SERVICE TECHNICIAN. Contact your supplier or plumbing professional for replacement parts or contact the company at the address given on the rating plate of the water heater. Provide the part name, model and serial numbers of the water heater when ordering parts.
TROUBLESHOOTING LED Status Control Status Probable Cause None (LED not on or flashing) Electrical power not present. Control power switch in “OFF” position. Supply voltage interrupted. One short flash every four seconds Stand-by mode, Thermostat is satisfied (no faults). Temperature demand is satisfied (no call for heat). Alternates bright and dim (Heartbeat) Thermostat calling for heat (no fault). Tank temperature below set point of thermostat. 1. Unstable pilot. 2.
Troubleshooting continued- LED Status Control Status Probable Cause Six flashes-two flashes, three second pause (Soft lockout) Pressure switch or blower temperature switch opened during burner operation. System auto resets after 5 minutes. 1. Pressure switch tubing kinked or blocked. 2. Vent blockage or improper vent configuration. 3. Vent termination being affected by windy conditions. 4. Blower not spinning up to speed. 5. Vent temperature too high. 6. Faulty pressure switch or blower temp. switch.
Control Sequence of Operation Start up Sequence Upon powering up, the control checks for the presence of the vapor sensor, if the resistance is in the expected range the control will begin normal operation after 5 to 8 seconds. Normal Heating Sequence 1. The thermostat senses a need for heat. 2. The control checks the pressure switch condition. 3. If the pressure switch is open, the control sends power to the blower motor. 4. The blower starts moving combustion air through the combustion system. 5.
PARTS LIST DRAWING PARTS LIST PART NAME AND DESCRIPTION 1. Blower Assembly 13. T&P Relief Valve 2. Temp. Switch 14 Pilot Assembly 3. Pressure Switch N.O. 15. Main Burner Orifice 4. Flue Baffle 16. Gas Feed line 5. Honeywell Gas Control Valve 17. Flammable Vapors Sensor 6. Drain Valve 18. Sensor Harness 7. Fiberglass Insulation (not shown) 19. Inner Door Assembly 8. Foam Insulation (not shown) 20. Blower Harness 9. Outer Door 21. Air intake boot 10. Steel Burner 22. Tee and vent pipe assembly 11.
THE FOLLOWING INSTRUCTIONS ARE FOR INSTALLATION OF: GAS WATER HEATERS SUITABLE FOR WATER (POTABLE) HEATING AND SPACE HEATING 1. All piping components connected to this water heater for space heating applications must be suitable for use with potable water. In Massachusetts, space heating piping length must not exceed 50 feet. 2. Toxic chemicals, such as those used for boiler treatment, must not be introduced into potable water used for space heating. 3.
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