Lochinvar Water Heater TNR Iamp;S 02 User Manual

TNR-I&S-02  
INSTALLATION & SERVICE MANUAL  
HIGH EFFICIENCY COMMERCIAL GAS WATER HEATER  
TEMPERATURE & PRESSURE RELIEF VALVE  
WARNING  
DANGER  
Use only vent terminals provided or factory authorized terminals for  
venting this water heater.  
If the information in these instructions is not followed exactly, a  
fire or explosion may result causing property damage, personal  
injury or death.  
This water heater is equipped with an adjustable thermostat to control  
water temperature. Hot water temperatures required for automatic  
dishwasher and laundry use can cause scald burns resulting in serious  
personal injury and/or death. The temperature at which injury occurs  
varies with the person’s age and the time of exposure. The slower  
response time of disabled persons increases the hazards to them. NEVER  
allow small children to use a hot water tap, or to draw their own bath water.  
NEVER leave a child or disabled person unattended in a bathtub or shower.  
Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or any other appliance.  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not touch any electrical switch; do not use any  
telephone in your building.  
• Immediately call your gas supplier from a neighbor’s  
telephone. Follow the gas supplier’s instructions.  
• If you cannot reach your gas supplier, call the fire  
department.  
Failure to properly install the vent and air intake (if applicable) system  
could result in property damage, personal injury, or death.  
Installation and service must be performed by a qualified  
installer, service agency or the gas supplier.  
WARNING  
Keep clear of the combination temperature and pressure relief  
valve discharge line outlet. The discharge may be hot enough to  
cause scald injury. The water is under pressure and may splash.  
TABLE OF CONTENTS  
GENERAL INFORMATION ...................................................... 1  
INSTALLATION .................................................................. 2  
Locating The Water Heater ........................................... 2  
Minimum Clearances ..................................................... 2  
Venting ........................................................................ 6  
Combustion Air Supply ................................................. 19  
Water Connections ....................................................... 4  
Gas Connections .......................................................... 14  
GENERAL OPERATION........................................................... 15  
MAINTENANCE ..................................................................... 17  
TROUBLESHOOTING GUIDE .................................................. 20  
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, ANSI Z21.22 and the Standard  
CAN1-4.4 Temperature, Pressure, Temperature and Pressure Relief Valves  
and Vacuum Relief Valves. The combination temperature and pressure  
relief valve must be marked with a maximum set pressure not to exceed  
the maximum working pressure of the water heater. The combination  
temperature and pressure relief valve rating must not be less than the  
hourly rating of the water heater.  
GENERAL INFORMATION  
Install the combination temperature and pressure relief valve into the  
opening provided and marked for this purpose on the water heater.  
Note: Some models may already be equipped or supplied with an installed  
combination temperature and pressure relief valve. Verify that the  
combination temperature and pressure relief valve complies with local  
codes. If the combination temperature and pressure relief valve does not  
comply with local codes, replace it with one that does.  
Install a discharge line so that water discharged from the combination  
temperature and pressure relief valve will exit within six (6) inches (15.2  
cm) above, or any distance below the structural floor and cannot contact  
any live electrical part. The discharge line is to be installed to allow for  
complete drainage of both the combination temperature and pressure  
relief valve and the discharge line. The discharge opening must not be  
subjected to blockage or freezing. DO NOT thread, plug or cap the discharge  
line. It is recommended that a minimum clearance of four (4) inches (10.2  
cm) be provided on the side of the water heater for servicing and  
maintenance of the combination temperature and pressure relief valve.  
Do not place a valve between the combination temperature and pressure  
relief valve and the tank!  
This gas-fired water heater is design certified by CSA International under  
the American National Standard, Z21.10.3 (as indicated on the rating  
plate) and CAN/CGA 4.3-M (as indicated on the rating plate) available  
from CSA Standards Association, 178 Rexdale Blvd., Etobicoke, Ontario,  
Canada M9W 1R3.  
This water heater must be installed in accordance with local codes. In the  
absence of local codes, it must be installed in compliance with 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 B149.2 Propane  
Installation Code (Latest Edition).  
DANGER  
DO NOT store or use gasoline or other flammable, combustible, or corrosive  
vapors and/or liquids in the vicinity of this or any other appliance.  
DO NOT install any damaged venting system components. If damage is  
evident then please contact the supplier where the water heater was  
purchased or the manufacturer listed on the rating plate for replacement  
parts.  
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AIR REQUIREMENTS  
1. Do not obstruct the flow of combustion and ventilating air.  
If horizontal ducts are used, each opening shall have a free area  
of not less than one square inch per 2000 Btu/hr of the total input  
of all appliances in the enclosure.  
2. For safe operation, adequate air is needed for combustion and  
ventilation. Sooting may result in serious damage to the water heater 3. If the water heater is installed as a direct vent (outside air piped  
and risk of fire or explosion. It can also create a risk of asphyxiation.  
Such a condition often will result in a yellow, luminous burner flame,  
causing carboning or sooting of the combustion chamber, burner and  
flue tubes.  
directly to the water heater), then additional opening, other than  
the opening for the air intake, are not required. However, adequate  
ventilation air must be provided in all cases to prevent increased  
room temperature.  
MECHANICAL EXHAUSTING OF ROOM AIR  
CHEMICAL VAPOR CORROSION  
1. Where an exhaust fan is installed in the same room with this water Corrosion of the flue ways and vent system will occur if air for combustion  
heater and combustion air is drawn from inside the room, sufficient contains certain chemical vapors. Such corrosion may result in poor  
openings for air must be provided in the walls.UNDERSIZED combustion and create a risk of asphyxiation. Spray can propellants,  
OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH cleaning solvents, refrigerator and air conditioning refrigerants, swimming  
THE WATER HEATER’S VENTING SYSTEM, CAUSING POOR COMBUSTION pool chemicals, calcium and sodium chloride, waxes and process chemicals  
THAT MAY BE HAZARDOUS TO LIFE. SOOTING MAY RESULT IN SERIOUS are corrosive. Products of this sort should not be stored near the water  
DAMAGE TO THE WATER HEATER AND RISK OF FIRE OR EXPLOSION heater or outside by the air intake (if applicable).  
WHICH CAN ALSO CREATE A RISK OF ASPHYXIATION. Refer to local  
codes and /or National Fuel Gas Code for proper air opening sizing.  
TYPICAL INSTALLATION ILLUSTRATION  
UNCONFINED SPACE  
1. In buildings of conventional frame, brick or stone construction,  
CAUTION  
unconfined spaces may provide adequate air for combustion and  
If building cold water supply has a back-flow preventer, check valve  
ventilation.  
or water meter with check valve provisions for thermal expansion of  
water in the hot water system must be provided.  
2. If the unconfined space is within a building of tight construction  
(buildings using the following construction: weather stripping, heavy  
insulation, caulking, vapor barrier, etc.), air for combustion and  
ventilation must be obtained from outdoors. This may be  
accomplished by piping air directly to the water heater from outside  
Figure 2  
Typical Front Inlet Connection  
or providing opening or ducts in the wall. The installation instructions  
for confined spaces in tightly constructed buildings must be followed  
to ensure adequate air supply.  
CONFINED SPACE  
1. When drawing combustion air from inside a conventionally  
constructed building to a confined space, such a space shall be  
provided with two permanent openings.  
The top opening is to be located within twelve (12) inches of the  
enclosure top and the bottom opening within twelve (12) inches  
of the enclosure bottom.  
Each opening shall have a free area of at least one square inch  
per 1000 Btu/hr of the total input of all appliances in the enclosure,  
but not less than 100 square inches.  
2. If the confined space is within a building of tight construction, air for  
combustion and ventilation must be obtained from outdoors. This  
may be accomplished by piping air directly to the water heater from  
outside or providing opening or ducts in the wall. When directly  
communicating with the outdoors through vertical ducts, two  
permanent openings, located in the above manner, shall be provided.  
Each opening shall have a free area of not less than one square  
inch per 4000 Btu/hr of the total input of all appliances in the  
enclosure.  
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Figure 3  
Figure 6 Typical Four Water Heater Connection  
Typical Front Inlet Connect with Storage Tank  
WATER CONNECTIONS  
WARNING  
Failure to install and maintain a new, listed temperature and pressure  
relief valve will release the manufacturer from any claim, which might  
result from excessive temperature and pressures.  
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. If hydrogen is present, there will be an unusual sound  
such as air escaping through the pipes as hot water begins to flow. Do  
not smoke or have open flame near the faucet at the time it is open.  
Figure 4  
Typical Two Water Heater Connection  
Keep clear of the combination temperature and pressure relief valve  
discharge line outlet. The discharge may be hot enough to cause scald  
injury. The water is under pressure and may splash.  
CAUTION  
If sweat fittings are to be used, DO NOT apply heat to the nipples in  
front or side of the water heater. Sweat the tubing to the adapter  
before fitting the adapter to the water connections. It is imperative  
that heat is not applied to the nipples containing a plastic liner.  
INSTRUCTIONS FOR CONNECTIONS  
Figure 5  
Typical Three Water Heater Connection  
1. 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. The COLD water inlet and HOT  
water outlet are identified on the water heater. Make the proper  
plumbing connections between the water heater and the plumbing  
system to the house. Install a shut-off valve in the cold water  
supply line.  
2. If this water heater is installed in a closed water supply system, such  
as the one having a back-flow preventer in the cold water supply,  
provisions must be made to control thermal expansion. DO NOT  
operate this water heater in a closed system without provisions for  
controlling thermal expansion. Warranties do not cover damages  
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from thermal expansion such as pressure bulges and/or deformities.Your  
water supplier or local plumbing inspector should be contacted on how  
to control this situation.  
Table 1  
Approximate Time/Temperature Scald Chart  
APPROXIMATE TIME/TEMPERATURE  
RELATIONSHIPS IN SCALDS  
3. After installation of the water lines, open the main water supply valve  
and fill the water heater. While the water heater is filling, open  
several hot water faucets to allow air to escape from the water system.  
When a steady stream of water flows through the faucets, close them  
and check all water connections for possible leaks.  
120° F  
125° F  
130° F  
135° F  
140° F  
145° F  
150° F  
155° F  
More than 5 minutes  
1½ to 2 minutes  
About 30 seconds  
About 10 seconds  
Less than 5 seconds  
Less than 3 seconds  
About 1½ seconds  
About 1 second  
4. Never operate the water heater without first being certain it is filled  
with water.  
SCALDING  
This water heater can deliver scalding temperature water at any faucet in  
the system. Be careful whenever using hot water to avoid scalding injury.  
Certain appliances such as dishwashers and automatic clothes washers  
may require increased temperature water. By setting the thermostat on  
this water heater to obtain the increased temperature water required by  
these appliances, you may create the potential for scald injury. To protect  
against injury, you should install ASSE approved mixing valve in the water  
system. This valve will reduce point of discharge temperature by mixing  
cold and hot water in branch supply lines. Such valves are available from  
the local plumbing supplier.  
ALTERNATE SPACE HEATING WATER CONNECTIONS  
DANGER  
Toxic chemical, such as those used for boiler treatment, shall not be  
introduced into potable water used for space heating.  
This water heater shall not be connected to an existing heating  
system or component(s) previously used with a non-potable water  
heating appliance.  
All piping components connected to this water heater for space  
heating applications must be suitable for use with potable water.  
Figure 7  
Scald Warning  
WARNING  
When the system requires water for space heating at temperatures  
higher than required for other means, a tempering valve shall be  
installed to temper the water for those uses in order to reduce the  
scald hazard potential.  
Failure to properly pipe this water heater may result in improper  
operation and damage to the water heater or structure.  
Oxygen contamination of this water heater will cause corrosion of iron  
and steel components, and can lead to water heater failure.  
Connect the system supply and return piping to the water heater.  
Refer to Figure 8 and Figure 9 for installation examples. Maintain a  
minimum ½” clearance from hot water piping to combustible materials.  
Figure 8  
Alternate Space Heating Connections  
The following chart details the relationship of water temperature and time  
with regard to scald injuy and may be used as a guide in determining the  
safest water temperature for your applications.  
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Figure 9  
Typical Plumbing Schematic for Zoned Heating  
TuboCharger Water Heater  
VENTING  
WARNING  
CAUTION  
The vent shall terminate a minimum of 12 inches above expected  
snowfall level to prevent blockage of vent termination.  
The vent system must be properly installed. Failure to properly install  
the vent system could result in property damage, personal injury, or  
death.  
The horizontal centerline of the exhaust vent terminal (if applicable)  
must not be located lower than the horizontal centerline of the air  
intake terminal if vented through the same wall.  
A service drain loop must be installed in the drain tubing to serve as  
a condensate trap to prevent flue gases from escaping in the room.  
DO NOT position air intake terminal above exhaust terminal.  
NEVER locate air intake terminal when exhaust gases can be introduced.  
DO NOT install damaged venting system components. If damage is  
evident then please contact the supplier where the water heater was  
purchased or the manufacturer listed on the rating plate for  
replacement parts.  
NOTICE  
Use only the vent terminals provided or factory authorized terminals  
for venting this water heater.  
Before beginning installation of any vent pipe, read the vent pipe  
manufacturer’s installation instructions.  
Water heater must be protected from freezing downdrafts during  
shutdown periods.  
The water heater requires its own separate venting system. Do not  
connect the exhaust vent into an existing vent pipe or chimney.  
Provide protection of the building materials from degradation by flue  
gases from the exhaust vent terminal.  
All of the exhaust venting connections must be leak checked with a  
soap solution upon initial start up of the water heater. Any leaks must  
be repaired before continuing operation of the water heater.  
The venting instructions must be followed to avoid restricted combustion  
or recirculation of flue gases. Such conditions cause sooting or risks of fire  
and asphyxiation.  
Do not terminate the venting where noise from the exhaust or intake  
will be objectionable. This includes locations close to or across from  
windows and doors. Avoid anchoring the vent and intake pipes directly  
to framed walls, floors, or ceilings unless rubber isolation pipe hangers  
are used. This prevents any vibrations from being transmitted into the  
living spaces.  
This water heater can be installed as either a direct vent system or power  
vent (air from inside) system. If it is installed as a direct vent system,  
then the air intake and the exhaust vent are piped to the outside. If a  
power vented system is used, then air is drawn from inside and only the  
exhaust is piped to the outside. Determine which system is best for your  
application and install as described in the following sections.  
Do not exceed the venting distances or the number of elbows listed in  
this manual. Exceeding the maximum venting distances may cause  
the water heater to malfunction or cause an unsafe condition.  
DIRECT VENT INSTALLATION  
Venting may be run horizontally through an outside wall or vertically  
through a roof through using either 3 inch (7.6 cm) or 4 inch (10.2 cm)  
diameter PVC or CPVC pipe. This water heater is supplied with a 3 inch PVC  
screened intake and exhaust 90° elbow referred to as the exhaust vent  
terminal and the air intake terminal.  
DO NOT operate this water heater until the venting installation is  
complete and the piping completed. Failure to complete installation  
before operation can result in property damage, personal injury, or  
death.  
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EXCEPTIONS FOR INSTALLATIONS  
The vent terminal must not terminate:  
NOTICE  
If 4 inch PVC or CPVC pipe is used, then a 4 inch PVC or CPVC screened  
intake and exhaust 90° elbow is required.  
1. Directly above a paved sidewalk or paved driveway which is located  
between two single-family dwellings and serves both dwellings;  
2. Less than 7 feet (2.1 m) above a paved sidewalk or a paved  
driveway located on public property;  
3. Within 6 feet (1.8 m) of a mechanical air supply inlet to any  
building;  
Direct Vent Terminal Location  
Plan the vent system layout so that proper clearances are maintained  
from plumbing and wiring. Before the vent is installed, determine the vent  
pipe termination location as shown below in Figure 10.  
Figure 10  
Vent Terminal Location  
4. Above a gas meter/regulator assembly within 3 feet (0.9 m)  
horizontally of the vertical centerline of the regulator;  
Vent terminals must terminate at least 3 feet (0.9 m) above any forced air inlet  
located within 10 feet (3.1 m). This provision does not apply to:  
5. Within 6 feet (1.8m) of any gas service regulator vent outlet;  
6. Less than 1 foot (30.5 cm) above grade level;  
7. Within 12 inches (30.5 cm) of a window or door, which can be  
opened in any building, any non-mechanical air, supply inlet to any  
building or the combustion air inlet of any other appliance;  
8. Underneath a veranda, porch or deck, unless:  
1. The combustion air intake of a direct vent appliance or the circulating air  
inlet and flue gas discharge of listed outdoor appliances.  
2. The exhaust vent terminal must be installed with at least 12 inches (30 cm)  
clearance from any air opening into a building.  
3. The bottom of the exhaust vent and combustion air intake terminals must  
be located at least 12 inches (30 cm) above grade and above the anticipated  
snow level.  
4. Must be installed at least 3 feet (0.9 m) from any gas meter, gas valve or  
other gas regulating equipment.Must be installed in a location where it will  
not be blocked by snow.  
The veranda, porch or deck is fully open on a minimum of two  
sides beneath the floor and  
The distance between the top of the vent termination and the  
underside of the veranda, porch or deck is greater than 1 foot  
(30.5 cm).  
5. The exhaust vent and combustion air intake terminals must be installed so  
that the centerline distances are at least 18 inches (45.7cm) apart and the  
exhaust vent terminal elbow extends 6 inches(15.2 cm) past the combustion  
air intake terminal.  
The vent system must terminate so that proper clearances are maintained  
as cited in local codes or the latest edition of the National Fuel Gas Code,  
ANSI Z223.1.73.4e and 7.8a, b as follows:  
1. Do not terminate the exhaust vent terminal over public area where  
condensate or vapor can cause nuisance or hazard.  
2. For direct vent, the venting system shall terminate at least 1 foot  
below, 1 foot horizontally from or 1 foot above any door, window,  
or gravity air inlet into building.  
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3. For horizontal, the venting system shall terminate 4 foot below, 4 2. Use the proper PVC cement to secure the 90° exhaust vent and air  
foot horizontally from or 1 foot above any door, window, or gravity  
air inlet into building.  
4. The manufacturer also recommends the vent system terminations  
not be installed closer than 3 feet from an inside corner of an L  
shaped structure.  
5. The vent termination shall not be mounted directly above or within  
3 feet horizontally from an oil tank vent or gas meter to avoid  
potential freeze-up from condensation.  
intake terminals provided with the water heater to the plastic pipes.  
The distance between the back edge of the 90° exhaust vent terminal  
and the exterior wall (see Figure 11) must be 6 inches (12.7 cm)  
more for the exhaust vent terminal than the air intake terminal. Use  
the proper cement or sealant and assembly procedures to secure the  
vent connector joints between the terminal and the blower outlet.  
Provide support brackets for every 3 feet (.91 m) of horizontal vent.  
6. The vent shall terminate a minimum of 12 inches above expected  
snowfall level to prevent blockage of vent termination.  
Figure 11. Typical Horizontal Direct Vent System  
Vent pipes serving power vented appliances are classified by building  
codes as “vent connectors”. Required clearances from combustible materials  
must be provided in accordance with information in this manual under  
LOCATION OF WATER HEATER and CLEARANCES, and with National Fuel Gas  
Code and local codes.  
NOTICE  
This unit can be vented using only PVC (Class 160, ASTM D-2241 Schedule  
40, ASTM D-1785; or Cellular Core Schedule 40 DWV, ASTM F-891),  
Schedule 40 CPVC (ASTM F-411). The fittings, other than the  
TERMINATIONS should be equivalent to PVC-DWV fittings meeting ASTM  
F-2665. (Use CPVC fittings, ASTM F-438 for CPVC pipe.) If CPVC pipe  
and fittings are used, then the proper cement must be used for all  
joints, including joining the pipe to the Termination (PVC material). PVC  
materials should use ASTM –D2564 grade cement; CPVC materials  
should use ASTM F-493 grade cement.  
For water heaters in locations with high ambient temperatures (above  
100° F) and/or insufficient dilution air, it is recommended that CPVC  
pipe and fittings (MUST USE SUPPLIED VENT TERMINAL) be used.  
Vertical Installation:  
Vertical venting system must be supported every 5 feet of vertical run  
and every 3 feet of horizontal run of vent pipe length.  
Horizontal Installation:  
Stress levels in the pipe and fittings can be significantly increased by  
In a horizontal application, it is important that condensate not be allowed improper installation. If rigid pipe clamps are used to hold the pipe in  
to buildup in the exhaust vent pipe. To prevent this from happening the place, or if the pipe cannot move freely through a wall penetration, the  
pipe should be installed with an slight upward slope so the condensate will pipe may be directly stressed, or high thermal stresses may be formed  
run back toward the water heater. The vent system should be supported when the pipe heats up and expands. Install accordingly to minimize such  
every 5 feet of vertical run and every 3 feet of horizontal run of vent pipe stresses.  
length.  
Follow the following procedure to vent through the roof:  
Stress levels in the pipe and fittings can be significantly increased by 1. Cut the necessary holes through the roof and ceiling.  
improper installation. If rigid pipe clamps are used to hold the pipe in 2. Install the exhaust vent and air intake plastic pipes as shown in  
place, or if the pipe cannot move freely through a wall penetration, the  
pipe may be directly stressed, or high thermal stresses may be formed  
when the pipe heats up and expands. Install accordingly to minimize such  
stresses.  
Figure 12. Make sure that the installation meets the local codes  
and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or  
CGA/CAN B149 Installation Code.  
Follow the following procedure to vent through the wall:  
1. Cut two 3 1/2 in. (8.9 cm) diameter holes (for 3" (7.6 cm) diameter  
pipe) or 4 ½” (11.4 cm) diameter holes (for 4" (10.2 cm) diameter  
pipe) in the wall with the centerline hole distances at least 18"  
(45.72 cm) apart in the location where the exhaust vent and air  
intake terminals will exit the outside wall if vented on the same wall.  
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Table 2  
Figure 12  
Typical Vertical Direct Vent System Installation  
Direct Vent Maximum Vent Length  
Rated Max Vent Length (ft) Max Vent Length (ft)  
Storage  
Capacity  
Input  
3" PVC or CPVC  
4" PVC or CPVC  
(Gallons) (BTU/HR)  
1 2 0  
1 0 0  
8 0  
1 2 0  
1 0 0  
8 0  
1 7 0  
1 5 0  
1 3 0  
1 7 0  
1 5 0  
1 3 0  
1 1 0  
1 0 0  
6 0  
6 0  
6 0  
1 0 0  
1 0 0  
1 0 0  
1 0 0  
1 0 0  
125,000  
150,000  
199,000  
150,000  
199,999  
250,000  
300,000  
399,999  
6 0  
5 0  
Determining required vent length:  
1. Determine the total length of straight vent pipe (in feet) required  
for both the intake and the exhaust.  
2. Add 5 feet of venting for every 90° elbow.  
3. Add 2 ½ feet of venting for every 45° elbow.  
4. Total vent length can not exceed “Max Vent Length” in  
Table 2.  
5. Air intake can not exceed exhaust by more than 30 feet in  
Through The Wall Venting with Low Ground Clearance:  
any venting situation.  
When venting cannot exit through the wall at a height greater than or  
equal to 12" (30.5 cm) (and above expected snow level) from the ground,  
then the installation must be modified as shown below (see Figure 13).  
NOTICE  
DO NOT include the 3" exhaust elbow or vent terminals in  
determining maximum vent length.  
Figure 13  
POWER VENT INSTALLATION  
Vent Terminal (Low Ground Clearance)  
Power venting is where the indoor air is used and the exhaust is vented to  
the outside. Venting may be run horizontally through an outside wall or  
vertically through a roof through using either 3 inch (7.6 cm) or 4 inch  
(10.2 cm) diameter PVC or CPVC. This water heater is supplied with a  
screened intake and exhaust 90° elbow referred to as the exhaust vent  
terminal and the air intake terminal.  
Power Vent Terminal Location  
Refer to the “Direct Vent Terminal Location” (see page 7) section  
previously mentioned to determine the proper exhaust vent location.  
Plan the vent system layout so that proper clearances are maintained  
from plumbing and wiring. Vent pipes serving power vented appliances  
are classified by building codes as “vent connectors”. Required  
clearances from combustible materials must be provided in accordance  
with information in this manual under LOCATION OF WATER HEATER  
and CLEARANCES, and with National Fuel Gas Code and local codes.  
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Figure 14  
Typical Horizontal Power Vent System  
NOTICE  
This unit can be vented using only PVC (Class 160, ASTM D-2241  
Schedule 40, ASTM D-1785; or Cellular Core Schedule 40 DWV, ASTM  
F-891), Schedule 40 CPVC (ASTM F-411) pipe. The fittings, other  
than the TERMINATIONS should be equivalent to PVC-DWV fittings  
meeting ASTM F-2665. (Use CPVC fittings, ASTM F-438 for CPVC pipe.)  
If CPVC pipe and fittings is used, then the proper cement must be  
used for all joints, including joining the pipe to the Termination (PVC  
material). PVC materials should use ASTM –D2564 grade cement;  
CPVC materials should use ASTM F-493 grade cement.  
For water heaters in locations with high ambient temperatures (above  
100° F) and/or insufficient dilution air, it is recommended that CPVC  
pipe and fittings (MUST USE SUPPLIED VENT TERMINAL) be used.  
Horizontal Installation:  
In a horizontal application, it is important that condensate not be allowed  
to buildup in the exhaust vent pipe. To prevent this from happening, the  
pipe should be installed with an slight upward slope. The vent system  
should be supported every 5 feet of vertical run and every 3 feet of  
horizontal run of vent pipe length.  
Vertical Installation:  
Vertical venting must be supported every 5 feet of vertical run and every 3 feet  
of horizontal run of vent pipe length.  
Stress levels in the pipe and fittings can be significantly increased by improper  
installation. If rigid pipe clamps are used to hold the pipe in place, or if the pipe  
cannot move freely through a wall penetration, the pipe may be directly  
stressed, or high thermal stresses may be formed when the pipe heats up and  
expands. Install accordingly to minimize such stresses.  
Stress levels in the pipe and fittings can be significantly increased by  
improper installation. If rigid pipe clamps are used to hold the pipe in  
place, or if the pipe cannot move freely through a wall penetration, the  
pipe may be directly stressed, or high thermal stresses may be formed  
when the pipe heats up and expands. Install accordingly to minimize such  
stresses.  
Follow the following procedure to vent through the roof:  
1. Cut the necessary holes through the roof and ceiling.  
Follow the following procedure to vent through the wall:  
1. Cut one 3 ½ in. (9.0 cm) diameter hole (for 3" (7.6 cm) diameter  
pipe) or 4 ½” (11.5 cm) diameter hole (for 4" (10.2 cm) diameter  
pipe).  
2. Install the exhaust vent and air intake plastic pipes as shown in  
Figure 15. Make sure that the installation meets the local codes  
and/or The National Fuel Gas Code ANSI Z223.1 (Latest Edition) or  
CGA/CAN B149 Installation Code.  
2. Use the proper PVC cement or sealant to secure the 90° exhaust vent  
terminal provided with the water heater to the plastic pipes. The  
distance between the back edge of the 90° exhaust vent terminal and  
the exterior wall (see Figure 14) must be 6 inches (13.0 cm). 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 3 feet (1.0 m) of horizontal vent.  
Figure 15  
Typical Vertical Power Vent System Installation  
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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) (and above expected snow level) from the ground,  
then the installation must be modified as shown below (see Figure 16).  
Refer to Tables 2 or 3 for maximum venting lengths using 3” (7.6 cm) or  
4” (10.2 cm) diameter plastic pipe.  
COAXIAL VENTING INSTALLATION PROCEDURE  
WARNING  
Improper installation, adjustment, service, or maintenance can cause  
property damage, personal injury, or death. Consult a qualified installer,  
service agency, or the gas supplier for information or assistance.  
This kit must be used only for terminating this water heater. Do not  
use this termination kit for any other appliance. Using this kit on other  
appliances and/or water heaters can result in property damage, personal  
injury, or death.  
Figure 16  
Vent Terminal (Low Ground Clearance)  
DO NOT operate this water heater until the installation and assembly  
of this kit is complete and the piping completed. Failure to complete  
installation before operation can result in property damage, personal  
injury, or death.  
Before beginning any installation, be sure the main electrical disconnect  
switch is in the OFF position. Electrical shock can cause personal injury  
or death.  
DO NOT operate this water heater with the rain cap removed or  
recirculation of combustion products may occur. Water may also collect  
inside larger combustion-air pipe and flow to the burner assembly.  
Failure to follow this warning could result in product damage, or improper  
operation, personal injury or death.  
CAUTION  
DO NOT use field-supplied couplings to extend pipes. Airflow  
restriction will occur and the water heater pressure switches may cause  
intermittent problems.  
Maximum Vent Length Determination  
Table 3  
Vertical Installation (Recommended)  
1. Become familiar with coaxial vent kit.  
Direct Vent Maximum Vent Length  
Storage  
Capacity  
Rated Max Vent Length (ft) Max Vent Length (ft)  
Figure 17  
Input  
3" PVC or CPVC  
4" PVC or CPVC  
Dimensional Layout of Concentric Vent Kit  
(Gallons) (Btu/Hr)  
1 2 0  
1 0 0  
8 0  
1 2 0  
1 0 0  
8 0  
1 7 0  
1 5 0  
1 3 0  
1 7 0  
1 5 0  
1 3 0  
1 2 0  
1 0 0  
6 0  
6 0  
6 0  
1 0 0  
1 0 0  
1 0 0  
1 0 0  
1 0 0  
125,000  
150,000  
199,999  
150,000  
199,999  
250,000  
300,000  
399,999  
6 0  
5 0  
Figure 18  
Concentric Vent Kit Part Identitication  
Determining required vent length:  
1. Determine the total length of straight vent pipe (in feet) required.  
2. Add 5 feet of venting for every 90° elbow.  
3. Add 2 ½ feet of venting for every 45° elbow.  
4. Total vent length can not exceed “Max. Vent  
ength” in Table 3.  
2. Determine the best location for the termination kit.  
3. Cut the recommended 5" diameter hole.  
NOTICE  
Do not include the 3" exhaust elbow or vent terminals in determining  
maximum vent length.  
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7. Install rain cap and small diameter pipe assembly in roof penetration  
assembly. Ensure small diameter pipe is cemented and bottomed in  
Y concentric fitting.  
4. Partially assemble vent kit by performing the following:  
a. Cement concentric Y fitting to larger diameter pipe. (See Figure  
18).  
b. Cement rain cap to smaller diameter pipe. (See Figure 19).  
8. Cement heater combustion-air and vent pipes to concentric y fitting  
assembly (Figure 18). (See Figure 20) for proper pipe attachment.  
Figure 19  
Rain Cap to Small Vent Pipe Ass’y  
9. Operate heater through one cycle to ensure combustion-air and vent  
pipes are properly connected to concentric vent termination  
connections.  
Horizontal Installation:  
1. Become familiar with coaxial vent kit. As shown in Figures 17 through  
19.  
2. Determine the best location for the termination kit.  
NOTICE  
Position termination where vent vapors will not damage plants/shrubs  
or air conditioning equipment.  
Position termination where vent vapors will not be adversely effected  
by wind condition.  
Position termination where it will not be damaged or be subjected to  
foreign objects.  
Position termination where vapors will not be objectionable.  
5. Install concentric Y fitting and pipe assembly through the structure’s  
hole and field-supplied roof boot/flashing. Do not allow insulation or  
other materials to accumulate inside pipe assembly when installing  
through the hole.  
6. Secure assembly to roof structure as shown in (Figure 20) using field-  
supplied metal strapping or equivalent support material.  
NOTICE  
3. Cut the recommended 5" diameter hole.  
Ensure termination height is above the roof surface or anticipated  
snow level. Figure 20. If assembly is too short to meet height  
requirements, the 2 pipe supplied in the kit may be replaced by using  
the same diameter pipe. DO NOT extend the overall dimension by  
more than 60 in. (See Figure 17).  
4. Partially assemble vent kit.  
a. Cement Y concentric fitting to larger diameter kit pipe. (See Figure  
18).  
b. Cement rain cap to smaller diameter kit pipe. (See Figure 19).  
5. Install concentric Y fitting and pipe assembly through the structure’s  
hole and field-supplied roof boot/flashing. Do not allow insulation or  
other materials to accumulate inside pipe assembly when installing  
through the hole.  
Figure 20  
Concentric Vent Roof Top Attachment  
6. Install rain cap and small diameter pipe assembly in concentric Y  
fitting and large pipe assembly. Ensure small diameter pipe is cemented  
and bottomed in concentric Y fitting.  
7. Secure assembly to structure as shown in Figure 21. Ensure clearances  
as shown in Figure 21.  
8. Cement heater combustion-air and vent pipes to concentric Y fitting  
termination assembly. (See Figure 21) for proper pipe attachment.  
9. Operate heater through one cycle to ensure combustion-air and vent  
pipes are properly connected to concentric vent termination  
connections.  
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Figure 21  
Concentric Vent Side Wall Attachment  
SELECTION OF MATERIALS  
VENT PIPE PREPARATION  
WARNING  
PRIMER – It is recommended that Tetrahydrofuran (THF) be used to  
prepare the surfaces of pipe and fittings for solvent welding. DO NOT use  
water, rags, gasoline or any other substitutes for cleaning PVC cellular core  
or CPVC surfaces. A chemical cleaner such as MEK may be used.  
DO NOT attempt to start this water heater until vent pipe solvent  
fumes completely clear from the room and inside the vent piping.  
INITIAL PREPARATION  
CEMENT – The cement should be a bodied cement of approximately 500  
to 1600 centipoises viscosity containing 10-20% (by weight) virgin PVC  
1. Make sure the solvent cement you are planning to use is designed for material solvated with tetrahydrofuran (THF). Small quantities of  
the specific application you are attempting.  
dimethylformamide (DMF) may be included to act as a retarding agent to  
extend curing time. Select the proper cement; Schedule 40 cement should  
2. Know the physical and chemical characteristics and limitations of the be used for Schedule 40 pipe. Never use all-purpose cements or commercial  
PVC, PVC cellular core or CPVC piping materials that you are glues and adhesives to join PVC or CPVC pipe and fittings.  
about to use.  
SAFETY PRECAUTION: PRIMERS AND CEMENTS ARE EXTREMELY  
3. Know the reputation of your pipe and cement manufacturer and their FLAMMABLE AND MUST NOT BE STORED OR USED NEAR HEAT OR OPEN  
products.  
FLAME. ALSO, USE ONLY IN A WELL VENTILATED AREA.  
4. Know your own qualifications or those of your contractor. The solvent  
welding technique of joining PVC, PVC cellular core or CPVC pipe is a  
specialized skill just as any other pipe fitting technique.  
5. Closely supervise the installation and inspect the finished job before  
start-up.  
6. Contact the manufacturer, supplier, or competent consulting agency if  
you have any questions about the application or installation of PVC,  
PVC cellular core or CPVC pipe.  
7. Take the time and effort to do a professional job. Shortcuts will only  
cause you problems and delays in start-up. The majority of failures in  
these systems are the result of shortcuts and/or improper joining  
techniques.  
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GAS CONNECTIONS  
WARNING  
Figure 22  
Drip Leg  
Connect this water heater only to the type of gas as shown on the  
rating plate. Use clean black iron pipe or equivalent material approved  
by local codes and ordinances. (Dirt and scale from the pipe can enter  
the gas valve and cause it to malfunction). The inlet gas line must  
have at least a 3 inch (7.62 cm) drip leg (sediment trap) installed as  
close to the water heater’s gas valve as possible. A ground joint union  
must be installed in the gas supply line, as close to the water heater as  
possible, to permit servicing of the water heater. Compounds used on  
the threaded joints of the gas piping must be resistant to the action of  
liquefied petroleum gases/propane gas. DO NOT apply pipe dope to  
the gas valve inlet and make certain that no pipe dope has become  
lodged in the inlet screen of the gas valve. Extreme care must be  
taken to ensure no pipe dope enters the gas valve and to avoid  
excessive torque when tightening the gas supply line to the gas valve.  
Excessive torque may result in cracking of the gas valve housing. The  
suggested maximum torque is 31.5 foot lbs. (4.4 kg-m). The  
manufacturer of this water heater will not be liable for any damage or  
injury caused as a result of a cracked gas inlet as a result of excessive  
torque.  
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 B149.2 Propane  
Installation Code (Latest Edition).  
GAS METER SIZE – NATURAL GAS ONLY  
Be sure that the gas meter has sufficient capacity to supply the full rated  
gas input of the water heater as well as the requirements of all other gas  
fired equipment supplied by the meter. If the gas meter is too small, ask  
the gas company to install a larger meter having adequate capacity.  
This water heater and its gas connection must be leak tested before  
placing the water heater in operation. Check for gas leaks with a soap  
and water solution and a brush or a commercial leak detector fluid.  
NEVER USE A MATCH OR OPEN FLAME FOR TESTING!  
GAS PRESSURE REGULATION  
Main line gas pressure to the water heater should be between a maximum  
14.0 inch W.C. and a minimum supply pressure as shown on the rating  
plate. The inlet gas pressure must not exceed the maximum value.  
The water heater is not intended for operation at higher than 14.0 inch  
water column (½ psi) supply gas pressure. Higher gas supply pressures  
require supplemental reducing service regulation. Exposure to higher  
gas supply pressure may cause damage to the gas controls which  
could result in fire or explosion. If overpressure has occurred such as  
through improper testing of gas lines or emergency malfunction of the  
supply system, the gas valve must be checked for safe operation.  
Make sure that the outside vents on the supply regulators and the  
safety vent valves are protected against blockage. These are parts of  
the gas supply system, not the water heater.  
BEFORE PLACING THE WATER HEATER IN OPERATION, CHECK FOR GAS  
LEAKAGE. USE SOAP AND WATER SOLUTION OR OTHER MATERIAL ACCEPTABLE  
FOR THE PURPOSE OF LOCATING GAS LEAKS.  
WARNING  
DO NOT USE MATCHES, CANDLES, FLAME OR OTHER SOURCES  
OF IGNITION FOR THIS PURPOSE.  
ELECTRICAL CONNECTIONS  
CAUTION  
WARNING  
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 ½ 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 ½ psi (3.5 kPa). The  
supply line must be capped when not connected to the water heater.  
If copper supply lines are used, they must be internally tinned and  
certified for gas service.  
Turn off or disconnect the electrical power supply to the water heater  
before servicing. Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and dangerous operation.  
Verify proper operation after servicing.  
All electrical wiring must be installed and grounded in accordance with  
local codes, or in the absence of local codes, the National Electrical  
Code, ANSI/NFPA 70 and/or CSA C22.2 Electrical Code.  
The water heater must be wired to a 120 VAC, 60 Hz, 15A power supply.  
The water heater should be connected to a GFI outlet and wired on a  
separate circuit and breaker. If a flexible line cord and plug is permitted  
by local code, then provide a three wire GFI grounding type receptacle  
within reach of the line cord provided on the control box. DO NOT plug  
the line cord into a receptacle that can have the power supply interrupted  
by a switch that is used to control lights or another appliance.  
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If wiring in conduit is required, remove the line cord and strain relief  
bushing in the control panel and install an electrical conduit connector.  
Connect the hot, neutral, and ground leads to the terminal block using  
quick connect terminals. Refer to the wiring diagram for the correct  
terminal locations for each wire lead.  
WARNING  
If the unit is exposed to the following, do not operate water heater  
until all corrective steps have been made by a factory authorized  
independent service contractor or qualified service professional.  
1. Flooding to or above the level of the burner or controls  
2. External firing  
CAUTION  
3. Damage  
4. Firing without water  
5. Sooting  
Do not energize the electric circuit before the water heater tank is  
filled with water.  
This controller is Polarity sensitive. If the Hot and Neutral Supply  
voltage is reversed, the controller will not sense flame and the water  
heater will not operate. Verify polarity before connecting the water  
NEVER OPERATE THE WATER HEATER WITHOUT FIRST BEING  
CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND  
PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE  
OPENING OF THE WATER HEATER.  
heater.  
WIRING DIAGRAM AND SCHEMATIC  
Figure 23  
Wiring Diagram and Schematic  
GENERAL INSTRUCTIONS  
OPERATING INSTRUCTIONS  
WARNING  
TO FILL THE WATER HEATER  
1. Close the water heater drain valve by turning the knob or valve stem  
clockwise. If alternative water connections are provided but not  
used, make certain they are plugged (i.e. rear connections).  
2. Open the cold water supply shut-off valve.  
3. Open several hot water faucets to allow air to escape from the  
system.  
4. When a steady stream of water flows from the faucets, the water  
heater is filled. Close the faucets and check for water leaks at the  
water heater drain valve, combination temperature and pressure  
relief valve and the hot and cold water connections.  
Water heaters are heat-producing appliances. To avoid damage or  
injury there must be no materials stored against the water heater or  
direct vent system, and proper care must be taken to avoid  
unnecessary contact (especially by children) with the water heater  
and direct vent system. UNDER NO CIRCUMSTANCES SHOULD  
FLAMMABLE MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE  
USED OR STORED IN THE VICINITY OF THIS WATER HEATER OR IN ANY  
LOCATION FROM WHICH FUMES COULD REACH THE WATER HEATER.  
Installation or service of this water heater requires ability equivalent  
to that of a licensed tradesman in the field involved. Plumbing, air  
supply, venting, gas supply and electrical work are required.  
Light the unit in accordance with the operating instructions label attached  
to the water heater.  
SEQUENCE OF OPERATION  
1. A call for heat from thermostat  
2. Blower ON  
6. Main burner ON  
7. Flame signal confirmed  
Under no circumstances should the input rate exceed the input rate  
shown on the water heater rating plate. Over firing could result in  
damage or sooting of the water heater.  
3. Pressure switch proves blower operation 8. Thermostat satisfied  
4. Blower pre-purge  
5. Igniter warm-up  
9. Main burner OFF  
10. Blower post-purge  
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LIGHTING INSTRUCTIONS  
Figure 24 Lighting Instruction Label  
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TEMPERATURE ADJUSTMENT  
The temperature selector knob of the thermostat has been adjusted to  
120° F when shipped from the factory.  
Figure 25  
Sight Glass Location  
NOTICE  
The lower the temperature setting, the greater the energy efficiency,  
both to heat the water and to maintain the storage temperature  
during standby periods. Lower water temperatures also extend tank  
life. Remember, no water heating system will provide exact  
temperatures at all times. Allow a few days of operation at this  
setting to determine the correct temperature setting consistent with  
the requirements for the installation.  
CAUTION  
This water heater, when set at a lower temperature setting is not  
capable of producing hot water of sufficient temperature for sanitizing  
purposes.  
During the winter season or any cold period, you may desire a higher  
temperature setting to adjust for the colder incoming water. This adjustment,  
however, may cause additional condensation to form on the colder tank  
surface. This does not mean the tank is leaking. During summer months,  
the warmer incoming water temperatures will benefit the performance of  
your water heater and reduce the amount of condensation developed.  
MAINTENANCE  
DANGER  
DO NOT ATTEMPT TO REPAIR GAS VALVE.  
Condensation does not mean your tank is leaking. Most of reported tank  
leaks on installation are proven to be condensation. To avoid unnecessary  
inconvenience and expense, make sure the tank is leaking before calling  
an independent servicing contractor or qualified service professional.  
DO NOT ATTEMPT TO REPAIR IGNITION MODULE.  
DO NOT ATTEMPT TO REPAIR VENTURI.  
DO NOT ATTEMPT TO REPAIR THERMOSTAT BOARD.  
DO NOT ATTEMPT TO REPAIR TRANSFORMER.  
DO NOT ATTEMPT TO REPAIR PRESSURE SWITCH.  
DANGER  
Hotter water increases the risk of scald injury. Scalding may occur  
within 5 seconds at a temperature setting of 135°F (57°C). To protect  
against hot water injury, install an anti-scald tempering valve in the  
water system. This valve will reduce point of discharge temperature  
by mixing cold and hot water in branch water lines. A licensed  
plumbing professional or local plumbing authority should be consulted.  
This water heater is equipped with an energy cut out device to  
prevent overheating. Should overheating occur or the gas supply  
fail to shut off, turn off the manual gas control valve to the appliance  
and call a qualified service agency.  
GENERAL  
KEEP APPLIANCE AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS,  
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.  
Water heater maintenance includes periodic tank flushing and cleaning,  
and removal of lime scale. The unit should be inspected and adjusted to  
maintain proper combustion. Refer to Table 4, “Suggested Maintenance  
Schedule”. A periodic inspection of the venting system should be made.  
If the water heater is to remain idle for 30 days or more or is subjected to  
freezing temperatures while shut off, the water heater and piping should  
be fully drained and the drain valve should be left fully open. Refer to the  
“General Operation” section of this Installation and Operating Instructions  
Manual for the procedure on draining the water heater.  
MAINTENANCE SCHEDULE  
Following are the instructions for performing some of the recommended  
maintenance. Unit inspection and adjustment should be performed by a  
competent technician.  
BURNER FLAME CHECK  
At the time of installation and at monthly intervals, a visual check of the  
burner flames should be made to determine if they are burning properly.  
The main burner may be seen through the sight glass window on the front  
of the combustion insert mounting bracket (Figure 25). The burner flames  
should be a blue flame near the burner surface in a uniform flame pattern.  
Occasional yellow or white streaks are normal.  
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Table 4  
Suggested Maintenance Schedule  
COMPONENT  
OPERATION  
INTERVAL  
REQUIRED  
Tank  
Sediment Removal  
Monthly  
Flushing  
Anode Rods  
Inspect  
Semi-Annually  
Semi-Annually  
As Required  
Every 3 Months  
Annually  
Replace as Required  
Proper Operation  
Relief Valve  
Check Operation  
Clean Inlet Screen  
Inspect  
Blower  
Soft Brush  
Vent & Air Intake System  
Ignition System  
Vent Terminal  
Combustion System  
Condensate Line  
Joints should be sealed  
Clean of dust and dirt  
Remove object that caused restriction  
Confirm S-OP  
Inspect  
Free of Shrubs & Debris  
Inspect  
Monthly  
Monthly  
Inspect  
Monthly  
Remove restriction  
the water. This is the lime scale which forms in pipes, water heaters and on  
cooking utensils.  
FLUSHING WATER HEATER  
1. Turn OFF the water heater electrical disconnect switch.  
2. Open the drain valve and allow water to flow until it runs clean.  
3. Close the drain valve when finished flushing.  
Lime accumulation not only reduces the life of the equipment but also  
reduces efficiency of the water heater and increases fuel consumption.  
4. Turn ON the water heater electrical disconnect switch.  
The usage of water softening equipment greatly reduces the hardness of  
the water. However, this equipment does not always remove all of the  
hardness (lime). For this reason it is recommended that a regular schedule  
of deliming be maintained.  
DRAINING WATER HEATER  
The water heater must be drained if it is to be shut down and exposed to  
freezing temperatures. Maintenance and service procedures may also  
require draining the water heater.  
1. Turn off the water heater electrical disconnect switch.  
2. Connect a hose to the drain valve.  
3. Locate hose’s discharge in an area where hot water will not cause  
any damage or injury.  
4. Close the cold water inlet valve to water heater.  
5. Open a nearby hot water faucet to vent the system.  
6. Open the heater drain valve.  
7. If the water heater is being drained for an extended shutdown, it  
is suggested the drain valve be left open during this period.  
The depth of the buildup should be measured periodically. Water heaters  
will have about 3 inches of lime buildup when the level of lime has reached  
the bottom of the cleanout opening or about 1 inch of lime buildup if it has  
reached the drain valve opening. A schedule for deliming should be set  
up, based on the amount of time it would take for a ½ inch buildup of lime.  
Example1:  
Initial inspection shows ½ an inch of lime accumulation. Therefore, the  
water heater can be delimed once a year.  
FILLING WATER HEATER  
To remove sediment and lime scale:  
1. Drain the heater. Refer to DRAINING THE WATER instructions in this  
section.  
2. Remove outer cover plate from lower side of water heater jacket.  
3. Remove cover and gasket from cleanout opening.  
4. Remove lime, scale or sediment using care not to damage the  
glass-lining.  
5. Inspect cleanout plate gasket: Replace gasket if necessary (Contact  
local distributor for correct part number).  
1. Close the water heater drain valve by turning the knob or valve  
stem clockwise. If alternative water connections are provided but  
not used, make certain they are plugged (i.e. rear connections).  
2. Open the cold water supply shut-off valve.  
3. Open several hot water faucets to allow air to escape from the  
system.  
4. When a steady stream of water flows from the faucets, the water  
heater is filled. Close the faucets and check for water leaks at the  
water heater drain valve, combination temperature and pressure  
relief valve and the hot and cold water connections.  
6. Install gasket and cleanout plate. Be sure to draw plate up tight by  
tightening screws securely.  
7. Close the drain valve. Open a hot water fixture to allow air to  
escape. Open the cold water supply to water heater and allow the  
tank to fill. Follow the lighting instructions.  
SEDIMENT AND LIME SCALE REMOVAL  
Waterborne impurities consist of the particles of soil and sand which settle  
out and form a layer of sediment on the bottom of the tank.  
8. Check for water leakage.  
9. Install outer jacket cover plate.  
The amount of calcium carbonate (lime) released from water is in direct  
proportion to water temperature and usage. The higher the water  
temperature or water usage, the more lime deposits are dropped out of  
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ANODE INSPECTION AND REPLACEMENT  
explosion. In areas with poor water conditions, it may be necessary to  
This water heater is equipped with multiple sacrificial anodes. Anodes inspect the T&P valve more often than the recommended maintenance  
protect the glass-lined tank from corrosion by sacrificing themselves through schedule.  
electrolysis. When the anode material is consumed, there is no more  
protection and corrosion of the tank accelerates.  
CAUTION  
Before manually operating the valve, make sure that a drain line has  
been attached to the valve to direct the discharge to an open drain.  
Failure to take this precaution could mean contact with extremely hot  
Inspection of the anode every 6 months allows you to identify the rate of  
anode degradation. The anode should be replaced when its diameter is  
3/8 of an inch, or annually which ever is first. Aggressive, very hot and  
softened water causes rapid consumption of the anode requiring frequent  
water passing out the valve during this checking operation.  
inspections. The replacement anodes rods are available from your local If the temperature and pressure relief valve on the water heater discharges  
distributor.  
periodically or continuously, it may be due to thermal expansion of water  
in a closed water supply system, or, it may be due to a faulty relief valve.  
To inspect or replace an anode:  
The anodes on this water heater are easily accessible from the top of the Thermal expansion is the normal response of water when it is heated. In a  
water heater making replacement simple and quick. Use the following closed system, thermal expansion will cause the system pressure to build  
procedure to remove and inspect the anodes.  
until the relief valve actuation pressure is equaled. Then, the relief valve  
will open, allowing some water to escape, slightly lowering the pressure.  
1. Drain the heater. Refer to DRAINING THE WATER HEATER instructions  
in this section.  
Contact your water supplier or local plumbing inspector on how to control  
2. Flush the heater. Refer to FLUSHING THE WATER HEATER instructions this situation.  
in this section.  
WARNING  
3. Remove the combustion surround top by unlatching.  
Above all, do not plug the temperature and pressure relief valve. This  
is not a solution and can create a hazardous situation.  
4. Remove the second pass access cover. (If equipped)  
5. Remove the second pass insulation.  
6. Remove the second pass collector cover.  
7. Remove the anode using a socket of the appropriate size. Sometimes VENT AND AIR INTAKE SYSTEM  
a breaker bar will need to be used. DO NOT use an impact wrench. Examine the vent and air intake system every 3 months. Points of inspection  
8. Inspect and replace the anode as required. Use pipe tape or sealant are as follows:  
when reinstalling the anode.  
9. Close the drain valve. Open a hot water fixture to allow air to escape.  
1. Check for obstructions and/or deterioration of vent piping and vent  
terminal. Replace immediately where needed.  
Open the cold water supply to water heater and allow the tank to fill. 2. Vent pipe and vent hood screen should be cleaned of any foreign  
Follow the lighting instructions.  
material. The screen is located inside the vent hood outlet and is  
accessible from the outside of the hood. DO NOT reach inside the  
vent hood when the water heater is in operation.  
10. Check your anode and drain valve for leaks.  
11. Replace second pass collector cover. Make sure to clean off any  
sealant and reseal before fastening.  
3. Check all vent system connections for leakage and reseal as required.  
12. Replace second pass insulation.  
13. Replace second pass access cover.  
14. Replace combustion surround top and latch it securely in place. COMBUSTION SYSTEM INSPECTION  
Inspect the operation of the combustion system monthly. Use the following  
procedure to inspect the combustion system.  
DRAIN VALVE AND TANK ACCESS PANEL  
The water heaters are equipped with a ¾ inch drain valve. An access panel 1. Turn off the main power switch of the water heater.  
covers the cleanout opening in the tank which is sealed by a gasket and 2. Adjust the thermostat to the Min. setting.  
cover.  
3. Remove the top of the combustion surround by unlatching it.  
4. While observing the ignition module, turn on the main power switch.  
5. Adjust thermostat to the Max. setting.  
RELIEF VALVE  
At least twice a year, the temperature and pressure relief valve should be 6. Watch the LED’s light as the controller goes through the S-OP as  
checked to ensure that it is in operating condition. To check the relief previously described.  
valve, lift the lever at the end of the valve several times. The valve should 7. Upon ignition, observe the main burner flame.  
seat properly and operate freely.  
8. Readjust thermostat to previous setting.  
9. Replace combustion surround top and latch it securely in place.  
If water does not flow, remove and inspect for obstructions or corrosion.  
Replace with a new valve of the recommended size as necessary. A thorough  
inspection of the valve should be performed at least every three years by  
removing the temperature and relief valve from the tank. Do not attempt  
to repair the valve, as this could result in improper operation and a tank  
1 9  
 
TNR-I&S-02  
TROUBLESHOOTING GUIDE  
Main power light is not lit.  
Make sure that water heater is plugged in.  
When the switch is on, is there 120VAC between L1 and N on the terminal block? If not, then  
check for loose wire connections on the “Power Switch Wire Harness.” If connections are ok, then  
replace the switch.  
If there is voltage between L1 and N then the light on the switch is burnt out. Replace switch.  
Thermostat does not call for heat.  
Make sure that the temperature of the tank is cool.  
If the thermostat does not call for heat, then check the PRIMARY voltage across the “Transformer”.  
If there is voltage across the PRIMARY, then check the voltage across the SECONDARY leads of  
the “Transformer”.  
Install a jumper wire from N.O. terminal to the COM terminal on the “Thermostat PC Board.” If  
the thermostat calls for heat after installing a jumper wire then check the “Thermostat Sensor  
Probe” leads for proper resistance with an OHM meter (See appendix A).  
If sensor reading are not correct, replace “Thermostat Sensor Probe.”  
If the sensor readings are correct, then check “Potentiometer” for the proper resistance. If the  
readings are correct, then replace the “Thermostat PC Board”, otherwise replace the  
“Potentiometer.”  
Ignition module “Power” LED is not lit.  
Blower does not energize.  
Check for 120 VAC at the ignition module on “120 VAC IN.” If there is voltage, then replace the  
ignition module.  
If there is not any voltage, check the voltage across the transformer as previously described.  
Is the “Vacuum Switch” (air intake switch) N.C.? If no, then check the hose and see if it is filled  
with condensate. If the hose is not filled with condensate, then replace vacuum switch. If filled,  
empty hose.  
Is the “Pressure Switch” (exhaust pressure switch) N.O.? If no, then check the hose and see if it  
is filled with condensate. If the hose is not filled with condensate, then replace pressure switch.  
If filled empty hose.  
Is the “Collector Limit Switch” N.C.? If no, then reset switch. If this switch trips more than 3  
times, call service.  
If all items above are ok, then replace the blower.  
Ignitor does not glow.  
Is there voltage to the “Hot Surface Ignitor”? Check for 120VAC to the ignitor from the ignition  
module.  
Is there continuity across the “Hot Surface Ignitor?” If no, then replace hot surface ignitor. If  
yes, then replace the ignition module.  
Main valve does not turn on.  
Put your hand on the gas valve. When the “Valve” LED lights on the ignition module, can you  
feel it energize? If not, then check the voltages at the ignition module across pins 2 and 7 on  
the plug “CONTROL”. If there is 24 VAC across these pins, then check to see if the “Rectifier  
Harness” is secure. If it is secure, then replace the “Gas Valve”.  
If you can feel the gas valve energize, check the main gas supply is not in the off position.  
Burner Flame keeps going out.  
Is there minimum gas supplied to water heater as stated on the rating plate? If not, then  
increase the supply pressure to the water heater.  
Measure the microAmps through the flame sensor using a multimeter. Is there at least 4  
microAmps? If not, then replace the “Flame Sensor” or flame sensor wire.  
Thermostat does not satisfy.  
Blower did not post purge  
Is the tank temperature above the temperature set point?  
Does the T&P relief valve leak? If yes, then replace “Thermostat PC Board.”  
Check “Vacuum Switch” (air intake switch) as previously mentioned.  
Check “Pressure Switch” (exhaust pressure switch) as previously mentioned.  
Check “Collector Limit Switch” as previously mentioned.  
If above switches are all ok, then replace “Ignition Module.”  
9/07 Printed in USA  
2 0  
 

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