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RESIDENTIAL GAS WATER HEATERS
WARNING: If the information in these instruc-
tions is not followed exactly, a fire or explosion
may result causing property damage, personal
injury or death.
- Do not store or use gasoline or other flamma-
ble 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 phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas suppli-
er's instructions.
• If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed by
a qualified installer, service agency or the
gas supplier.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
2006
POWER DIRECT VENT GAS ULTRA LOW NOx MODELS
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
Installation and Operating Manual
•
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
WITH HOT SURFACE IGNITION
WARNING
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
•
For Your Safety
100324051_2000579115 _Rev. 01
GPDNL-40
GPDNL-50
SERIES 100
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Related Manuals for A.O. Smith ProLine XE GPDNL-40 Series
Summary of Contents for A.O. Smith ProLine XE GPDNL-40 Series
- Page 1 Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS ULTRA LOW NOx MODELS WITH HOT SURFACE IGNITION GPDNL-40 GPDNL-50 SERIES 100 WARNING: If the information in these instruc- tions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
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Page 2: Table Of Contents
TABLE OF CONTENTS Safe Installation, Use And Service ....3 Low Profile Side Wall Vent Termination... 28 General Safety . -
Page 3: Safe Installation, Use And Service
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. -
Page 4: General Safety
GENERAL SAFETY WARNING WARNING Read and understand instruction Fire Hazard manual and safety messages For continued protection against before installing, operating or risk of fire: servicing this water heater. • Do not install water heater on Failure to follow instructions and carpeted floor. - Page 5 GENERAL SAFETY CAUTION WARNING Improper Installation, use and service may result • Before servicing the water heater, make sure the blower assembly is unplugged in property damage. or the electrical supply to the water • Do not operate water heater if flood damaged. heater is tumed "OFF".
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Page 6: Introduction
INTRODUCTION Thank You for purchasing this water heater. Properly water heater and your safety. Since we cannot put installed and maintained, it should give you years of trouble everything on the first few pages, READ ENTIRE free service. This water heater is suitable for potable water MANUAL BEFORE ATTEMPTING TO INSTALL OR heating and space heating applications but not for space OPERATE THE WATER HEATER. -
Page 7: Installation Requirements For The Commonwealth Of
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:... -
Page 8: Massachusetts
INSTALLATION GRAPHIC: GAS-FIRED POTABLE WATER HEATING/SPACE HEATING SYSTEM • If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following graphic during installation and during modifications to the water supply system. This water heater is not equiped with Side Taps for "Combo"... -
Page 9: Typical Installation
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5) 1 Termination Elbow with Vent Screen 22 Hot-Water Outlet Nipple/Anode 42 Intake Air Pressure Switch (NC) 2 *Vent Pipe 23 *Inlet Water Shut-off Valve (inside box) (see Figure 4) 3 *Vent Pipe Elbow (long radius) 24 ***Rubber Coupling (see Figure 4) 43 Capacitor (see Figure 4) -
Page 10: Replacement Parts And Deliming Products
Notes: Items not supplied with the water heater. ** Caution: harness has 120 VAC during operation. *** See "Vent Pipe Installation" for more information. REPLACEMENT PARTS AND DELIMING PRODUCTS Replacement parts and recommended delimer may be ordered through authorized servicers or distributors. When ordering parts, provide complete model and serial numbers (see rating plate), quantity and name of part desired. -
Page 11: Water Heater Operation
WATER HEATER OPERATION Time for Permanent Water Time for 1st Burns 2nd & 3rd Figure 7 shows the water heater’s sequence of operation Temperature Degree Burns Degree (Most when a call for heat is initiated. The ignition control module °F (Less Severe Burns) Severe Burns) will attempt to light the burner three times. -
Page 12: Electrical Requirements & Wiring Diagram
ELECTRICAL REQUIREMENTS & WIRING DIAGRAM CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN WARNING CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. Electric Shock Hazard NOTE: REFER TO THE “INSTALLATION CHECKLIST” Disconnect power before BEFORE OPERATING THIS HEATER. -
Page 13: Safety Lockouts
SAFETY LOCKOUTS This water heater has several lockout features designed The switch will auto reset once the temperature drops to prevent the heater from operating in unsafe conditions. sufficiently. HIGH LIMIT CONTROLS (ENERGY CUT OFF) BLOWER AIR PRESSURE SWITCHES Thermostat/Water Temperature The blower/heater is equipped with two air pressure This feature is a part of the gas control valve/thermostat switches located in the junction box (see Figure 4, item... -
Page 14: Clearances To Combustibles
Clearances For Servicing WARNING When installing the heater, consideration must be given to proper location. Location selected should be as close to Fire or Explosion Hazard the wall as practicable and as centralized with the water piping system as possible. •... -
Page 15: Important Notes And Warnings
INSULATION BLANKETS WARNING Insulation blankets are available to the general public for external use on gas water heaters but are not necessary Breathing Hazard - Carbon Monoxide Gas with these products. The purpose of an insulation blanket is to reduce standby heat loss encountered with storage tank •... -
Page 16: Installing The New Water Heater
INSTALLING THE NEW WATER HEATER WATER PIPING Consult a Qualified Installer or Service Agency. Follow manufacturer’s instructions for installation of valves. To reduce the risk of unusually hot water reaching Before changing the factory setting on thermostat, read the fixtures in the house, install Thermostatic Mixing "Operating The Temperature Control System"... -
Page 17: Combo Heating
COMBO HEATING 2. Install a drain valve at the lowest point of the heating loop so that water can be drained from the heating This section serves as a guide for the installation and use module without affecting the water heater. of “Combo”... -
Page 18: Closed Water Systems
CLOSED WATER SYSTEMS SHUT-OFF VALVE Water supply systems may, because of code requirements HOT-WATER COLD- OUTLET or such conditions as high line pressure, among others, WATER INLET have installed devices such as pressure-reducing valves, UNION UNION check valves, and back flow preventers. Devices such as these cause the water system to be a closed system. -
Page 19: Temperature-Pressure Relief Valve
TEMPERATURE-PRESSURE RELIEF VALVE No valve or other obstruction is to be placed between the T&P valve and the tank. Do not connect discharge piping directly to the drain unless a maximum of 6” air gap is WARNING provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge Explosion Hazard water in adequate quantities should circumstances... -
Page 20: Temperature-Pressure Relief Valve And Pipe
Note: The purpose of a temperature-pressure relief valve HIGH ALTITUDE INSTALLATION is to prevent excessive temperatures and pressures in the storage tank. The T&P valve is not intended for the constant WARNING relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see "Closed Water Systems"... -
Page 21: Sediment Traps
Make sure the gas supplied is the same type listed on the The appliance and its individual shut-off valve should be model rating plate. The inlet gas pressure must not exceed disconnected from the gas supply piping system during 14” w.c. for natural gas. The minimum inlet gas pressure any pressure testing of that system at test pressures in shown on the rating plate is that which will permit firing excess of 1/2 psi. -
Page 22: Filling The Water Heater
methods of installation shown in Figure 15 and Figure 16. FILLING THE WATER HEATER Contaminants in the gas lines may cause improper operation of the gas control valve/thermostat that may CAUTION result in fire or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. -
Page 23: Venting
VENTING Plan the vent system layout so that proper clearances are VENT KIT maintained from plumbing and wiring. Vent pipes serving A Vent Kit included with this water heater may be used for power vented appliances are classified by building codes as standard sidewall or roof termination. -
Page 24: Termination Clearances (Side Wall)
TERMINATION CLEARANCES (SIDE WALL) R N E E C O I N S I D D E T A Vent terminal Air supply inlet Area where terminal is not permitted F I X E S E D C L O R A B O P E F I X E... -
Page 25: Termination Types
TERMINATION TYPES ROOF VENT TERMINATION (STANDARD) The combustion air intake and exhaust vent system and Important: When terminating the vents through a roof, termination may be installed in one of the following type the following specifications pertaining to terminal location terminations: must be followed (see Figure 20). -
Page 26: Side Wall Vent Option For Cold Climates
SIDE WALL VENT OPTION FOR COLD CLIMATES DELUXE HORIZONTAL VENTING KIT Some winter weather conditions present a risk of ice The Deluxe Horizontal Venting kit was an optional through- accumulation at the intake termination screen. Such the-wall-only concentric flue system for use only on accumulation will restrict intake air flow. -
Page 27: Mushroom" Vent Terminal
“Mushroom” Vent Terminal SCREW O-RING VENT 3” VENT 3” VENT PIPING PIPING PIPING “MUSHROOM” (INTAKE) (EXHAUST) VENT TERMINAL Figure 25. Figure 23. AIRBOX INTAKE PIPING EXHAUST PIPING Figure 24. Connections To The Air Box 1. Slide an O-ring over each of the fittings on the air box. Note: An appropriate sized O-ring can be ordered from the heater manufacturer. -
Page 28: Low Profile Side Wall Vent Termination
LOW PROFILE SIDE WALL VENT TERMINATION 3. To fasten the Base to the wall, use the supplied screws and anchors. A 3/16” hole, 1-3/16” deep, will need to The Low Profile termination is certified to be used on all PDV be drilled for the anchors. -
Page 29: Concentric Vent Termination
CONCENTRIC VENT TERMINATION 45° ELBOW (SEE A concentric vent termination kit (see Table 3) may be LOCAL used for vertical or horizontal terminations. Figure 30 CODES) PIPE NIPPLE illustrates the concentric vent kit for a horizontal (side wall) installation. To prevent rain water from entering the exhaust VENT SCREEN outlet, slope the vent kit at a downward pitch of 1/4”... -
Page 30: Multiple Concentric Vent Termination
MULTIPLE CONCENTRIC VENT TERMINATION 8” MIN. APPLY SEALANT When two concentric vent kits are being installed, the vent TO BOTH SIDES VENT SCREEN OF WALL - INSTALL IN hood centers shall be either less than 9.5” apart or more TERMINATION than 43.5”... -
Page 31: Vent Pipe Material
VENT PIPE MATERIAL POLYPROPYLENE VENT SYSTEMS Polypropylene vent systems do not use cement to connect Vent Pipe Pipe and fitting Applicable the pipe and elbow sections but use a push together gasket Material nomenclature Standard seal method. Do not attempt to connect polypropylene ASTM D2665 or with sealant cement. -
Page 32: Vent Pipe Length And Sizing
VENT PIPE LENGTH AND SIZING Refer to Table 6 and Table 7 for vent pipe sizing. If the installation requires a vent riser, suitable drainage must be provided to ensure condensation does not accumulate (see Figure 47). The specified maximum lengths are for each of the intake and exhaust systems and not for the combined lengths of both systems. - Page 33 PRESSURE SWITCH 2 PIPE CONC. VENT WATER HEATER VENT SIZE (INSIDE SETTINGS EQUIV. VENT LENGTH EQUIV. VENT LENGTH HEATER INPUT DIAM.) (in. W.C.) MODEL (BTU/HR) N.C. N.O. MAX. MIN. MAX. MIN. 40 gal. -1.8 7’ plus 7’ plus term. elbow 50’...
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Page 34: Vent Screens
Vent Screens VENT VENT SCREEN SIZE WARNING (INSIDE RESTRICTIVE DEBRIS DIAM.) Breathing Hazard - Carbon Monoxide Gas Failure to install the appropriate screen could result in improper heater operation with attendant risk of property damage, personal injury or death by fire or carbon monoxide poisoning. -
Page 35: Vent Pipe Installation
Vent Pipe Installation Vent Pipe Runs The following guidelines should be followed when installing 1. The exhaust vent system must not, under any the air intake and exhaust vent system: circumstances, be run downhill then run uphill thus • Venting should be as direct as possible with a minimum forming a valley. -
Page 36: Vent Pipe Preparation
VENT PIPE PREPARATION Primer: It is recommended that Tetrahydrofuran (THF) be 1. INITIAL PREPARATION used to prepare the surfaces of pipe and fittings for • Make sure the solvent cement you are planning to solvent welding. Do not use water, rags, gasoline use is designed for the specific application you are or any other substitutes for cleaning PVC or CPVC attempting. - Page 37 3. MAKING THE JOINT C. Test dry fit of the joint A. Cutting Tapered fitting sockets are designed so that Pipe must be squarely cut to allow for the proper an interfaced fit should occur when the pipe is interfacing of the pipe end and the fitting socket inserted about 1/3 to 2/3 of the way into the socket.
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Page 38: Blower Assembly Installation
BLOWER ASSEMBLY INSTALLATION 1. This power vented water heater comes with blower assembly installed. 2. After unit is set in place, make sure blower assembly is still mounted securely. Make sure there is no damage to blower. 3. Make sure there is no packing material in the inlet or discharge of the blower. -
Page 39: Connections To The Blower And Air Duct
Connections To The Blower And Air Duct Figure 44 shows the configuration for heaters direct 1. The vent piping connects into the rubber coupling connected to 2” venting. located on the top of the blower assembly. This 2” VENT 2” INLET PIPE PIPE coupling includes gear clamps to connect the venting... -
Page 40: Condensate (Exhaust)
• The restrictive screen (see Figure 38) and the air intake Analyze entire vent system to make sure that piping should be secured in place with a screw. To prevent condensate will not become trapped in a section of damage to the equipment, first position the restrictive vent pipe and therefore reduce open cross sectional screen in place, then drill a pilot hole suitable for the screw area of vent. -
Page 41: Installation Checklist
INSTALLATION CHECKLIST Note: Use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Vent Termination Water Heater Location Horizontal Centrally located with the water piping system. 12” min. above grade/snow level. Located as close to gas piping and vent pipe system ... -
Page 42: Lighting Instructions
LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before This heater is equipped with a Honeywell gas control/ attempting to operate the water heater. Make sure the thermostat and a hot-surface igniter. This control is a burner viewport is not missing or damaged. Make sure combination gas valve, thermostat and ignition controller the tank is completely filled with water before operating for use on this power vented water heater. -
Page 43: Operating The Temperature Control System
OPERATING THE TEMPERATURE CONTROL SYSTEM Install Thermostatic Mixing Valves (see Figure 6) to demand of application, to reduce the risk of scalding, regulate the temperature of the water supplied to each install Thermostatic Mixing Valves (temperature limiting point-of-use (for example, kitchen sink, bathroom sink, valves) (see Figure 6) at each point-of-use. -
Page 44: Gas Control Valve/Thermostat
GAS CONTROL VALVE/THERMOSTAT 130°F 140°F 150°F 155°F 120°F 110°F 70°F ON/OFF TEMPERATURE SWITCH SETTING DIAL Figure 48. Approximate Time to induce a 2nd Temperature Temperature and 3rd Degree burn Dial Setting °F to adult skin VERY HOT Less than 1 second About 1.5 seconds Less than 5 seconds More than 30 seconds... -
Page 45: For Your Information
FOR YOUR INFORMATION START UP CONDITIONS OPERATIONAL CONDITIONS Condensation Smelly Water Whenever the water heater is filled with cold water, some Each water heater contains at least one anode rod for condensate will form while the burner is ON. A water corrosion protection of the tank. -
Page 46: Periodic Maintenance
PERIODIC MAINTENANCE • GENERAL UPKEEP Check all vent system connections for damage or deterioration which could cause improper venting or Make it a habit to look around the heater, the vent piping, leakage of combustion products. Repair or reseal as and the hot and cold water pipes. -
Page 47: Combustion Chamber And Burner Cleaning
TEMPERATURE-PRESSURE RELIEF VALVE TEST DANGER • Burn hazard. • Hot water discharge. • Keep clear of temperature-pressure relief valve discharge. BURN It is recommended that the temperature-pressure relief valve be checked to ensure it is in operating condition at Figure 49. least once a year. -
Page 48: Draining And Flushing
4. Connect a garden hose to the drain valve and place WARNING the other end of the hose in an adequate drain, outside, or in buckets. Note that sediment in the bottom Explosion Hazard of the tank may clog the valve and prevent it from draining. -
Page 49: Anode Rod Maintenance
ANODE ROD MAINTENANCE CAUTION Property Damage Hazard • Avoid water heater damage. • Inspection and replacement of anode rod required. The anode rod is a sacrificial metal rod that helps avoid corrosion and premature failure (leaks) in the tank. The anode rod is a consumable item. -
Page 50: Leakage Checkpoints
LEAKAGE CHECKPOINTS SERVICE Leakage from other appliances, water lines, or ground seepage should also be checked. If a condition persists or you are uncertain about the operation of the water heater contact a service agency. * To check where threaded portion enters tank, insert Use this guide to check a “leaking”... -
Page 51: Reference Parts Listing
REFERENCE PARTS LISTING Replacement parts may be ordered 10 Outer Gas Door 35 Hot-Surface Igniter (see Figure 3) (see 11 Manifold Door Assembly (behind also Figure 56) through your plumber or the local outer door) (see Figure 3) (see also 36 Manifold Door Gasket (see Figure 3) distributor. - Page 52 Shown with Junction Box Cover removed for clarity. Figure 56. Figure 57. Notes: Items not supplied with the water heater. ** Caution: harness has 120 VAC during operation. *** See "Vent Pipe Installation" for more information. www.hotwater .com 100324051_2000579115 _Rev. 01...
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Page 53: Troubleshooting Guidelines
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualified service IGNITION STATE AND TIMING agent. IGNITION STATE TIMING Pre-purge 5 seconds LOCKOUTS Hot Surface Igniter Soft Lockout 10 seconds • (HSI) Warmup Occurs when a system safety device trips to break the sequence of operation. -
Page 54: System Status And Error Codes
SYSTEM STATUS AND ERROR CODES The micro-controller inside the gas control monitors the ignition sequence, temperature settings, and overall operation of the heater. If any of these parameters does not operate properly the controller will shut down the water heater, diagnose the failure and flash an error code. -
Page 55: Corrective Actions
CORRECTIVE ACTIONS See the table below for corrective actions corresponding to the Corrective Action Number in the "System Status And Error Codes" section above. If following those corrective actions does not resolve the error, refer to "Other Symptoms" table later in this manual. - Page 56 Corrective Action Corrective Action Number 1. Gas supply is turned off or gas pressure is too low. Ensure supply pressure and manifold gas pressures are within requirements. Manifold pressure is nonadjustable, if gas supply pressure proves correct and manifold pressure is off by more than 0.3” WC replace the control. 2.
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Page 57: Other Symptoms
OTHER SYMPTOMS WARNING! Because of the increased risk from scalding, if you set the water heater’s gas control knob higher than 120°F, install Thermostatic Mixing Valves (see Figure 6) at each point-of-use. Due to the increased risk of scalding, do not set the temperature of the Thermostatic Mixing Valves above 120°F. Problem Possible Cause(S) Corrective Action... -
Page 58: Notes
NOTES www.hotwater .com 100324051_2000579115 _Rev. 01... - Page 59 NOTES 100324051_2000579115 _Rev. 01 www.hotwater .com...
- Page 60 500 Tennessee Waltz Parkway, Ashland City, TN 37015 • Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com Copyright © 2020 A. O. Smith Corporation. All rights reserved.