A.O. Smith RESIDENTIAL GAS WATER HEATERS Installation And Operating Manual
Power vented gas models with hot surface ignition
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Installation and Operating Manual
RESIDENTIAL GAS WATER HEATERS
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
•
•
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1210
322151-001
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Summary of Contents for A.O. Smith RESIDENTIAL GAS WATER HEATERS
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Page 1: For Your Safety
Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS POWER VENTED GAS MODELS WITH HOT SURFACE IGNITION NOT FOR USE IN MANUFACTURED (MOBILE) HOMES • • For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER. -
Page 2: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS Polypropylene Vent Systems ....29 SAFE INSTALLATION, USE AND SERVICE Condensate....... 29 GENERAL SAFETY Exhaust Venting . -
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 www.hotwater.com... - Page 5 GENERAL SAFETY DANGER WARNING Breathing Hazard - Carbon Monoxide Gas • Install vent system in accordance with codes. • Do not operate water heater if flood damaged. • For operation above 10,100’ (3,079 m), a high altitude orifice must be installed. •...
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Page 6: Introduction
INTRODUCTION Thank You for purchasing this water heater. Properly we cannot put everything on the fi rst few pages, installed and maintained, it should give you years of trouble READ ENTIRE MANUAL BEFORE ATTEMPTING TO free service. INSTALL OR OPERATE THE WATER HEATER. The installation must conform with these Abbreviations found in this Installation and Operating instructions and local code authority having... -
Page 7: Installation Requirements For The Commonwealth Of Massachusetts
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 fi... - Page 8 INSTALLATION GRAPHIC: GAS-FIRED POTABLE WATER HEATING/SPACE HEATING SYSTEM • If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following graphic during installation and during modifications to the water supply system. TYPICAL MIXING VALVE INSTALLATION COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM EXPANSION TANK COLD WATER INLET...
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Page 9: Typical Installation
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (list referencing Figures 1-7) 1. Vent Termination Elbow with Rodent 18. **Combo Heating System Return 34. Flame Sensor Rod (see Figures 3 & Screen Inlet (Optional) 2. *Vent Pipe 19. -
Page 10: Replacement Parts And Deliming Products
Natural gas and Propane main burner with igniter assembly for 40k to 50k Btu/hr models Figure 6 Vacuum relief valve install per local codes (not supplied with heater). Figure 3 Natural gas and Propane main burner with igniter assembly for 60k to 75k Btu/hr models Figure 7 Notes:... -
Page 11: Water Piping - Mixing Valve Usage
WATER PIPING - MIXING VALVE USAGE are considered suitable for Water (Potable) Heating and Space Heating. Note: Do not use in space heating only Mixing Valves applications. Water temperature over DANGER 125°F (52°C) can cause The water supply pressure should not exceed 80 psi. If this severe burns instantly resulting in severe injury or occurs, a pressure reducing valve with a bypass should be... -
Page 12: Water Heater Operation
Some people are more likely to be permanently injured WATER HEATER OPERATION by hot water than others. These include the elderly, Figure 11 shows the water heater’s sequence of operation children, the infi rm and the physically/mentally disabled. when a call for heat is initiated. The ignition control module Table 1 (published by U.S. -
Page 13: 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 POWER VENT WIRING SCHEMATIC. Disconnect power before NOTE: REFER TO THE “INSTALLATION CHECKLIST” servicing. -
Page 14: Safety Lockouts
SAFETY LOCKOUTS This water heater has several lockout features designed to If there is a problem with the wiring of the fl ammable prevent the heater from operating in unsafe conditions. vapor sensor or the fl ammable vapor interface, the LED will fl... -
Page 15: Locating The New Water Heater
LOCATING THE NEW WATER HEATER FACTS TO CONSIDER ABOUT THE LOCATION However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used Carefully choose an indoor location for the new water in conjunction with a piped metal drain pan. These devices heater because the placement is a very important are available from some plumbing supply wholesalers consideration for the safety of the occupants in the building... -
Page 16: Clearances To Combustibles
Clearance for servicing WARNING Adequate clearance of 24” (61cm) for servicing this appliance should be considered before installation, such Fire or Explosion Hazard as changing the anodes, etc. • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. -
Page 17: Insulation Blankets
If this water heater will be used in beauty shops, barber AIR REQUIREMENTS shops, cleaning establishments, or self-service laundries For safe operation an adequate supply of fresh, with dry cleaning equipment, it is imperative that the water uncontaminated air for combustion dilution and ventilation heater or water heaters be installed so that combustion must be provided. -
Page 18: Direct Vent Appliances
method used to provide fresh air to the confi ned space and the total Btu/hr input rating of all appliances installed in the space. DIRECT VENT APPLIANCES Other appliances installed in a Direct Vent confi guration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total appliance input Btu/hr calculations used to determine the size of openings providing fresh... -
Page 19: Chemical Vapor Corrosion
Figure 19 4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum short side dimension of rectangular air ducts shall not be less than 3” (76mm) (see Figure 20). Figure 21 6. -
Page 20: Installing The New Water Heater
INSTALLING THE NEW WATER HEATER WATER PIPING Consult a Qualifi ed Installer or Service Agency. Follow manufacturer’s instructions for installation of valves. Water temperature over DANGER Before changing the factory setting on thermostat, read 125°F (52°C) can cause “Operating The Temperature Control System” section in severe burns instantly resulting in severe injury or this manual. -
Page 21: Combo Heating
COMBO HEATING 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 22: Closed Water Systems
CLOSED WATER SYSTEMS SHUT-OFF VALVE HOT-WATER Water supply systems may, because of code requirements OUTLET COLD- 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 fl ow preventers. Devices such as these cause the water system to be a closed system. -
Page 23: 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” WARNING (15cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must Explosion Hazard be allowed to discharge water in adequate quantities... -
Page 24: Temperature-Pressure Relief Valve And Pipe Insulation
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 WARNING constant relief of thermal expansion. A properly sized thermal expansion tank must be installed on all closed systems to control thermal expansion, see “Closed Water Breathing Hazard - Carbon Monoxide Gas Systems”... -
Page 25: Sediment Traps/Dirt Leg
Make sure the gas supplied is the same type listed on the excess of 1/2 psi (3.5 kPa). It should be isolated from the model rating plate. The inlet gas pressure must not exceed gas supply piping system by closing its individual manual 14 inch w. -
Page 26: Filling The Water Heater
dirt or foreign material in the gas supply line, a sediment To fi ll the water heater with water: trap (sometimes called a dirt leg) must be incorporated in 1. Close the water heater drain valve by turning handle the piping. The sediment trap must be readily accessible. to the right (clockwise). -
Page 27: Termination Clearances Sidewall Power Vent
TERMINATION CLEARANCES SIDEWALL POWER VENT R N E E C O I N S I D D E T A Vent terminal Air supply inlet Area where is not permitted F I X E S E D C L O R A B O P E F I X E... -
Page 28: Blower Assembly Installation
BLOWER ASSEMBLY INSTALLATION grounding terminal or lead on the water heater (see Figure 13; the wiring diagram). 1. This power vented water heater comes with blower g. Close the panel on the junction box. Make sure that assembly installed (see Figure 30). the access panel is secured shut. -
Page 29: Polypropylene Vent Systems
or any region that experiences hot summers. Ambient Polypropylene vent systems are designed to use specifi c conditions hotter than 110°F (43°C) require that the venting adaptors to connect into the rubber coupling on the top material be either CPVC or polypropylene. Areas that can of the blower. -
Page 30: Exhaust Venting
EXHAUST VENTING Important Notes and Warnings • This heater is certifi ed to be installed using PVC, CPVC, This heater is designed to exhaust the products of ABS or polypropylene plastic vent material. Only use combustion (fl ue gases) to the outdoors using a sealed approved material. -
Page 31: Venting Terminations And Sizing
• Venting terminations and sizing 50 and 75 gallon heaters with a rated input of 60k Btu/ hr or more are supplied with a 3”-3” rubber coupling • Refer to Figure 34 and Table 2 for vent pipe materials to attach the venting to the blower and a 3”, 45° vent and sizing. -
Page 32: Calculating Equivalent Feet
Calculating Equivalent Feet WATER HEATER VENT SIZE PRESSURE MAXIMUM EQUIVALENT MINIMUM EQUIVALENT HEATER INPUT (Inside SWITCH VENT LENGTH VENT LENGTH MODEL (Btu/hr) Diam) SETTING 40 & 50 gal. 40,000 - 0.27 in. w.c. 50 ft. (15.2m) + 7 ft. (2.1m) + 60 gal. -
Page 33: Venting Instructions
Venting instructions Note: DO NOT use solvent cement on polypropylene 1. Plan the venting layout starting at the vent termination vent systems. and work back toward the heater. Take into consideration 11. Install the properly sized rodent screen into the outlet the style and position of the vent termination, the vent elbow and secure with a small quantity of silicone pipe routing, elbows and connectors required and the... -
Page 34: Vent Pipe Connection To Blower
Different coupling installations according to vent 3” (76mm) TERMINATION sizes MIN. LENGTH MAY BE 90° ELBOW A VENT USED IN A SPECIAL VENTING CONFIGURATION 2” VENT SYSTEM WITH POSITIVE FOR 40, 50 AND PIPE VENT PRESSURE AND 60-GALLON (LO- PASSING THROUGH A 18”... -
Page 35: Blower Exhaust Direction
• Know your own qualifications or those of your CONFIGURATION 4” VENT FOR HI-INPUT PIPE contractor. The solvent welding technique of joining HEATER 3”-4” PVC and CPVC pipe is a specialized skill just as any CONNECTED TO ADAPTER other pipe fi tting technique. 4”... - Page 36 Cement: The cement should be a bodied cement of approximately 500 to 1600 centipoise viscosity containing 10-20% (by weight) virgin PVC material solvated with Tetrahydrofuran (THF). Small quantities of Dimethyl Formamide (DMF) may be included to act as a retarding agent to extend curing time.
- Page 37 D. Inspection, cleaning, priming A good joint will have suffi cient cement to make a Visually inspect the inside of the pipe and fi tting bead all the way around the outside of the fi tting hub. sockets and remove all dirt, grease or moisture The fi...
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Page 38: Installation Checklist
INSTALLATION CHECKLIST Note: Use and complete this checklist before lighting the heater. Correct any conditions that do not meet these instructions. Check Here Check Here Water Heater Location Vent Termination Centrally located with the water piping system. Horizontal Located as close to gas piping and vent pipe 12 in. -
Page 39: Lighting Instructions
LIGHTING INSTRUCTIONS Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the burner viewport is not missing or damaged. Make sure the tank is completely fi lled with water before operating the water heater. The gas control valve/thermostat has an “On/Off Switch”... -
Page 40: Operating The Temperature Control System
OPERATING THE TEMPERATURE CONTROL SYSTEM It is recommended that lower water temperatures be used area is not available, a cover should be installed over the to avoid the risk of scalding. It is further recommended, in thermostat to prevent tampering. all cases, that the water temperature be set for the lowest temperature which satisfi... -
Page 41: 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 49 Approximate Time to induce a 2nd Temperature Temperature and 3rd Degree burn Dial Setting °F (°C) to adult skin VERY HOT 155 (68) Less than 1 second 150 (65) About 1.5 seconds... -
Page 42: For Your Information
FOR YOUR INFORMATION START UP CONDITIONS Closed water systems See “Closed Water Systems” section elswhere in this Condensate manual. Whenever the water heater is fi lled with cold water, some condensate will form while the burner is ON. A water Smoke/odor heater may appear to be leaking when in fact the water is It is not uncommon to experience a small amount of... -
Page 43: Air" In Hot-Water Faucets
“AIR” IN HOT-WATER FAUCETS WARNING Explosion Hazard • Flammable hydrogen gases may be present. • Keep all ignition sources away from faucet when turning on hot water. HYDROGEN GAS: Hydrogen gas can be produced in a hot-water system that has not been used for a long period of time (generally two weeks or more). -
Page 44: Periodic Maintenance
PERIODIC MAINTENANCE GENERAL UPKEEP If after inspection of the vent system you found sooting or deterioration, something is wrong. Call the local gas utility Make it a habit to look around the heater, the vent piping, to correct the problem and clean or replace the fl ue and and the hot and cold water pipes. -
Page 45: Burner Operation And Inspection
Accessing the blower wheel through the outlet, use BURNER OPERATION AND INSPECTION the paint brush to brush off the outer edge of the Flood damage to a water heater may not be readily visible blower wheel to dislodge the dirt stuck on the blades or immediately detectable. -
Page 46: Combustion Chamber And Burner Cleaning
COMBUSTION CHAMBER AND BURNER CLEANING The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of In the event your burner or burner air openings require the anode rod dictates its replacement. Note: Artifi cially cleaning, Call your service agency to remove and clean softened water requires the anode rod to be inspected the burner and correct the problem that required the burner... -
Page 47: Installing Anode Rod
Installing Anode Rod: TEMPERATURE-PRESSURE RELIEF VALVE TEST Use Tefl on tape or an approved pipe sealant on ® threads of the new anode rod. DANGER Place the anode rod in the spud (top of the tank) and turn clockwise until the threads are hand tight. Using a •... -
Page 48: Draining And Flushing
Temperature-pressure relief valve leakage due to pressure To drain the water heater storage tank: build up in a closed system that does not have a thermal Turn “OFF” the electrical supply to the water heater. expansion tank installed is not covered under the Limited Turn “OFF”... -
Page 49: 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 * To check where threaded portion enters tank, insert operation of the water heater contact a service agency. cotton swab between jacket opening and fi... -
Page 50: Reference Parts Listing
REFERENCE PARTS LISTING Replacement parts may be ordered Gas Valve Electronic Control Module 26. Rubber Coupling (see also Figure through your plumber or the local (Honeywell) And Cover distributor. When ordering replacement 12. Drain Valve 27. Gear Clamp (see also Figure 62) parts, always have the following 13. - Page 51 Natural gas and Propane main burner with igniter assembly for 40k to 50k Btu/hr models Flare Nut** Figure 62 Notes: * Natural gas models have Right-hand thread, Propane models have Left-hand thread. ** For Natural gas models the Flare Nut has Right- Figure 59 hand thread.
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Page 52: Troubleshooting Guidelines
TROUBLESHOOTING GUIDELINES These guidelines should be utilized by a qualifi ed service agent. PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION Air inlets blocked Unblock inlet air openings BURNER FLAME Insuffi cient secondary air Provide ventilation to water heater TOO HIGH Orifi ce too large Replace with correct orifi... - Page 53 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION Filling the new water heater for the fi rst Normal operation: the condensation time should disappear after heater warms up M o i s t u r e f r o m t h e p r o d u c t s o f Normal operation: the condensation CONDENSATION combustion...
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Page 54: Resetting The Heater Control
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION 1. Air pressure switch not closing due to 1. Determine cause of insuffi cient insuffi cient draft – check for: draft. Check draft with manometer at a. Vent piping blocked pressure switch b. Piping length too long a. -
Page 55: Ignition State And Timing
IGNITION STATE AND TIMING SYSTEM STATUS AND ERROR CODES The micro-controller inside the gas control monitors the IGNITION STATE TIMING fl ammable vapor safety features, the ignition sequence, 5 seconds (NG models) temperature settings and overall operation of the heater. Pre-purge 15 seconds (LP models) If any of these parameters does not operate properly the... - Page 56 This page intentionally left blank. May be used for notes or to record other installation information. www.hotwater.com...
- Page 57 This page intentionally left blank. May be used for notes or to record other installation information. www.hotwater.com...
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Page 58: Limited Warranty
LIMITED WARRANTY RESIDENTIAL GAS LIMITED WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL • fi lled with potable water, free to circulate at all times and OWNER ONLY, in accordance with the warranty terms and with the tank free of damaging water sediment or scale conditions specifi... - Page 59 SERVICE AND LABOR RESPONSIBILITY PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION UNDER THIS LIMITED WARRANTY, THE WARRANTOR DATE ARE REQUIRED TO SUPPORT WARRANTY WILL PROVIDE ONLY A REPLACEMENT WATER HEATER CLAIM FROM ORIGINAL OWNER. THIS FORM DOES OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR NOT CONSTITUTE PROOF-OF-PURCHASE OR PROOF- ALL OTHER COSTS.
- 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 © 2012 A. O. Smith Corporation. All rights reserved.