A.O. Smith DIRECT VENTED GAS MODELS Installation And Operating Manual
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A.O. Smith DIRECT VENTED GAS MODELS Installation And Operating Manual

A.O. Smith DIRECT VENTED GAS MODELS Installation And Operating Manual

Residential gas water heaters
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Installation and Operating Manual
RESIDENTIAL GAS WATER HEATERS
DIRECT VENTED GAS MODELS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
www.hotwater.com
•
•

For Your Safety

AN ODO RANT 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.
1404
326940-001

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Summary of Contents for A.O. Smith DIRECT VENTED GAS MODELS

  • Page 1: For Your Safety

    Installation and Operating Manual RESIDENTIAL GAS WATER HEATERS DIRECT VENTED GAS MODELS NOT FOR USE IN MANUFACTURED (MOBILE) HOMES www.hotwater.com • • For Your Safety AN ODO RANT 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE ... 3 LIGHTING INSTRUCTIONS..... . . 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 Fire or Explosion Hazard • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this water heater, the vent termination hood or any other appliance. • Avoid all ignition sources if you smell gas. •...
  • Page 5 GENERAL SAFETY DANGER FLAMMBLE Flammable Vapors Vapors from flammable Water heater has a main liquids may explode and burner and pilot. While catch fire causing death or operating, the pilot flame: severe burns. 1. is in continuous operation Do not use or store 2.

  • Page 6: Introduction

    INTRODUCTION Thank You for purchasing this water heater. Properly also contains warnings throughout the manual that installed and maintained, it should give you years of trouble you must read and be aware of. All warnings and free service. instructions are essential to proper operation of the This water heater is suitable for potable water heating water heater and your safety.

  • 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...

  • Page 9: Typical Installation

    TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5) 1 Vent Termination Hood 16 *Sediment Trap 32 Gas Manifold (see Figure 3 & 2 Wall Plate 17 *Ground Joint Union (gas Figure 4) 3 ***Vent Pipe connection) 33 Manifold Door Gasket (see Figure 3 4 Cold Water Inlet Nipple/Diptube...

  • Page 10: Replacement Parts And Deliming Products

    Vacuum relief valve install per local codes (not supplied with heater). Figure 5 Notes: Items not supplied with the water heater. ** The side recirculation loop connections may not be used as the primary water inlet and outlet connections. See “Combo Heating Inlet And Outlet Side Taps” below.

  • Page 11: Locating The New Water Heater

    LOCATING THE NEW WATER HEATER • FACTS TO CONSIDER ABOUT THE LOCATION Water supply shut-off devices that activate based on the water pressure differential between the cold water Carefully choose an indoor location for the new water and hot water pipes connected to the water heater. heater because the placement is a very important •...

  • Page 12: Air Requirements

    AIR REQUIREMENTS Floors With Carpeting This water heater must not be installed directly on For safe operation an adequate supply of fresh, carpeting. Carpeting must be protected by a metal or uncontaminated air must be provided for combustion. wood panel beneath the appliance extending beyond This gas-fi...

  • Page 13: Storage Of Flammable Liquids

    The water heater must be located and/or protected so it WARNING is not subject to physical damage by a moving vehicle. Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly fl ammable in many cases, will also react to form corrosive hydrochloric acid when exposed to Flammable Vapors the combustion products of the water heater.

  • Page 14: Water Piping

    WATER PIPING Water temperature over DANGER 125°F can cause severe Water Pressure burns instantly resulting in The water supply pressure should not exceed 80 psi. If this severe injury or death. occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line.

  • Page 15: Installing The New Water Heater

    INSTALLING THE NEW WATER HEATER WATER PIPING INSTALLATION SHUT-OFF HOT WATER VALVE Note: Water piping and vent piping occupy the space OUTLET above the water heater. Plan the water piping to ensure COLD UNION it does not cause interference with the vent piping (see WATER INLET “Venting”).

  • Page 16: Temperature-Pressure Relief Valve

    A properly-sized and charged thermal expansion tank must designated opening nor plugged. The T&P valve must be be installed on all closed systems to control the harmful installed directly into the fi tting of the water heater designed effects of thermal expansion. Contact a plumbing service for the relief valve.

  • Page 17: Temperature-Pressure Relief Valve And

    The T&P valve must be manually operated at least once 1. Locate the hot water (outlet) and cold water (inlet) a year. Caution should be taken to ensure pipes to the water heater. 1. no one is in front of or around the outlet of the 2.

  • Page 18: Space Heating And Potable Water Systems

    SPACE HEATING AND POTABLE WATER SYSTEMS This appliance has been design certifi ed as complying with American National Standard/CSA Standard for water heaters and are considered suitable for Water (Potable) Heating and Space Heating. Note: This water heater may be used in combination potable water/space heating system.

  • Page 19: 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 20: Gas Piping

    GAS PIPING There must be: • A readily accessible manual shut-off valve in the gas supply line serving the water heater, and WARNING • A sediment trap ahead of gas control valve/thermostat to help prevent dirt and foreign materials from entering Fire and Explosion Hazard the gas control valve/thermostat.

  • Page 21: Sediment Trap

    HIGH ALTITUDE INSTALLATIONS CERTIFIED GAS GROUND SUPPLY FLEX PIPE Installations above 7,700’ . require replacement of the JOINT (PROPERLY SIZED UNION FOR THE HEATER burner orifi ce in accordance with the current edition of (OPTIONAL) INPUT RATE) the “National Fuel Gas Code” (ANSI Z223.1/NFPA 54). Failure to replace the orifi...

  • Page 22: Venting

    VENTING WARNING This direct vent water heater uses a sealed venting system to supply fresh combustion air to the heater and Breathing Hazard - Carbon Monoxide Gas to exhaust the products of combustion (fl ue gases) to the • Install vent system In accordance with codes. outdoors.

  • Page 23: Dv Termination Safety Cover

    EXHAUST FRESH GAS OUT COMBUSTION AIR IN Figure 18 VENT CONNECTIONS After the location for the vent terminal has been selected as outlined in Figure 6 & Figure 15, use the following illustrations for installation: LOCATING CLEARANCE HOLE FOR VENT SCREW Cut a clearance hole, approximately 7”...

  • Page 24: Vent Assembly

    VENT ASSEMBLY junction of the vent terminal base plate and the exterior wall with exterior type sealant (not included). Slide the trim The vent piping and the vent termination hood are to be plate (inside) over the outer corrugated tube and fasten the connected as shown in Figure 20.

  • Page 25: Vent Connection To The Water Heater

    SMOOTH, OUTER EASY CURVE CORRUGATED PIPE INNER CORRUGATED PIPE APPLY SILICONE TO AIRBOX BEFORE RESTRICTER ATTACHING FLUE TUBE PLATE PIPING REDUCER GEAR CLAMP APPLY SECURE SILICONE WITH A SHEET METAL SCREW Figure 23 Figure 25 VENT CONNECTION TO THE WATER HEATER OFFSET VENT ARRANGEMENT Bend both the corrugated pipes toward the fl...
  • Page 26 Low Vent installation High Vent installation 12” MIN. BELOW ABOVE 17” SOFFIT ANTICIPATED MIN. SNOW LEVEL OR 12” ABOVE GRADE 72” MAX. Figure 28 DIM. 4038 5040 5047 80” MAX. 9” MIN. 63.63” 73.00” 74.00” (RECOMMENDED) 60.75 69.50 70.50 (MINIMUM) 14.25”...

  • Page 27: 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 Hood Water Heater Location  Securely fastened to exterior wall.  Centrally located with the water piping system. ...

  • Page 28: Lighting Instructions

    LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A.

  • Page 29: Temperature Regulation

    TEMPERATURE REGULATION TEMPERATURE REGULATION Important: Adjusting the thermostat past the 120°F mark on the temperature dial will increase the risk of scald injury. Hot water can produce fi rst degree burns within: Time for Permanent Water Time for 1st Burns 2nd & 3rd Temperature Degree Burns Degree (Most...

  • Page 30: For Your Information

    FOR YOUR INFORMATION EXTERNAL DAMAGE Smoke/Odo r It is not uncommon to experience a small amount of smoke Do not operate the water heater until it has been fully and odo r during the initial start-up. This is due to burning off checked out by a qualifi...

  • Page 31: Strange Sounds

    STRANGE SOUNDS “Air” In Hot Water Faucets Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not necessarily represent harmful or dangerous conditions. Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal.

  • Page 32: Maintenance

    MAINTENANCE FOR YOUR SAFETY AND SATISFACTORY OPERATION, Be sure the vent piping is properly connected to prevent IT IS RECOMMENDED THAT THIS HEATER BE escape of dangerous fl ue gasses which could cause CHECKED ONCE A YEAR BY A COMPETENT SERVICE deadly asphyxiation.

  • Page 33: Burner Flames

    BURNER FLAMES Replacing The Gas Control Valve/Thermostat: To replace the gas control valve/thermostat, reassemble Inspect the burner flames through the viewport and in reverse order. When replacing the gas control valve/ compare them to the drawings in Figure 32. A properly thermostat, thread a 4”...

  • Page 34: Removing The Burner From The Manifold/Burner

    free the manifold tube and pilot tube. REPLACING THE PILOT/THERMOPILE ASSEMBLY 7. Remove the screws (1/4” nut driver) securing the 1. Remove the manifold door assembly as described in manifold/burner assembly to the combustion chamber “Removing The Manifold/Burner Assembly” section. (Figure 34).

  • Page 35: Replacing The Manifold/Burner Assembly

    8. Using the pilot screw removed earlier, attach the new Important: Do not operate the water heater if the door pilot/thermopile assembly. Reattach the burner to the gasket does not create a seal between the manifold door manifold using the screws removed earlier. and the combustion chamber.

  • Page 36: Piezoelectric Igniter System

    PIEZOELECTRIC IGNITER SYSTEM The piezoelectric igniter system consists of the igniter button, electrode, and wire. The pilot is ignited by an electric spark generated when the igniter button is pressed (see Figure 39). THERMOPILE PILOT Figure 40 PILOT/ THERMOPILE If the Temperature-Pressure Relief Valve on the water BRACKET ELECTRODE heater weeps or discharges periodically, it may be due to...

  • Page 37: To Refi Ll The Water Heater Storage Tank

    To Refi ll The Water Heater Storage Tank 7. Check for leaks. Repair as needed. 1. Close the water heater drain valve. 8. Follow the lighting instructions on the label or see 2. Remove the drain hose. “Lighting Instructions” to restart the water heater. 3.

  • Page 38: To Remove The Anode Rod

    Note: This rod may reduce but not eliminate water odo r To Install The Anode Rod: problems. The water supply system may require special 1. Use Tefl on tape or an approved pipe sealant on ® fi ltration equipment from a water conditioning company to threads of the new anode rod.

  • Page 39: Leakage Checkpoints

    LEAKAGE CHECKPOINTS • SERVICE * To check where threaded portion enters tank, insert cotton swab between jacket opening and fi tting. If cotton If a condition persists or you are uncertain about the is wet, follow the draining instructions in this manual, operation of the water heater contact a service agency.

  • Page 40: Reference Parts Listing

    REFERENCE PARTS LISTING Replacement parts may be ordered 15 Flexible Manifold Tube (see 35 Two Piece Grommet With Clip (see through your plumber or the local Figure 3 & Figure 4) (see also Figure 3 & Figure 4) (see also distributor.
  • Page 41 Natural gas and Propane (LP) main burner with igniter assembly for 47k Btu/hr models † Flare † Flare †† †† Natural gas and Propane (LP) main burner with igniter assembly for 38k to 42k Btu/hr models Figure 47 Figure 48 Notes: †...

  • Page 42: Troubleshooting Guidelines

    TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE(S) CORRECTION 1. Pilot not lit 1. Light pilot 2. Thermostat set too low 2. Turn temp. dial to desired temperature 3. No gas 3. Check with gas utility company BURNER WILL NOT 4. Dirt in the gas lines 4.
  • Page 43 PROBLEM POSSIBLE CAUSE(S) CORRECTION 1. Thermostat set too low 1. Turn temperature dial to desired setting 2. Sediment or lime in tank 2. Drain/flush-provide water treatment if 3. Water heater too small needed 4. Wrong piping connections 3. Install adequate size heater 5.
  • Page 44 STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES (LED NOT LIT) Pilot light is not lit or Turn Gas Control Valve/Thermostat knob to thermopile has not yet reached “OFF”. Wait 10 minutes, then attempt to relight normal operating temperature.
  • Page 45 LED STATUS PROBLEM CORRECTIVE ACTION 4 FLASHES The Gas Control Valve’s Relight pilot and verify 4 flashes. If 4 flashes are temperature sensor has observed, turn Gas Control Valve/Thermostat detected that the water knob to “OFF”. Turn Main Gas Supply “OFF.” temperature was too high.

  • Page 46: Notes

    NOTES www. hotwater .com...
  • Page 47 NOTES www. hotwater .com...
  • Page 48 500 Tennessee Waltz Parkway, Ashland City, TN 37015 Phone: 800-527-1953 • Fax: 800-644-9306 www.hotwater.com...

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