State Industries Water Heater Green Choice User Manual
Instruction Manual  
RESIDENTIAL DIRECT VENT GAS WATER HEATERS  
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES  
GAMA certification applies to  
all residential gas water  
heaters with capacities of 20  
to 100 gallons with input rating  
of 75,000 BTU/Hr. or less.  
• For Your Safety •  
ANODORANTISADDEDTOTHEGASUSED  
BYTHISWATERHEATER.  
ALLTECHNICALAND WARRANTY QUESTIONS: SHOULD BE DIRECTEDTOTHE LOCALDEALER FROM WHOM THE WATER HEATER WAS  
PURCHASED.IFYOUAREUNSUCCESSFUL,PLEASEWRITETOTHECOMPANYLISTEDONTHERATINGPLATEONTHEWATERHEATER.  
KEEPTHIS MANUALIN THE POCKET ON HEATER FOR FUTURE REFERENCE  
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.  
PRINTED 1005  
183774-001  
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GENERAL SAFETY  
3
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TABLE OF CONTENTS  
SAFE INSTALLATION, USEAND SERVICE ...............................2  
Start Up Conditions ........................................................ 31  
Condensate .................................................................... 32  
Smoke/Odor .................................................................... 32  
Thermal Expansion ......................................................... 32  
Strange Sounds.............................................................. 32  
OPERATIONALCONDITIONS .................................................. 32  
Smelly Water .................................................................. 32  
“Air” in Hot Water Faucets ............................................. 32  
High Temperature Shut Off System ............................... 32  
PERIODICMAINTENANCE ....................................................... 33  
Venting System Inspection ............................................ 33  
Burner Inspection ........................................................... 33  
Burner Cleaning.............................................................. 33  
Housekeeping ................................................................ 34  
Anode Rod Inspection .................................................... 34  
Temperature-Pressure Relief Valve Operation.............. 34  
Draining .......................................................................... 34  
Drain Valve Washer Replacement ................................. 35  
LEAKAGECHECKPOINTS ...................................................... 35  
REPAIRPARTS ....................................................................... 36  
TROUBLESHOOTING .............................................................. 40  
NOTES .............................................................................. 41-43  
WARRANTY ..................................................................... Insert  
GENERAL SAFETY .................................................................. 3  
TABLE OF CONTENTS .............................................................. 4  
INTRODUCTION ........................................................................ 4  
Preparing for the New Installation ...................................4  
TYPICALINSTALLATION ...................................................... 5-6  
LOCATINGTHE NEW WATER HEATER ..................................... 7  
Facts to Consider About Location ............................... 7-8  
Venting Clearances .......................................................... 8  
Optional Wire Grill ............................................................ 9  
Flue Extensions ................................................................9  
Vertical Height (Extension Kit) ....................................... 10  
Horizontal (Extension Kit) .............................................. 10  
Vent Installations ....................................................... 11-24  
INSTALLINGTHE NEW WATER HEATER ................................ 25  
Water Piping ................................................................... 25  
Temperature-Pressure Relief Valve............................... 26  
Filling the Water Heater .................................................. 27  
Gas Piping ................................................................ 27-28  
Sediment Traps .............................................................. 28  
Installation Checklist....................................................... 29  
LIGHTING & OPERATING LABEL ............................................ 30  
TEMPERATUREREGULATION ................................................ 31  
FORYOUR INFORMATION ..................................................... 31  
INTRODUCTION  
Thank You for purchasing this water heater. Properly installed and  
maintained, it should give you years of trouble free service.  
2. The installation must conform with these instructions and the local  
code authority having jurisdiction. In the absence of local codes,  
installations shall comply with the National Fuel Gas Code ANSI  
Z223.1/NFPA54. This publication is available from the Canadian  
StandardsAssociation, 8501 East Pleasant Valley Rd., Cleveland  
Ohio 44131, or The National Fire Protection Association, 1  
Batterymarch Park, Quincy, MA02269.  
Abbreviations Found In This Instruction Manual:  
• CSA- Canadian StandardsAssociation  
• ANSI -American National Standards Institute  
• NFPA- National Fire ProtectionAssociation  
• ASME -American Society of Mechanical Engineers  
• GAMA- GasAppliance Manufacturer’sAssociation  
3. If after reading this manual you have any questions or do not  
understand any portion of the instructions, call the local gas utility or  
the manufacturer whose name appears on the rating plate.  
This gas-fired water heater is design certified by CSAINTERNATIONAL  
underAmerican National Standard/CSAStandard for Gas Water Heaters  
ANSI Z21.10.1 • CSA 4.1 (current edition).  
4. Carefully plan the place where you are going to put the water heater.  
Correct combustion, vent action and vent pipe installation are very  
important in preventing death from possible carbon monoxide  
poisoning and fires, see Figures 1 and 2.  
This gas-fired water heater is equipped with a piezo-electric spark  
device used for pilot burner ignition, and complies with the Standard for  
Manually-Operated Piezo-Electric Spark Gas Ignition Systems and  
Components, ANSI Z21.77 • CGA6.23.  
Examine the location to ensure the water heater complies with the  
“Locating the New Water Heater” section in this manual.  
PREPARING FOR THE INSTALLATION  
5. For California installation this water heater must be braced, anchored  
or strapped to avoid falling or moving during an earthquake. See  
instructions for correct installation procedures. Instructions may be  
obtained from California Office of the StateArchitect, 400 P Street,  
Sacramento, CA 95814.  
1. Read the “General Safety” section, page 3 of this manual first and  
then the entire manual carefully. If you don’t follow the safety rules,  
the water heater will not operate properly. It could cause DEATH,  
SERIOUSBODILYINJURYAND/ORPROPERTYDAMAGE.  
This manual contains instructions for the installation, operation, and  
maintenance of the gas-fired water heater. It also contains warnings  
throughout the manual that you must read and be aware of. All  
warnings and all instructions are essential to the proper operation  
of the water heater and your safety. Since we cannot put everything  
on the first few pages, READ THE ENTIRE MANUAL BEFORE  
ATTEMPTING TO INSTALLOROPERATE THE WATER HEATER.  
6. Massachusetts Code requires this water heater to be installed in  
accordance with Massachusetts 248-CMR 2.00: State Plumbing Code  
and 248-CMR 5.00.  
7. Complies with SCAQMD rule #1121 and districts having equivalent  
NOx requirements.  
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TYPICAL INSTALLATION  
GET TO KNOW YOUR WATER HEATER - GAS MODELS  
A
B
C
D
E
F
Vent Assembly  
Flue Outlet  
Anode  
Hot Water Outlet  
Outlet  
Insulation  
I
J
Ground Joint Union  
Drip Leg (Sediment Trap)  
Inner Door  
Outer Doors with Gaskets  
Union  
P
Q
R
S
T
U
V
W
X
Y
Inlet Dip Tube  
Temperature-Pressure Relief Valve  
Rating Plate  
Flue Baffle  
Thermostat  
Drain Valve  
Pilot and Main Burner  
Flue  
Drain Pan  
Piezo Ignitor  
K
L
M
N
O
Inlet Water Shut-off Valve  
Cold Water Inlet  
G
H
Gas Supply  
Manual Gas Shut-off Valve  
Thermostat Shield (optional)  
(V) PILOT & MAIN BURNER  
(T) THERMOSTAT  
* ALL PIPING MATERIALS TO BE  
SUPPLIED BY CUSTOMERS.  
FIGURE1.  
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TYPICAL INSTALLATION  
MIXING VALVE USAGE  
FIGURE2.  
HOT WATER CAN SCALD:  
This appliance has been design certifiedascomplyingwithAmericanNational  
Standard/CSAStandard for water heaters and is considered suitable for:  
Water heaters are intended to produce hot water. Water heated  
to a temperature which will satisfy space heating, clothes  
washing, dish washing, and other sanitizing needs can scald  
and permanently injure you upon contact. Some people are  
more likely to be permanently injured by hot water than others.  
These include the elderly, children, the infirm or physically/  
mentally handicapped. If anyone using hot water in your home  
fits into one of these groups or if there is a local code or state  
law requiring a certain temperature water at the hot water tap,  
then you must take special precautions. In addition to using  
the lowest possible temperature setting that satisfies your  
hot water needs, a means such as a *Mixing Valve shall be  
used at the hot water taps used by these people or at the  
water heater. Mixing valves are available at plumbing supply  
or hardware stores. Consult a Qualified Installer or Service  
Agency. Follow mixing valve manufacturer’s instructions for  
installation of the valves. Before changing the factory setting  
on the thermostat, read the “Temperature Regulation” section  
in this manual, see Figures 109 and 110.  
Water (Potable) Heating: All models are “considered suitable for  
water (potable) heating.”  
Water (Potable) Heating and Space Heating: Certain models are  
“considered suitable for water (potable) heating and space heating.”  
Refer to the model and rating plate of the water heater.  
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LOCATING THE NEW WATER HEATER  
FACTS TO CONSIDER ABOUT THE LOCATION  
Carefully choose an indoor location for the new water heater, because  
the placement is a very important consideration for the safety of the  
occupants in the building and for the most economical use of the  
appliance. This water heater is not for use in manufactured  
(mobile) homes or outdoor installation.  
Whether replacing an old water heater or putting the water heater in a  
new location, the following critical points must be observed:  
1. The location selected should be indoors, as close as practical to the  
outside wall through which the water heater vent is going to be  
installed, and as centralized with the water piping system as possible.  
The water heater, as all water heaters, will eventually leak. Do not  
install without adequate drainage provisions where water flow will  
cause damage.  
2. Selected location must provide adequate clearances for servicing  
and proper operation of the water heater.  
INSTALLATIONSINAREASWHEREFLAMMABLELIQUIDS(VAPORS)  
ARELIKELYTOBEPRESENTORSTORED(GARAGES,STORAGEAND  
UTILITYAREAS, ETC.): Flammable liquids (such as gasoline, solvents,  
propane [LP or butane, etc.] and other substances such as adhesives,  
etc.) emit flammable vapors which can be ignited by a gas water heater’s  
pilot light or main burner. The resulting flashback and fire can cause  
death or serious burns to anyone in the area, as well as property damage.  
If installation in such areas is your only option, then the installation must  
be accomplished in a way that the pilot flame and main burner flame are  
elevated from the floor at least 18 inches (45.7 cm). While this may  
reduce the chances of flammable vapors, from a floor spill being ignited,  
gasoline and other flammable substances should never be stored or  
used in the same room or area containing a gas water heater or other  
open flame or spark producing appliance. NOTE: Flammable vapors may  
be drawn by air currents from other areas of the structure to the appliance.  
Installation of the water heater must be accomplished in such a manner  
that if the tank or any connections should leak, the flow will not cause  
damage to the structure. For this reason, it is not advisable to install the  
water heater in an attic or upper floor. When such locations cannot be  
avoided, a suitable drain pan should be installed under the water heater.  
Drain pans are available at your local hardware store. Such a drain  
pan must have a minimum length and width of at least 2 inches (5.1 cm)  
greater that the water heater dimensions and must be piped to an  
adequate drain. Drain pan depth must allow for access to the outer  
doors for servicing the pilot and burner.  
Water heater life depends upon water quality, water pressure and  
the environment in which the water heater is installed. Water heaters  
are sometimes installed in locations where leakage may result in  
property damage, even with the use of a drain pan piped to a drain.  
However, unanticipated damage can be reduced or prevented by a  
leak detector or water shut-off device used in conjunction with a  
piped drain pan. These devices are available from some plumbing  
supply wholesalers and retailers, and detect and react to leakage in  
various ways:  
• Sensors mounted in the drain pan that trigger an alarm or turn off the  
incoming water to the water heater when leakage is detected.  
• Sensors mounted in the drain pan that turn off the water supply to  
the entire home when water is detected in the drain pan.  
• Water supply shut-off devices that activate based on the water  
pressure differential between the cold water and hot water pipes  
connected to the water heater.  
• Devices that will turn off the gas supply to a gas water heater while  
at the same time shutting off its water supply.  
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No vent damper, whether it is operated thermally or otherwise, is to  
be installed on this direct vent water heater. Alteration of any part  
of the factory-furnished vent assembly could result in improper  
operation due to restriction of flue gases and may cause carbon  
monoxide poisoning.  
Also, the water heater must be located and/or protected so it is not  
subject to physical damage by a moving vehicle.  
This water heater must not be installed directly on carpeting. Carpeting  
must be protected by metal or wood panel beneath the appliance  
extending beyond the full width and depth of the appliance by  
at least 3 inches (7.62 cm) in any direction, or if the appliance  
is installed in an alcove or closet, the entire floor must be  
covered by the panel. Failure to heed this warning may result in a  
fire hazard.  
Venting Clearances  
Minimum clearances between the water heater and combustible and  
noncombustible construction are 0 inch at the sides, 0 inches from  
”
”
back, 4 (10.2 cm) from front of jacket to closet door and 3 (7.6 cm)  
from top of jacket to combustible and noncombustible material. Minimum  
vent clearance: 0 inches.  
When determining the installation location for a direct vent water heater,  
snow accumulation and drifting should be considered in areas where  
applicable. See Figures 4 through 8 and items below.  
• 18” minimum in all directions from any obstruction that may interfere.  
• 18” minimum from the ground and 12 “ from ceiling overhangs.  
• The direct vent terminal shall terminate at least 3 feet above any  
forced air inlet located within 10 feet. See Figure 5.  
•
9” minimum horizontally from or above any door, window or gravity  
air inlet into the building (50,000 BtuH input or less.)  
• 12” minimum horizontally from or above any door, window or gravity  
air inlet into the building (over 50,000 BtuH input).  
• 12” minimum below any door, window or gravity air inlet into the  
building (50,000 BtuH input or less).  
• 18” minimum below any door, window or gravity air inlet into the  
building (over 50,000 BtuH input).  
• 18” minimum from other gravity or natural appliance outlet vents  
when directly above or 135° to either side of center line. See Figure 6.  
• 36” minimum from any outlet vents when directly below or 45° to  
either side of center line. See Figure 7.  
FIGURE3.  
• 36” minimum in all directions from any other forced air appliance  
outlet vent. See Figure 7.  
NOTE: Provide 24 inches (61 cm) front clearance for servicing and  
a adequate clearance between the jacket top and ceiling for servicing  
the flue area.  
• The location selection must provide clearances for servicing and  
proper operation of the water heater. See Figure 8.  
• Vent termination must not be within 4 feet of any items such as gas  
meters, gas valves or other gas regulating equipment.  
Combustion Air and Ventilation  
• Unless specified at time of ordering, a standard extension  
kit (No. 9000687) is individually packaged and shipped with  
the water heater.  
FIGURE 4.  
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Some local codes may require a vent cap cover. Figure 9 shows the  
optional wire vent cap protector available from the water heater  
manufacturer.  
A wire mesh chain link fence (see Figure 9) may be used instead of the  
factory cover. Care should be taken to maintain adequate ventilation  
around the vent cap. If a chain link fence is installed, it must not be used  
as a storage area for items that may block proper ventilation.  
FIGURE 5.  
FIGURE9.  
Flue Extensions  
There are three optional extension kits available.Any combination of  
the three kits can be chosen; however, only one kit can be used  
vertically and/or horizontally, see Figures 10 & 11.  
Unless otherwise specified at the time of ordering, a standard exten-  
sion kit (9000687) is individually packaged and shipped within the water  
heater carton.  
FIGURE10.  
FIGURE 8.  
Optional Wire Grill  
When the water heater vent cap is low enough to be touched  
accidentally, or is accessible to small children, installation of a  
protective vent cover is recommended. See Figure 9.  
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BTU’s  
DIMENSION “F” (IN CENTIMETERS)  
Vertical Height (Extension Kit)  
*Gal. in 1000’s 9000687  
9001246  
MIN. MAX.  
183 196  
205 218  
183 196  
214 228  
215 227  
9001247  
9001248  
MIN.  
Cap. Nat/L.P  
40 36/36  
50 38/38  
40 40/40  
50 48/44  
STD.  
162  
183  
162  
193  
MIN.  
MAX.  
224  
247  
224  
256  
255  
MAX.  
279  
302  
279  
312  
311  
196  
219  
196  
228  
227  
224  
247  
224  
256  
255  
75 55 NAT. 194  
*Check the model and rating plate attached to the water heater for  
specific model number and other detailed information.  
Horizontal (Extension Kit)  
To determine the horizontal length and extension kit needed, simply  
plug the dimensions “D” and “G” into the equation below. The answer  
“E” should then be located in Chart #2. The size range in which “E”  
dimension falls indicates the kit that should be used horizontally to  
obtain the desired length.  
It is simple to determine which kit is needed for vertical height. Take the  
total height (to the top of the flue) required and comparing that to “F  
dimension” in the chart #1, it can be determined which kit needs to be  
used vertically.  
“D” = The wall thickness  
“G” = The distance wanted between the edge of the water heater  
and the inside edge of the wall  
“E” = The distance the extension kit must be able to extend  
The Equation: D + G = E  
FIGURE 11.  
FIGURE13.  
CHART #2.  
DIMENSION “E” (IN INCHES)  
40-50 GAL.  
75 GAL.  
VENT KITS  
MIN  
MAX  
MIN  
MAX  
9000687-Std.  
9001246  
9001247  
3 1/2  
10  
15 1/2  
26 1/2  
10  
7/8  
7 3/8  
15 1/2  
26 1/2  
48  
7 3/8  
12 7/8  
23 7/8  
12 7/8  
23 7/8  
45 3/8  
9001248  
DIMENSION “E” (IN CENTIMETERS)  
40-50 GAL. 75 GAL.  
VENT KITS  
9000687-Std.  
9001246  
MIN  
MAX  
MIN  
2.2 cm  
18.7 cm  
32.7 cm  
MAX  
8.9 cm  
25.4 cm  
39.4 cm  
25.4 cm  
29.4 cm  
67.3 cm  
18.7 cm  
32.7 cm  
60.6 cm  
FIGURE 12.  
9001247  
9001248  
67.3 cm  
121.9 cm  
60.6 cm  
115.3 cm  
CHART #1.  
BTU’s  
DIMENSION “F” (IN INCHES)  
9001246 9001247  
MIN. MAX. MIN.  
BTU’s  
*Gal. in 1000’s  
Cap. Nat.  
DIMENSION “A, B,C” (INCHES/CENTIMETERS)  
*Gal. in 1000’s 9000687  
9001248  
Cap. Nat/L.P  
40 36/36  
50 38/38  
40 40/40  
50 48/44  
STD.  
MAX.  
MIN.  
MAX.  
A
B
C
63 3/4 72  
72  
63 3/4 72  
76 84 1/4 89 3/4 89 3/4 100 3/4 100 3/4 122 3/4  
77  
77  
88  
88  
110  
40 36/36 48 3/4” 124 cm 41 3/4” 106 cm  
50 38/38 57 1/2” 146 cm 50 1/2” 128 cm  
40 40/40 48 3/4” 124 cm 41 3/4” 106 cm  
50 48/44  
75 55 NAT.  
21” 53 cm  
21” 53 cm  
21” 53 cm  
21” 53 cm  
80 3/4 86 86 1/4 97 1/4 97 1/4 118 3/4  
77 77 88 88 110  
61”  
63”  
155 cm  
54”  
137 cm  
75 55 NAT. 76 1/4 84 1/2 89 1/2 89 1/2 100 1/2 100 1/2 122 1/2  
160 cm 54 3/4” 139 cm 26 1/4” 67 cm  
10  
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ALL INSTALLATIONS  
Standard Vent Kit - Installation #1  
For ease of assembly the installation of the various kit combinations  
has been broken into individual sections. The two steps below are  
common to all installations. Once these have been performed, you  
need only to refer to the type installation that pertains to you.  
The opening through the wall should be cut at this time. If this has not  
been done, refer to “Cutting The Opening Through The Outside Wall ”  
section.  
Installation Using Vent Kits:  
1. Standard Vent Kit 9000687 ............................................. Page 11  
2. Optional Vertical Vent Kit................................................. Page 14  
with Standard Vent Kit  
3. Optional Horizontal Vent Kit ............................................. Page 17  
4. Optional Horizontal.......................................................... Page 19  
and Vertical Vent Kits  
Cutting The Opening Through The Outside Wall  
After thoroughly reading the “Locating the New Water Heater”  
section of this manual and you have chosen a suitable water  
heater installation site, use Chart #1 to determine dimensions for  
the wall opening.  
1. Lock the elbow to the straight 3” (76 mm) flue pipe. Set this assembly  
in place on the end of the water heater’s flue collar.  
Cut a 6 1/4” (159 mm) diameter hole completely through the outside  
wall.  
FIGURE15.  
2. Mark the flue collar at the slots in the elbow. Using a #22 drill bit, drill  
holes into the flue collar at the two slots and secure the elbow to the  
flue collar using the screws provided.  
FIGURE14.  
NOTE: Make sure elbow is properly aligned to opening in the  
outside wall.  
Water Heater Attitude  
There is a certain amount of variance with regard to the direction the  
water heater faces.  
Standing in front of the water heater (gas control facing you), set the  
3” (76 mm) diameter elbow (slotted end) on the flue. This will give you  
a better understanding of the relation of the vent assembly to the  
opening in the wall and more importantly any possibility of interference  
of venting and water piping.  
The direction of the water heater can now be made. Also consider the  
gas control valve to insure installation, lighting and maintenance  
accessibility are retained.  
FIGURE16.  
3. Using the tube of sealant supplied, run an ample amount around the  
oval flare of the jacket.  
NOTE: Supplementary installation instructions are applicable only if  
this direct vent water heater is provided with the alternate brown  
porcelain-enameled vent cap and the 6” (152 mm) vent wall assembly  
show below, See pages 22 thru 24.  
FIGURE 17.  
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4. First remove the 3” (76 mm) horizontal extension from the elbow. Start-  
ing with the long end (with four securing holes), place the 6” (152 mm)  
diameter vent elbow over the 3” (76 mm) diameter elbow. Bend the  
round end “oval” to fit the flared oval end of the jacket top.  
FIGURE21.  
8. Slide the vent collar (to be installed later) over the 6” (152 mm) vent  
elbow.  
FIGURE18.  
5. Making sure the 6” (152 mm) diameter elbow is centered around the 3”  
(76 mm) diameter flue, secure the 6” (152 mm) diameter vent pipe  
using four sheet metal screws at the connection of the jacket top.  
FIGURE22.  
9. Place the water heater at the opening in the wall, at the predetermined  
clearance.  
FIGURE19.  
6. The standard vent kit includes a 6” (152 mm) diameter extension pipe  
which is used when “E” dimension is over 6 1/2” (165 mm).  
FIGURE23.  
10. Move outdoors with all the remaining vent parts. Using the tube of  
sealant supplied, run an ample amount on the inside surface of the  
collar assembly that will contact the exterior wall and also fill the  
bead on the end of the 6” ((152 mm) diameter vent collar.  
FIGURE 20.  
7. If “E” dimension is less than 6 1/2” (165 mm) move to next step.  
If “E” dimension is over 6 1/2” (165 mm), assemble the 6” (152 mm)  
diameter extension pipe (crimped end) to the 6” (152 mm) diameter vent  
elbow and secure using two sheet metal screws.Apply an ample amount  
of sealant around the joint to ensure a good seal.  
FIGURE24.  
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11. Install the vent collar assembly through the wall, connecting it to the 15. The vent cap has four holes around the outer edge. Remove the four  
extension and/or elbow (depending on which one was used).  
screws used to temporarily attach the collar to the exterior wall.  
Then secure the vent cap assembly with the vent collar assembly to  
the exterior wall using the same four screws.  
NOTE: Screws are supplied: However, substitution may be  
necessary depending on the exterior wall material.  
FIGURE25.  
12. We have supplied four wood screws to temporarily attach the collar  
to the exterior wall of the building. However, other types of screws  
may have to be substituted depending on the material used in the  
construction of the exterior wall.  
FIGURE28.  
16. Go back indoors toattachinsidecollartotheinsidewall. Placethe collar  
against the wall. Securetowallbyusingfourlongsheet metal screws.  
FIGURE26.  
NOTE: Screws are supplied: However, substitution may be  
necessary depending on the interior wall material.  
13. Insert the 3” (76 mm) diameter flue extension pipe into the vent collar  
assembly (flared & notched end first) and lock (turn clockwise to  
lock studs to slots) the flue extension pipe to the flue elbow.  
FIGURE29.  
17. Using the tube of sealant supplied, run an ample amount of sealant  
around the edge of the vent pipe where it is inserted through the  
inside collar to seal air drafts from wall.  
14. Connect the vent cap by sliding its end over the 3” (76 mm) diameter  
extension pipe and O-ring.  
NOTE: To facilitate ease of assembly of the vent cap to the 3”(76mm)  
pipe, a soap solution can be applied to the O-ring gasket.  
FIGURE27.  
FIGURE30.  
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2. Set the vertical 3” (76 mm) diameter telescoping flue section in place  
on the flue collar. Using a # 22 drill bit, drill two holes (180° apart) and  
secure the vertical assembly to the flue collar.  
Optional Vertical Vent Kit with Standard Horizontal  
Vent Kit - Installation #2  
Any Optional Vent Kit  
FIGURE33.  
3. Slide the 6” (152 mm) vent telescoping section apart to reveal the  
beads. Using the caulking supplied, fill the beads.  
*Each part is stamped with a part number.  
The opening through the wall should be cut at this time. If this has not been  
done, refer to “CuttingThe OpeningThroughThe Outside Wall,” onpage11.  
1. First it must be determined how far the vertical 3” (76 mm) diameter  
telescoping flue sections are set and locked together using the two  
screws supplied.  
FIGURE 34.  
4.Apply an ample amount of sealant around the oval flare of the jacket.  
FIGURE31.  
Use chart #3, drawing and simple equation below, to find the length of  
expansion of the telescoping flue sections. Because of manufacturing  
tolerances, place the telescoping extension on the water heater and  
adjust the height (“X” Dimension) and mark the point. Once the length has  
been determined, lock the two sections together by drilling two holes  
(180° apart) in the pipe and securing with the screws supplied.  
FIGURE 35.  
5. Place the 6” (152 mm) vent section over the 3” (76 mm) flue section.  
Subtract 3/4” (19 mm) from the predetermined “X” dimension. This  
determines the length of the 6” (152 mm) vent extension. Slide the 6”  
(152 mm) vent extension apart to this dimension and secure with the  
two screws supplied.  
FIGURE36.  
6. Form the round end of the 6” (152 mm) vent extension to the top of the  
jacket and secure with four sheet metal screws.  
FIGURE32.  
CHART #3  
*GAL CAP.  
*BTU’s in 1000’s - NAT./L.P.  
A
40  
50  
40  
50  
75  
36/36  
38/38  
40/40  
48/44  
55 NAT.  
48 3/4”  
57 1/2”  
48 3/4”  
61”  
124 cm  
146 cm  
124 cm  
155 cm  
160 cm  
63”  
*Check the model and rating plate attached to the water heater for  
specific model number and other detailed information.  
FIGURE 37.  
14  
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7. Place the 3” (76 mm) elbow on the flue extension.  
NOTE: Make sure elbow is properly aligned to opening in  
the outside wall.  
Mark the 3” (76 mm) diameter end of the flue extension at the slots  
in the elbow. Using a #22 drill bit, drill holes into the flue extension  
at the two slots and secure the elbow to the flue extension using  
the screws provided.  
10. If “E” dimension is less than 61/2”(165 mm) move to next step. If “E”  
dimension is over 61/2” (165 mm), assemble the 6” (152 mm) diameter  
extension pipe to the 6” (152 mm) diameter vent elbow and secure  
using two sheet metal screws. Using the tube of sealant supplied,  
run an ample amount around the joint to insure a good seal.  
FIGURE41.  
11. Slidethevent collar (tobe installed later)overthe6”(152mm)ventelbow.  
FIGURE 38.  
8. Be sure the 6” (152 mm) diameter elbow is centered around the 3”  
(76 mm) diameter flue. Secure the 6” (152 mm) diameter vent pipe  
using two sheet metal screws at the cnnection of the elbow and  
6” (152 mm) vertical extension.  
FIGURE42.  
12. Move the water heater into position at the vent opening.  
FIGURE39.  
9. The standard vent kit includes a 6” (152 mm) diameter extension  
pipe which is used when dimension “E” (refer to Chart 2) is over  
6 1/2” (165 mm).  
FIGURE43.  
13. Take the remaining vent parts outside to complete the installation.  
Using the tube of sealant supplied, apply an ample amount of sealant  
to the inside surface of the collar assembly that will contact the  
exterior wall. Also, apply sealant to the bead around the outside  
edge at the end of the 6” (152 mm) diameter vent collar.  
FIGURE40.  
FIGURE44.  
15  
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14. Install the vent collar assembly through the wall, connecting it to the 18. The vent cap has four holes around the outer edge. Remove the four  
extension and/or elbow depending on which one was used.  
screwsused to temporarily attach the collar to the exterior wall. Then  
secure the vent cap to the exterior wall using the same four screws.  
NOTE: Screws are supplied. However, substitution may be  
necessary depending on the exterior wall material.  
FIGURE 45.  
15. Four wood screws are supplied to temporarily attach the collar to the  
exterior wall of the building. However, other types of screws may  
have to be substituted depending on the construction material of the  
exterior wall.  
FIGURE 49.  
19. Go back indoorstoattach insidecollar totheinsidewall. Placethecollar  
againstthe wall. Secure to wall by using four long sheet metal screws.  
NOTE: Screws are supplied. However, substitution may be  
necessary depending on the exterior wall material.  
FIGURE46.  
16. Insert the 3” (76 mm) diameter flue extension pipe into the vent collar  
assembly (flared and notched end first) and rotate clockwise to lock  
the studs to the slots in the extension pipe.  
FIGURE50.  
FIGURE 47.  
20. Using the tube of sealant supplied, apply an ample amount of sealant  
around the edge of the vent pipe where it is inserted through the  
inside collar. This will seal air draft from the walls.  
17. Connect the vent cap by sliding it’s end over the 3” (7.6 cm) diam-  
eter extension pipe an O-ring.  
NOTE: to facilitate ease of assembly of the vent cap to the 3”  
(7.6 cm) pipe a soap solution can be applied to the O-ring  
gasket.  
FIGURE48.  
FIGURE 51.  
16  
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Optional Horizontal Vent Kit - Installation #3  
FIGURE54.  
4. First remove the 3” (7.6 cm) horizontal extension from the elbow.  
Starting with the long end, which has four mounting holes, place the 6”  
(152 mm) diameter vent elbow over the 3” (76 mm) elbow. Bend the  
round end to fit the flared oval end of the jacket top.  
If the vent hole has not been cut, refer to “Cutting The Opening  
Through The Outside Wall.” See page 11.  
1. Lock the elbow to the straight 3” (76 mm) flue pipe. Set this assembly  
in place on the end of the water heater’s flue collar.  
FIGURE55.  
5. Be sure the 6” (152 mm) diameter elbow is centered around the  
3” (76 mm) diameter flue. Secure the vent pipe with four sheet metal  
screws at the connection at the jacket top.  
FIGURE52.  
FIGURE56.  
2. Mark the flue collar at the slots in the elbow. Using a # 22 drill bit, drill  
holes into the collar at the two slots and secure the elbow to the collar  
with the screws provided.  
NOTE: the standard kit includes a 3” (76 mm) flue extension  
and a 6” (152 mm) elbow extension. These parts will not  
be used with the horizontal kit.  
NOTE: make sure elbow is properly aligned to the opening in  
the outside wall.  
6. Slide the vent collar (to be installed later) over the 6” (152 mm)  
vent elbow.  
FIGURE53.  
3. Using the tube of sealant supplied run an ample amount around the  
oval flare of the jacket.  
FIGURE57.  
17  
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11. Insert the vent collar assembly through the wall opening, connect-  
ing to the 6” (152 mm) telescoping extension. Remember, the vent  
extension has not been connected so it may be necessary to go  
back outdoors and push it back up into the wall opening for a tight  
fit to the collar.  
7. Place the waterheater at the opening in the wall at the  
predetermined clearance.  
FIGURE62.  
12. Four wood screws were supplied to temporarily attach the collar to  
the exterior wall of the building. However, you may have to substi-  
tute other types of screws depending on the construction material of  
the exterior wall.  
FIGURE58.  
8. Slide the 6” (152 mm) telescoping vent section apart to expose the  
beads. Use the supplied tube of sealant and fill the exposed beads.  
FIGURE 63.  
13. Insert the vent cap into the vent collar assembly.  
FIGURE59.  
9. Insert the 6” (152 mm) telescoping vent section into the opening in  
the wall.  
FIGURE 64.  
14. The vent cap has four holes around the outer edge. Remove the four  
screws used to temporarily attach the collar to the exterior wall.  
Then secure the vent cap assembly with the vent collar assembly to  
the exterior wall using the same screws.  
FIGURE60.  
Note: Screws are supplied; however, substitution may be  
necessary depending on the exterior wall material.  
10. The remaining vent parts will be installed from the outside. Apply ample  
amount of sealant to the inside surface of the collar assembly that will  
contact the exterior wall. Also, apply sealant to the bead around the  
outside edge at the end of the 6” (152 mm) diameter vent collar.  
FIGURE65.  
15. The remainder of the installation will be indoors to complete the  
assembly process.  
FIGURE61.  
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16. Collapse the 6” flue extension assembly as shown below. Install 20. Secure the 6” (15.2 cm) vent extension to the vent elbow with the  
the O-ring end of the 3” (7.6 cm) extension approximately 1 1/4”  
(3.2 cm) into the end of the vent cap. If necessary, apply a soap  
solution to the O-ring to ease the assembly. Rotate the 3” extension  
clockwise until the other end is locked to the studs on the elbow.  
two provided screws spacing them 180° apart.  
FIGURE70.  
Optional Vertical and Horizontal Vent Kit -  
Installation #4  
FIGURE66.  
17. Using a # 22 drill bit, drill holes 180° apart at the connection point of  
the two 3” (7.6 cm) flue extensions. Secure with the two screws  
provided.  
FIGURE67.  
18. Expand the 6” (15.2 cm) telescoping extension to connect at the  
vent elbow.  
If the vent hole has not been cut, refer to section, “Cutting The Opening  
Through The Outside Wall.” See page 11.  
1. First determine how far the vertical 3” (7.6 cm) diameter telescoping  
flue sections are to be set and locked together with two screws  
supplied.  
FIGURE68.  
19. Push the vent collar from the elbow against the wall and secure with  
the four provided screws.  
FIGURE 71.  
Use the Chart #4, and figure 72 to determine the length of expansion of  
the telescoping flue sections. Because of manufacturing tolerances, put  
the telescoping extension on the water heater, adjust the height (dimen-  
sion “X”) and mark the point. Once the length has been determined, lock  
the two sections together by drilling two holes (180° apart) in the pipe  
and secure with the supplied screws.  
FIGURE69.  
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5. Place the 6” (15.2 cm) vent section over the 3” (7.6 cm) flue section.  
Subtract 3/4” (1.9 cm) from the predetermined “X” dimension. This  
determines the length of the 6” (15.2 cm) vent extension. Slide the 6”  
(15.2 cm) vent extension apart to this dimension and secure with the  
two screws supplied.  
FIGURE72.  
CHART #4.  
*GAL CAP *BTU’s in 1000’s - NAT./L.P.  
A
FIGURE76.  
40  
50  
40  
50  
75  
36/36  
38/38  
40/40  
48/44  
55 NAT.  
48 3/4” 124 cm  
57 1/2” 146 cm  
48 3/4” 124 cm  
6. Form the round end of the 6” (15.2 cm) vent extension to the top of the  
jacket and secure with four sheet metal screws.  
61”  
63”  
155 cm  
160 cm  
*Check the model and rating plate attached to the water heater for  
specific model number and other detailed information.  
2. Set the vertical 3”(7.6cm)diameter telescoping fluesection in place on  
the fluecollar. Using a #22 drill bit, drilltwoholes(180°apart)andsecure  
the vertical assembly to the flue collar with the two supplied screws.  
FIGURE 77.  
7. Place the 3” (7.6 cm) elbow on the flue extension. Align the elbow to  
the hole previously made in the outside wall. Using the slots in the  
elbow, mark the 3” (7.6 cm) diameter end of the flue extension. Using  
a #22 drill bit, drill two holes into the flue extension and secure with  
the two provided sheet metal screws.  
FIGURE73.  
3. Slide the 6” (15.2 cm) vent telescoping section apart to reveal the  
beads. Fill the beads using the supplied caulking.  
FIGURE74.  
FIGURE78.  
4.Apply an ample amount of sealant around the oval flare of the jacket.  
NOTE: the standard kit includes a 3” (7.6 cm) flue extension  
and a 6” (15.2 cm) elbow extension. These parts will not  
be used with the horizontal kit.  
FIGURE75.  
20  
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8. Be sure the 6” (15.2 cm) diameter elbow is centered around the 3”  
(7.6 cm) diameter flue, secure using two sheet metal screws at the  
connection of the elbow and the 6”(15.2 cm) vertical extension.  
11. Slide the 6” (15.2 cm) telescoping vent section apart to expose the  
beads. Use the supplied tube of caulking and fill the exposed beads.  
FIGURE 82.  
12. Insert the 6”(15.2 cm) telescoping vent section into the wall.  
FIGURE79.  
9. Slide the vent collar(to be installed later)over the 6”(15.2cm) vent elbow.  
FIGURE 83.  
13. The remaining vent parts will be installed from the outside. Apply  
ample amount of sealant to the inside surface of the collar assembly  
that will contact the exterior wall. Also, apply sealant to the bead  
around the outside edge at the end of the 6” (15.2 cm) diameter vent  
collar.  
FIGURE80.  
10. Move the water heater into position at the vent opening.  
FIGURE 84.  
14. Install the vent collar assembly through the wall, connecting to the  
6” (15.2cm) telescoping extension. Remember, the extension is not  
connected and may be necessary to return indoors to push the  
extension back against the interior wall for a tight fit to the collar.  
FIGURE85.  
FIGURE81.  
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15. Four wood screws were supplied to temporarily attach the collar to  
the exterior wall of the building. However, you may have to substitute  
other types of screws depending on the construction material of the  
20. Using a #22 drill bit, drill holes 180° apart at the connection point of  
the two 3” (76 mm) flue extensions. Secure with the two screws  
provided.  
exterior wall.  
FIGURE 86.  
16. Insert the vent cap into the vent collar assembly.  
FIGURE90.  
21. Expand the 6” (152 mm) telescoping extension pipes to connect at  
the vent elbow.  
FIGURE87.  
17. The vent cap has four holes around the outer edge. Remove the four  
screws used to temporarily attach the collar to the exterior wall.  
Then secure the vent cap assembly with the vent collar assembly to  
the exterior wall using the same screws.  
Note: Screws are supplied; however, substitution may be  
necessary depending on the exterior wall material.  
FIGURE 91.  
22. Push the vent collar from the elbow against the wall and secure with  
the four provided screws.  
FIGURE 88.  
18. The remainder of the installation will be conducted indoors to  
complete the assembly process.  
19. Collapse the 6” extension assembly as shown below. Install the O-  
ringend of the 3” (7.6 cm) extension approximately 11/4” (3.2 cm) into the  
end of the vent cap. If necessary, apply a soap solution to the O-ring  
to ease the assembly. Rotate the extension clockwise until the other  
end is locked to the studs on the elbow.  
FIGURE 92.  
23. Secure the 6” (152 mm) vent extension to the vent elbow with the  
two provided screws spacing them 180° apart.  
FIGURE93.  
Optional Vent Cap - Porcelain-Enameled  
These supplementary installation instructions are applicable only  
if this direct vent water heater is provided with the alternate brown  
FIGURE89.  
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porcelain-enameled vent cap assembly and the 6” (15.2 cm) vent 16. Insert the 3” (7.6 cm) diameter flue extension pipe into the vent collar  
wall assembly shown by Figure 94.  
assembly (flared and notched end first). Lock the flue extension pipe  
to the flue elbow by rotating clockwise to lock studs to slots.  
FIGURE94.  
FIGURE97.  
The water heater model designation on the rating plate will have a suffix  
“P” to indicate this alternate vent cap assembly.  
4. Connect the vent cap by sliding it over the 3” (7.6 cm) diameter  
extension pipe and O-ring.  
The alternate installation instructions below will replace the itemized  
instructions in the manual as follows: Items 11 thru 15 on page 13 and  
items 14 thru 18 on page 16.  
NOTE: for ease of assembly of the vent cap to the 3” (7.6 cm) pipe a  
soap solution can be applied to the O-ring gasket.  
1. Making sure the arrow points “UP”, install the vent collar assembly  
through the wall, connecting it to the extension and/or elbow  
depending on which one was used.  
FIGURE98.  
5. The vent cap has six holes around the outer edge. The three larger  
ones are to fit over the three screws securing the vent collar assem-  
bly to the exterior wall. The three smaller ones will now be used to  
attach the vent cap assembly.  
FIGURE95.  
2. Three wood screws are supplied to attach the collar to the NOTE: screws are supplied. However, substitution may be necessary  
exterior wall of the building. However, other types of screws depending on the exterior wall material.  
may have to be substituted depending on the construction of the  
exterior wall.  
NOTE: alternate screws used must not have a head larger than 3/8”  
(.95 cm).  
The three screws must be placed at every other hole (120° apart) to  
secure the vent collar assembly to the outside wall.  
FIGURE99.  
FIGURE96.  
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The following alternate illustrated instructions will replace the  
itemized instructions in the manual as follows: Items 11 through  
14 on page 18 and Items 14 through 17 on pages 21 and 22.  
3. Insert the vent cap in the vent collar assembly.  
1. Making sure the arrow points “up”, install the vent collar assembly  
through the wall, connecting it to the 6” (15.2 cm) telescoping  
extension. Remember, the extension is not connected, and it may be  
necessary to return indoors to push the extension back against the  
interior wall for a tight fit to the collar.  
FIGURE102.  
4. The vent cap has six holes around its outer edge. The three larger  
ones are to fit over the three screws securing the vent collar assembly  
to the exterior wall. The three smaller ones will now be used to attach  
the vent cap assembly.  
FIGURE100.  
2. Three wood screws are supplied to attach the collar to the exterior  
wall of the building. However, other types of screws may be substituted  
depending on the construction of the exterior wall.  
NOTE: screws are supplied. However, substitution may be necessary,  
depending on the exterior wall material.  
NOTE:alternate screws used must not have heads larger than 3/8”(.95cm).  
The three screws must be placed at every other hole 120° apart to  
secure the vent collar assembly to the outside wall.  
FIGURE103.  
FIGURE101.  
24  
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INSTALLING THE NEW WATER HEATER  
WATER PIPING  
As water is heated, it expands (thermal expansion) and closed systems  
do not allow for the expansion of heated water.  
The water within the water heater tank expands as it is heated and  
increases the pressure of the water system. If the relieving point of the  
water heater’s temperature-pressure relief valve is reached, the valve  
will relieve the excess pressure. The temperature-pressure relief  
valve is not intended for the constant relief of thermal  
expansion. This is an unacceptable condition and must be corrected.  
It is recommended that any devices installed which could create a closed  
system have a by-pass and/or the system have an expansion tank to  
relieve the pressure built by thermal expansion in the water system.  
Expansion tanks are available for ordering through a local plumbing  
contractor. Contact the local water supplier and/or a service agency for  
assistance in controlling these situations.  
NOTE: To protect against untimely corrosion of hot and cold  
water fittings, it is strongly recommended that di-electric unions  
or couplings be installed on this water heater when connected  
to copper pipe.  
HOTTER WATER CAN SCALD:  
Water heaters are intended to produce hot water. Water heated to a  
temperature which will satisfy space heating, clothes washing, dish  
washing, cleaning and other sanitizing needs can scald and permanently  
injure you upon contact. Some people are more likely to be permanently  
injured by hot water than others. These include the elderly, children, the  
infirm, or physically/mentally handicapped. If anyone using hot water in  
your home fits into one of these groups or if there is a local code or state  
law requiring a certain temperature water at the hot water tap, then you  
must take special precautions. In addition to using the lowest possible  
temperature setting that satisfies your hot water needs, a means such  
as a *mixing valve, shall be used at the hot water taps used by these  
people or at the water heater, see Figure. Valves for reducing point of  
use temperature by mixing cold and hot water are also available. Consult  
a Qualified Installer or ServiceAgency. Follow manufacturer’s instructions  
for installation of the valves. Before changing the factory setting on the  
thermostat, read the “Temperature Regulation” section in this manual.  
This water heater shall not be connected to any heating systems or  
component(s) used with a non-potable water heating appliance.  
All piping components connected to this unit for space heating applications  
shall be suitable for use with potable water.  
Toxic chemicals, such as those used for boiler treatment shall not be  
introduced into this system.  
When the system requires water for space heating at temperatures  
higher than required for domestic water purposes, a tempering valve  
must be installed. Please refer to Figure 2 for suggested piping  
arrangement.  
Water supply systems may, because of such events as high line  
pressure, frequent cut-offs, the effects of water hammer among others,  
have installed devices such as pressure reducing valves, check valves,  
back flow preventers, etc. to control these types of problems. When  
these devices are not equipped with an internal by-pass, and no other  
measures are taken, the devices cause the water system to be closed.  
FIGURE104.  
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Figure 104 shows the typical attachment of the water piping to the The valve must be marked with a maximum set pressure not to exceed  
water heater. The water heater is equipped with 3/4 inch NPT water the marked hydrostatic working pressure of the water heater  
connections.  
(150 psi = 1,035 kPa) and a discharge capacity not less than the water  
heater input rate as shown on the model rating plate.  
NOTE: If using copper tubing, solder tubing to an adapter before  
attaching the adapter to the cold water inlet connection. Do For safe operation of the water heater, the relief valve must not be  
not solder the cold water supply line directly to the cold water removed from its designated opening nor plugged.  
inlet. It will harm the dip tube and damage the tank.  
The temperature-pressure relief valve must be installed directly into the  
T & P Valve and Pipe Insulation  
fitting of the water heater designed for the relief valve. Position the  
valve downward and provide tubing so that any discharge will exit only  
within 6 inches (153 mm) above, or at any distance below the structural  
floor. Be certain that no contact is made with any live electrical part. The  
discharge opening must not be blocked or reduced in size under any  
circumstances. Excessive length, over 30 feet (9.14 m), or use of more  
than four elbows can cause restriction and reduce the discharge  
capacity of the valve, see Figure 106.  
Remove insulation for T & P valve and pipe connections from carton.  
No valve or other obstruction is to be placed between the relief valve  
and the tank. Do not connect tubing directly to discharge drainunless a 6  
inch air gap is provided. To prevent bodily injury, hazard to life,orproperty  
damage, the relief valve must be allowed to discharge water in quantities  
should circumstances demand. If the discharge pipe is not connected to a  
drain or other suitable means, the water flowmaycauseproperty damage.  
FIGURE105.  
Fit pipe insulation over the incoming cold water line and the hot water  
line. Make sure that the insulation is against the top cover of the heater.  
Fit T & P valve insulation over valve. Make sure that the insulation does  
not interfere with the lever of the T & P valve.  
Secure all insulation using tape.  
The Discharge Pipe:  
TEMPERATURE-PRESSURE RELIEF VALVE  
• Shall not be smaller in size than the outlet pipe size of the valve, or  
have any reducing couplings or other restrictions.  
• Shall not be plugged or blocked.  
• Shall be of material listed for hot water distribution.  
• Shall be installed so as to allow complete drainage of both the  
temperature-pressure relief valve, and the discharge pipe.  
• Shall terminate at an adequate drain.  
• Shall not have any valve between the relief valve and tank.  
This heater is provided with a properly certified combination  
temperature - pressure relief valve by the manufacturer.  
The valve is certified by a nationally recognized testing laboratory that  
maintains periodic inspection of production of listed equipment of  
materials as meeting the requirements for Relief Valves andAutomatic  
Gas Shut-off Devices for Hot Water Supply Systems, ANSI Z21.22 •  
CSA4.4, and the code requirements ofASME.  
The temperature-pressure relief valve must be manually operated at least  
once a year. Caution should be taken to ensure that (1) no one is in front  
of or around the outlet of the temperature-pressure relief valve discharge  
line, and (2) the water manually discharged will not cause any bodily  
injury or property damage because the water may be extremely hot.  
If replaced, the valve must meet the requirements of local codes, but  
not less than a combination temperature and pressure relief valve  
certified as indicated in the above paragraph.  
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If after manually operating the valve, it fails to completely reset and  
continues to release water, immediately close the cold water inlet to the  
water heater, follow the draining instructions, and replace the  
temperature-pressure relief valve with a new one.  
GAS PIPING  
Make sure the gas supplied is the same type listed on the model rating  
plate. The inlet gaspressuremustnotexceed14inch watercolumn(2.6kPa)  
for natural and propane gas (L.P.). The minimum inlet gas pressure  
shown on the rating plate is that which will permit firing at rated input.  
If the gas control valve is subjected to pressures exceeding 1/2 pound  
per square inch (3.5 kPa), the damage to the gas control valve could  
result in a fire or explosion from leaking gas.  
If the main gas line Shut-off serving all gas appliances is used, also turn  
“off” the gas at each appliance. Leave all gas appliances shut “off” until  
the water heater installation is complete.  
FIGURE106.  
Agas line of sufficient size must be run to the water heater. Consult the  
current edition of National Fuel Gas CodeANSI Z223.1/NFPA54 and your  
gas supplier concerning pipe size.  
FILLING THE WATER HEATER  
There must be:  
• A readily accessible manual shut off valve in the gas supply line serving  
the water heater, and  
• A drip leg (sediment trap) ahead of the gas control valve to help prevent  
dirt and foreign materials from entering the gas control valve.  
• A flexible gas connector or a ground joint union between the shut off  
valve and control valve to permit servicing of the unit.  
Be sure to check all the gas piping for leaks before lighting the water  
heater. Use a soapy water solution, not a match or open flame. Rinse  
off soapy solution and wipe dry.  
Never use this water heater unless it is completely full of water. To  
prevent damage to the tank, the tank must be filled with water. Water  
must flow from the hot water faucet before turning “ON” gas to the  
water heater.  
To fill the water heater with water:  
1. Close the water heater drain valve by turning the handle to the  
right (clockwise). The drain valve is on the lower front of the  
water heater.  
2. Open the cold water supply valve to the water heater.  
NOTE: The cold water supply valve must be left open when  
the water heater is in use.  
3. To insure complete filling of the tank, allow air to exit by opening the  
nearest hot water faucet. Allow water to run until a constant flow  
is obtained. This will let air out of the water heater and the piping.  
4. Check all water piping and connections for leaks. Repair as needed.  
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When installed at elevations above 2,000 feet (610 meters), input rating  
should be reduced at the rate of 4 percent for each 1,000 feet  
(305 meters) above sea level which requires replacement of the  
burner orifice in accordance with National Fuel Gas CodeANSI Z223.1/  
NFPA 54. Contact your local gas supplier for further information.  
GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL  
Failure to replace the standard orifice with a high altitude orifice when  
installed could result in improper and inefficient operation of the appliance,  
producing carbon monoxide gas in excess of safe limits, which could  
result in serious injury or death. Contact your gas supplier for any  
specific changes which may be required in your area.  
FIGURE108.  
SEDIMENT TRAPS  
Use pipe joint compound or teflon tape marked as being resistant to the  
action of petroleum [Propane (L.P.)] gases.  
The appliance and its gas connection must be leak tested before placing  
the appliance in operation.  
The appliance and its individual Shut-off valve shall be disconnected  
from the gas supply piping system during any pressure testing of that  
system at test pressures in excess of 1/2 pound per square inch  
(3.5 kPa). It shall be isolated from the gas supply piping system by  
closing its individual manual Shut-off valve during any pressure testing  
of the gas supply piping system at test pressures equal to or less than  
1/2 pound per square inch (3.5 kPa).  
A sediment trap shall be installed as close to the inlet of the water  
heater as practical at the time of water heater installation. The sediment  
trap shall be either a tee fitting with a capped nipple in the bottom outlet  
or other device recognized as an effective sediment trap. If a tee fitting  
is used, it shall be installed in conformance with one of the methods of  
installation shown in Figures 107and108.  
Connecting the gas piping to the gas control valve of the water heatercanbe  
accomplished by either of thetwo methods shown in Figures 107 and 108.  
GAS PIPINGWITHFLEXIBLECONNECTOR  
Contaminants in the gas lines may cause improper operation of the gas  
control valve that may result in fire or explosion. Before attaching the  
gas line be sure that all gas pipe is clean on the inside. To trap any dirt  
or foreign material in the gas supply line, a drip leg (sometimes called a  
sediment trap) must be incorporated in the piping. The drip leg must be  
readily accessible. Install in accordance with the “Gas Piping” section.  
Refer to the current edition of the National Fuel Gas Code,  
ANSI Z223.1/NFPA54.  
FIGURE 107.  
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INSTALLING THE NEW WATER HEATER (cont’d.)  
INSTALLATION CHECKLIST  
BEFORE LIGHTING THE PILOT:  
1. Check the gas line for leaks.  
6. Is there proper clearance between the water heater and anything  
that might catch fire? See the “Locating the New Water Heater”  
section.  
a. Use a soapy water solution. DO NOT test for gas leaks using  
a match or open flame.  
b. Brush the soapy water solution on all gas pipes, joints and fittings.  
c. Check for bubbling soap. This means you have a leak. Turn  
“OFF” gas and make the necessary repairs.  
d. Recheck for leaks.  
7. Do you have adequate ventilation so that the water heater will  
operate properly? See “CombustionAir and Ventilation” in the “Locating  
the New Water Heater” section.  
e. Rinse off soapy solution and wipe dry.  
8. Is the vent piping properly secured? See “Venting” instructions in  
the “Installing the New Water Heater section.  
2. Is this new temperature-pressure relief valve properly installed  
and piped to an adequate drain? See “Temperature-Pressure Relief  
Valve” section.  
9. Is there proper clearance between the vent pipe and anything that  
might catch fire? See “Venting” instructions in the “Installing the New  
Water Heater” section.  
3. Are the cold and hot water lines connected to the water heater  
correctly? See “Water Piping” instructions in the “Installing the New  
Water Heater” section.  
10. Is the vent pipe properly sloped and does the vent terminate outdoors?  
See “Venting” instructions in the “Installing the New Water Heater”  
section.  
4. Is the water heater completely filled with water? See “Filing the Water  
Heater” instructions in the “Installing the New Water Heater” section.  
11. Do you need to call your gas company to check the gas pipe and its  
hookup?  
5. Will a water leak damage anything? See the “Locating the New  
Water Heater” section.  
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TEMPERATURE REGULATION  
NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is  
recommended by most dishwasher manufacturers.  
The thermostat of this water heater has been factory set at its lowest  
position (PILOT LIGHTING). It is adjustable and must be reset to the  
desired temperature setting to reduce the risk of scald injury. The mark  
(
) indicative of approximately 120°F (49°C) is preferred starting  
point. Some States have a requirement for a lower setting.  
Turn the water temperature dial clockwise (  
temperature, or counterclockwise (  
temperature.  
) to decrease the  
) to increase the  
Should overheating occur or the gas supply fail to shut off, turn off the  
manual gas control valve to the appliance.  
HOTWATER CAN SCALD: Water heaters are intended to produce hot  
water. Water heated to a temperature that will satisfy space heating,  
clothes washing, dish washing, and other sanitizing needs can scald  
and permanently injure you upon contact. Some people are more likely to  
be permanently injured by hot water than others. These include the  
elderly, children, the infirm, or physically/mentally handicapped. If anyone  
using hot water in your home fits into one of these groups or if there is  
a local code or state law requiring a specific hot water temperature at  
the tap, then you must take special precautions. Never allow small  
children to use a hot water tap, or to draw their own bath water. Never  
leave a child or handicapped person unattended in a bathtub or shower.  
It is recommended that lower water temperatures be used to avoid the  
risk of scalding. It is further recommended, in all cases, that the water  
temperature be set for the lowest temperature that satisfies your hot  
water needs. This will also provide the most energy efficient operation  
of the water heater.  
FIGURE 109.  
Figure 110 shows the approximate water temperatures produced at  
various thermostat settings. Short repeated heating cycles caused by  
small hot water uses can cause temperatures at the point of use to  
exceed the thermostat setting by up to 30°F (17°C). If you experience  
this type of use you should consider using lower temperature settings to  
reduce scald hazards.  
Valves for reducing the point-of-use temperature by mixing cold and hot  
water are available. See Figure 2.Also available are inexpensive devices  
that attach to faucets to limit hot water temperatures. Contact a licensed  
plumber or the local plumbing authority.  
FIGURE 110.  
FOR YOUR INFORMATION  
Moisture from the products of combustion condense on the cooler tank  
surfaces and form drops of water which may fall onto the burner or  
other hot surfaces to produce a “sizzling” or “frying” noise.  
START UPCONDITIONS  
CONDENSATE  
Excessive condensation can cause pilot outage due to water running  
down the flue tube onto the main burner and putting out the pilot.  
Because of the suddenness and amount of water, condensation water  
may be diagnosed as a “tank leak”. After the water in the tank warms  
up (about 1-2 hours), the condition should disappear.  
Whenever the water heater is filled with cold water, some condensate  
will form while the burner is on. A water heater may appear to be  
leaking when in fact the water is condensation. This usually  
happens when:  
Do not assume the water heater is leaking until there has been enough  
time for the water in the tank to warm up.  
a. A new water heater is filled with cold water for the first time.  
b. Burning gas produces water vapor in water heaters, particularly  
high efficiency models where flue temperatures are lower.  
c. Large amounts of hot water are used in a short time and the  
refill water in the tank is very cold.  
An undersized water heater will cause more condensation. The water  
heater must be sized properly to meet the family’s demands for hot water  
including dishwashers, washing machines and shower heads.  
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will cause a reaction between this rod and the water. The most common  
complaint associated with the anode rod is one of a “rotten egg smell” in  
the hot water. This odor is derived from hydrogen sulfide gas dissolved  
in the water. The smell is the result of four factors which must all be  
present for the odor to develop:  
Excessive condensation may be noticed during the winter and early spring  
months when incoming water temperatures are at their lowest.  
Good venting is essential for a gas fired water heater to operate properly  
as well as to carry away products of combustion and water vapor.  
SMOKE/ODOR  
a. Aconcentration of sulfate in the supply water.  
b. Little or no dissolved oxygen in the water.  
It is not uncommon to experience a small amount of smoke and odor during  
the initial start-up. This is due to burning off of oil from metal parts, and will  
disappear in a short while.  
c. A sulfate reducing bacteria which has accumulated within the water  
heater (this harmless bacteria is nontoxic to humans).  
d. An excess of active hydrogen in the tank. This is caused by the  
corrosion protective action of the anode.  
THERMALEXPANSION  
Smelly water may be eliminated or reduced in some water heater models  
by replacing the anode(s) with one of less active material, and then  
chlorinating the water heater tank and all hot water lines. Contact the  
local water heater supplier or service agency for further information  
concerning anAnode Replacement Kit and this chlorination treatment.  
If the smelly water persists after the anode replacement and chlorination  
treatment, we can only suggest that chlorination or aeration of the water  
supply be considered to eliminate the water problem.  
Do not remove the anode leaving the tank unprotected. By  
doing so, all warranty on the water heater tank is voided.  
Water supply systems may, because of such events as high line  
pressure, frequent cut-offs, the effects of water hammer among others,  
have installed devices such as pressure reducing valves, check valves,  
back flow preventers, etc. to control these types of problems. When  
these devices are not equipped with an internal by-pass, and no other  
measures are taken, the devices cause the water system to be closed.  
As water is heated, it expands (thermal expansion) and closed systems  
do not allow for the expansion of heated water.  
“AIR” IN HOT WATER FAUCETS  
The water within the water heater tank expands as it is heated and  
increases the pressure of the water system. If the relieving point of the  
water heater’s temperature-pressure relief valve is reached, the valve  
will relieve the excess pressure. The temperature-pressure relief  
valve is not intended for the constant relief of thermal  
expansion. This is an unacceptable condition and must be corrected.  
It is recommended that any devices installed which could create a closed  
system have a by-pass and/or the system have an expansion tank or  
device to relieve the pressure built by thermal expansion in the water  
system. Expansion tanks are available for ordering through a local  
plumbing contractor. Contact the local water heater supplier or service  
agency for assistance in controlling these situations.  
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). Hydrogen gas is extremely flammable and explosive. To prevent  
the possibility of injury under these conditions, we recommend the hot  
water faucet, located farthest away, be opened for several minutes  
before any electrical appliances which are connected to the hot water  
system are used (such as a dishwasher or washing machine). If hydrogen  
gas is present, there will probably be an unusual sound similar to air  
escaping through the pipe as the hot water faucet is opened. There  
must be no smoking or open flame near the faucet at the time it is open.  
STRANGESOUNDS  
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. See  
“Condensation” in this section.  
HIGHWATERTEMPERATURESHUTOFFSYSTEM  
This water heater is equipped with an automatic gas Shut-off system.  
This system works when high water temperatures are present. Turn  
“OFF” the entire gas supply to the water heater. The high temperature  
Shut-off is built into the gas control valve. It is non-resettable. If the high  
temperature Shut-off activates, the gas control valve must be replaced.  
Contact your gas supplier or service agency.  
OPERATIONAL CONDITIONS  
SMELLYWATER  
In each water heater there is installed at least one anode rod (see parts  
sections) for corrosion protection of the tank. Certain water conditions  
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PERIODIC MAINTENANCE  
You should check for sooting. Soot is not normal and will impair proper  
VENTING SYSTEM INSPECTION  
combustion.  
Soot build-up indicates a problem that requires correction before further  
use. Turn “OFF” gas to water heater and leave off until repairs are  
made, because failure to correct the cause of the sooting can result in a  
fire causing death, serious injury, or property damage.  
FIGURE111.  
BURNER CLEANING  
At least once a year a visual inspection should be made of the venting  
system. You should look for:  
In the event your burner needs cleaning, follow these instructions:  
If inspection of the burner shows that cleaning is required, turn the gas  
1. Obstructions which could cause improper venting. The combustion  
and ventilation air flow must not be obstructed.  
control knob clockwise (  
) to the “OFF” position, depressing slightly.  
NOTE: The knob cannot be turned from “PILOT” to “OFF” unless  
knob is depressed slightly. DO NOT FORCE.  
2. Damage or deterioration which could cause improper venting or  
leakage of combustion products.  
Loose deposits on or around the burner can be removed by carefully  
using the hose of a vacuum cleaner inserted through the access doors  
of the water heater. If the burner needs to be removed for additional  
cleaning, call the local gas utility to remove and clean the burner and  
correct the problem that required the burner to be cleaned.  
3. Rusted flakes around top of water heater.  
Be sure the vent piping is properly connected to prevent escape of  
dangerous flue gasses which could cause deadly asphyxiation.  
L.P. GAS CONTROL VALVE & BURNERASSEMBLY  
Propane (L.P.) gas control valve and burner assembly replacement in-  
formation.  
Obstructions and deteriorated vent systems may present serious health  
risk or asphyxiation.  
Chemical vapor corrosion of the flue and vent system may occur if air for  
combustion contains certain chemical vapors. Spray can propellants,  
cleaning solvents, refrigerator and air conditioner refrigerants, swimming  
pool chemicals, calcium and sodium chloride, waxes, bleach and process  
chemicals are typical compounds which are potentially corrosive.  
For Propane (L.P.) Gas Models Only:  
Your water heater is equipped with a Propane (L.P.) gas control valve  
and a main burner assembly with left hand threads for the following  
fittings and their connections.  
• The connection between the manifold and the gas control valve (A to  
B) are left hand threads.  
If after inspection of the vent system you found sooting or deterioration,  
something is wrong. Call the local gas utility to correct the problem and  
clean or replace the flue and venting before resuming operation of the  
water heater.  
• The connection between the main burner orifice and the manifold (C to  
D) are left hand threads.  
For ordering these replacement parts, please refer to the  
“Repair Parts” section of this manual.  
BURNER INSPECTION  
Flood damage to a water heater may not be readily visible or immediately  
detectable. However, over a period of time a flooded water heater will  
create dangerous conditionswhich can cause DEATH, SERIOUS BODILY  
INJURY, OR PROPERTYDAMAGE. Contact a qualified installer or service  
agency to replace a flooded water heater. Do not attempt to repair the  
unit! It must be replaced!  
At least once a year a visual inspection should be made of the main  
burner and pilot burner, see Figure 111.  
FIGURE112.  
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The temperature-pressure relief valve must be manually operated at  
least once a year.  
HOUSEKEEPING  
Vacuum around base of water heater for dust, dirt, and lint on a regular  
basis.  
FIGURE113.  
When checking the temperature-pressure relief valve operation, make  
sure that(1) no one is in front of or around the outlet of the temperature-  
pressure relief valve discharge line, and (2) that the water discharge  
will not cause any property damage, as the water may be extremely  
hot, see Figure 113.  
If after manually operating the valve, it fails to completely reset and  
continues to release water, immediately close the cold water inlet to the  
water heater, follow the draining instructions, and replace the  
temperature-pressure relief valve with a new one.  
INSTALLED IN SUITABLE AREA: To insure sufficient ventilation and  
combustion air supply, proper clearances from the water heater must be  
maintained. See “Locating the New Water Heater” section. Combustible  
materials such as clothing, cleaning materials, or flammable liquids, etc.  
must not be placed against or adjacent to the water heater which can  
cause a fire.  
If the temperature-pressure relief valve on the appliance weeps or  
discharges periodically, this may be due to thermal expansion. You may  
have a check valve installed in the water line or a water meter with a  
check valve. Consult your local water supplier or service agency for  
further information. Do not plug the temperature-pressure relief valve.  
ANODE ROD INSPECTION  
DRAINING  
The anode rod is used to protect the tank from corrosion. Most hot water  
tanks are equipped with an anode rod. The submerged rod sacrifices  
itself to protect the tank. Instead of corroding the tank, water ions attack  
and eat away the anode rod. This does not affect the water’s taste or  
color. The rod must be maintained to keep the tank in operating condition.  
The water heater should be drained if being shut down during freezing  
temperatures. Also periodic draining and cleaning of sediment from the  
tank may be necessary.  
Anode deterioration depends on water conductivity, not necessarily  
water condition. A corroded or pitted anode rod indicates high water  
conductivity and should be checked and/or replaced more often than an  
anode rod that appears to be intact. Replacement of a depleted anode  
rod can extend the life of your water heater. Inspection should be  
conducted by a qualified technician, and at a minimum should be checked  
annually after the warranty period.  
1. Turn the gas control knob to the “OFF” position.  
2. CLOSE the cold water inlet valve to the water heater.  
3. OPEN a nearby hot water faucet and leave open to allow for draining.  
4. Connect a hose to the drain valve and terminate to an adequate drain.  
5. OPEN the water heater drain valve to allow for tank draining.  
TEMPERATURE-PRESSURE  
RELIEF VALVE OPERATION  
NOTE: If the water heater is going to be shut down and  
drained for an extended period, the drain valve should be  
left open with hose connected allowing water to terminate  
to an adequate drain.  
6. CLOSE the drain valve.  
7. Follow instructions in the “Filling The Water Heater” section.  
8. Follow the lighting instructions on the label, see page 29 under “Lighting  
Instructions” to restart the water heater.  
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DRAIN VALVE WASHER REPLACEMENT  
8. Follow the lighting instructions in the “Lighting” section to restart the  
water heater.  
(See Figure 114)  
1. Turn “OFF” gas supply to water heater.  
2. Follow “Draining” instructions.  
3. Turning counterclockwise (  
screw handle.  
), remove the hex cap below the  
4. Remove the washer and put the new one in place.  
5. Screw the handle and cap assembly back into the drain valve and  
retighten using a wrench. DO NOT OVER TIGHTEN.  
6. Follow instructions in the “Filling The Water Heater” section.  
7. Check for leaks.  
FIGURE114.  
LEAKAGE CHECKPOINTS  
Read this manual first. Then before checking the water heater make  
sure the gas supply has been turned “OFF”, and never turn the gas “ON”  
before the tank is completely full of water.  
Never use this water heater unless it is completely filled with water. To  
prevent damage to the tank, the tank must be filled with water. Water  
must flow from the hot water faucet before turning “ON” gas to the  
water heater.  
A. Water at the draft hood is water vapor which has condensed out of  
the combustion products. This is caused by a problem in the vent.  
Contact the gas utility.  
B. *Condensation may be seen on pipes in humid weather or pipe  
connections may be leaking.  
C. *The anode rod fitting may be leaking.  
D. Small amounts of water from temperature-pressure relief valve may  
be due to thermal expansion or high water pressure in your area.  
E. *The temperature-pressure relief valve maybe leaking at the tank fitting.  
F. Water from a drain valve may be due tothevalve being slightly opened.  
G. *The drain valve may be leaking at the tank fitting.  
H. Combustion products contain water vapor which can condense on  
the cooler surfaces of the tank. Droplets form and drip onto the  
burner or run on the floor. This is common at the time of start-up after  
installation and when incoming water is cold.  
I. Water in the water heater bottom or on the floor may be from  
condensation, loose connections, or the relief valve. DO NOT replace  
the water heater until a full inspection of all possible water sources  
is made and necessary corrective steps taken.  
Leakage from other appliances, water lines, or ground seepage should  
also be checked.  
*
To check where threaded portion enters tank, insert cotton swab  
between jacket opening and fitting. If cotton is wet, follow “Draining”  
instructions in the “Periodic Maintenance” section and then remove  
fitting. Put pipe dope or teflon tape on the threads and replace. Then  
follow “Filling the Water Heater” instructions in the “Installing the New  
Water Heater” section.  
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REPAIR PARTS LIST  
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REPAIR PARTS LIST (cont’d.)  
PARTS  
GAL. CAP.  
40  
50  
40  
50  
75  
KEY# DESCRIPTION BTU’s in 1000’s NAT/L.P.  
36/36  
38/38  
40/40  
48/44  
55 NAT.  
1.  
2.  
3.  
4.  
Access Door Clips (Pkg. 2)  
Right Access Door w/Gasket  
Left Access Door w/Gasket  
Burner Orifice (Nat.)  
(Drill Size)  
9000694  
9000694  
9000694  
9000694  
9000694  
9000695  
9000696  
9005165  
#36  
9000695  
9000696  
9005170  
#35  
9000695  
9000696  
9001700  
#33  
9000695  
9000696  
9005171  
1/8  
9000695  
9000696  
9001701  
#30  
4.  
4.  
4.  
Burner Orifice (Nat.) Hi-Altitude  
(Drill Size)  
9005928  
#39  
9001886  
#37  
9005165  
#36  
9001700  
#33  
9005172  
#31  
Burner Orifice (L.P.) LHT  
(Drill Size)  
9004005  
#51  
9004005  
#51  
9002134  
#50  
9002130  
#49  
—
Burner Orifice (L.P.) Hi-Altitude/LHT  
(Drill Size)  
9002129  
#52  
9002129  
#52  
9004005  
#51  
9002134  
#50  
—
5.  
Thermocouple  
9000876  
9000249  
9002123  
9002413  
9002415  
9000278  
9002411  
9002411  
9000281  
9003084  
9003085  
9000058  
9001305  
9000705  
9000728  
9000707  
9000399  
9000709  
9000709  
—
9000876  
9000249  
9002123  
9002413  
9002415  
9000278  
9002411  
9002411  
9000281  
9003084  
9003085  
9000058  
9001305  
9000705  
9000728  
9000279  
9000399  
9002836  
9000806  
—
9000876  
9000249  
9002123  
9002413  
9002415  
9000278  
9002411  
9002411  
9000281  
9003084  
9003085  
9000058  
9001305  
9000705  
9000728  
9000707  
9000399  
9002837  
9001287  
9001289  
9001291  
9001293  
9000876  
9000249  
9002123  
9002413  
9002415  
9000278  
9002411  
9000349  
9000281  
9003084  
9003085  
9000058  
9001305  
9000705  
9000728  
9000279  
9000399  
9001288  
9001288  
9001290  
9001292  
9001294  
9002002  
9000249  
9002123  
9003046  
—
6.  
Gas Control Valve (Nat.)  
Gas Control Valve Propane (L.P.)  
Gas Manifold (Nat.)  
Gas Manifold (L.P.)  
Pilot Tubing w/Fittings  
Burner (Nat.)  
6.  
7.  
7.  
8.  
9000278  
9003040  
—
9.  
9.  
Burner Propane (L.P.)  
Inner Door  
10.  
11.  
11.  
12.  
13.  
14.  
15.  
16.  
17.  
18.  
18.  
19.  
20.  
21.  
9000281  
9003084  
—
Pilot (Nat.) w/electrode  
Pilot Propane (L.P.) w/electrode  
Drain Valve  
9001588  
9001305  
9000705  
9000728  
9000734  
9002298  
9002297  
—
Jacket Clips (Pkg. 8)  
SecondaryAnode w/Nipple*  
Temperature-Pressure Relief Valve  
Anode Rod  
Nipple  
Flue Baffle (Nat.)  
Flue Baffle (L.P.)  
FlueAdaptor  
9001290  
9001292  
9001294  
Adaptor Gasket  
—
—
Adaptor Plate w/Gasket  
Standard Kit No. 9000687  
O-Ring Gasket  
—
—
22.  
23.  
9000710  
9000711  
9000710  
9000711  
9000710  
9000711  
9000710  
9000711  
9000710  
9000711  
3” I.D. x 9.5” Flue Extension Pipe with  
Gaskets  
24.  
25.  
Rope Gasket  
9000712  
9000713  
9000712  
9000713  
9000712  
9000713  
9000712  
9000713  
9000712  
9000713  
3” I.D. x 5 1/2” Vent Extension Pipe  
KitAVK-1 No. 9001246  
26.  
3” I.D. x 7 7/8” Flue Extension Pipe with 9001280  
Gaskets  
9001280  
9001280  
9001280  
9001280  
27.  
28.  
29.  
30.  
31.  
6” I.D. x 8 1/8” Vent Pipe  
6” O.D. x 8 1/8” Vent Extension Pipe  
3” O.D. x 8 3/8” Flue Pipe  
Rope Gasket  
9001277  
9001274  
9001283  
9000712  
9000710  
9001277  
9001274  
9001283  
9000712  
9000710  
9001277  
9001274  
9001283  
9000712  
9000710  
9001277  
9001274  
9001283  
9000712  
9000710  
9001277  
9001274  
9001283  
9000712  
9000710  
O-Ring Gasket  
37  
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REPAIR PARTS LIST  
38  
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REPAIR PARTS LIST (cont’d.)  
PARTS  
GAL. CAP.  
40  
50  
40  
50  
75  
KEY # DESCRIPTION BTU’s in 1000’s NAT/L.P.  
36/36  
38/38  
40/40  
48/44  
55 NAT.  
KitAVK-2 No. 9001247  
32.  
3” I.D. x 13 7/8” Flue Extension Pipe with  
Gaskets  
9001281  
9001281  
9001281  
9001281  
9001281  
33.  
34.  
35.  
36.  
37.  
6” O.D. x 13 5/8” Vent Extension Pipe  
3” O.D. x 13 3/8” Flue Pipe  
6” I.D. x 13 5/8” Vent Pipe  
Rope Gasket  
9001275  
9001284  
9001278  
9000712  
9000710  
9001275  
9001284  
9001278  
9000712  
9000710  
9001275  
9001284  
9001278  
9000712  
9000710  
9001275  
9001284  
9001278  
9000712  
9000710  
9001275  
9001284  
9001278  
9000712  
9000710  
O-Ring Gasket  
KitAVK-3 No. 9001248  
3” I.D. x 24 3/8” Flue Extension Pipe with  
Gaskets  
38.  
9001282  
9001282  
9001282  
9001282  
9001282  
39.  
40.  
41.  
42.  
43.  
44.  
45.  
46.  
47.  
48.  
49.  
50.  
51.  
52.  
53.  
54.  
55.  
56.  
57.  
6” O.D. x 24 3/8” Vent Extension Pipe  
3” O.D. x 24 3/8” Flue Pipe  
6” I.D. x 24 3/8” Vent Pipe  
Rope Gasket  
9001276  
9001285  
9001279  
9000712  
9000710  
9000718  
9000712  
9000719  
9003168  
9003166  
9003165  
9002769  
—
9001276  
9001285  
9001279  
9000712  
9000710  
9000718  
9000712  
9000719  
9003168  
9003166  
9003165  
9002769  
—
9001276  
9001285  
9001279  
9000712  
9000710  
9000718  
9000712  
9000719  
9003168  
9003166  
9003165  
9002769  
—
9001276  
9001285  
9001279  
9000712  
9000710  
9000718  
9000712  
9000719  
9003168  
9003166  
9003165  
9002769  
—
9001276  
9001285  
9001279  
9000712  
9000710  
9000718  
9000712  
9000719  
9003168  
9003166  
9003165  
—
O-Ring Gasket  
3” Flue Elbow  
Rope Gasket  
6” Vent Elbow  
Inside Wall Collar  
6” Vent Wall Assembly  
Vent CapAssembly  
24” Diameter Drain Pan w/Side Drain  
28” Diameter Drain Pan w/Side Drain  
24” Base Stand  
9001608  
—
9001422  
9000915  
*9002365  
9000724  
9000725  
9003410  
9001422  
9000915  
9001595  
9000724  
9000725  
9003410  
9001422  
9000915  
*9002365  
9000724  
9000725  
9003410  
9001422  
9000915  
*9002361  
9000724  
9000725  
9003410  
Wire Grill Protector  
9000915  
*9001598  
9000724  
9000725  
9003410  
Dip Tube  
6” Vent Wall Assembly  
Brown-Porcelain Vent CapAssembly  
Piezo Ignitor w/Bracket  
*NOTE: Some models are factory equipped with a special dip tube to retard a build-up of mineral deposits precipitating from  
the water supply over time. This is not illustrated and is not a replaceable part.  
Now that you have purchased this water heater, should a need ever exist for repair parts or service, simply contact the  
company it was purchased from or direct from the manufacturer listed on the rating plate on the water heater.  
Be sure to provide all pertinent facts when you call or visit.  
Selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed  
accordingly.  
The model number of your water heater will be found on the rating plate located above the gas control valve.  
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION:  
MODEL NUMBER  
SERIAL NUMBER  
TYPE GAS  
PARTDESCRIPTION  
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.  
39  
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TROUBLESHOOTING GUIDELINES  
These guidelines should be utilized by a qualified service agent.  
Problem  
Cause  
Solution  
Improperly sealed, hot or cold supply connection,  
relief valve, drain valve, or thermostat threads.  
Leakage from other appliances or water lines.  
Condensation of flue products.  
Tighten threaded connections.  
WATER LEAKS  
Inspect other appliances near water heater.  
Refer to CONDENSATE.  
Thermal expansion in closed water system.  
Improperly seated valve.  
Install thermal expansion tank (DO NOT plug T&P valve).  
Check relief valve for proper operation  
(DO NOT plug T&P valve).  
LEAKING T&P VALVE  
SMELLY ODORS  
High sulfate or mineral content in water supply.  
Drain and flush heater thoroughly, then refill.  
Bacteria in water supply.  
Chlorinate or aerate water supply.  
Refer to LIGHTING INSTRUCTIONS.  
Turn on main gas Shut-off valve.  
Adjust ignitor tip.  
Gas control knob not positioned correctly.  
Main gas supply off.  
Igniter tip more than 1/8" from pilot hood.  
Melted insulation on ignitor wire or shorting  
of ignitor wire.  
Contact a service agency to determine cause.  
PILOT WILL NOT LIGHT  
Wire disconnected from spark ignitor.  
Broken electrode or electrical wire.  
Piezo Ignitor generator fails to operate or  
malfunctions.  
Reconnect wire connector to spark ignitor.  
Replace pilot assembly.  
Replace Piezo Ignitor generator.  
BURNER WILL NOT  
STAY LIT  
Thermocouple malfunction.  
Replace pilot assembly.  
Defective Gas Control.  
Replace Gas Control.  
Dirty pilot burner.  
Clean pilot assembly.  
PILOT OUTAGE  
Thermocouple tip is not in contact with pilot flame.  
Thermocouple malfunction.  
Insert thermocouple correctly.  
Replace pilot assembly.  
Defective Gas Control.  
Replace Gas Control.  
Heater not lit or thermostat not on.  
Thermostat set too low.  
Refer to LIGHTING INSTRUCTIONS.  
Refer toTEMPERATURE REGULATION.  
Reduce hot water use.  
Heater undersized.  
NOT ENOUGH  
HOT WATER  
Low gas pressure.  
Contact your gas supplier.  
Incoming water is unusually cold.  
Leaking hot water pipes or fixtures.  
High temperature limit switch activated.  
Allow more time for heater to re-heat.  
Have plumber check and repair leaks.  
Contact a service agency to  
determine cause.  
WATER TOO HOT  
WATER HEATER SOUNDS  
SIZZLING - RUMBLING  
Thermostat set too high.  
Refer toTEMPERATURE REGULATION.  
Refer to CONDENSATE above.  
Clean sediment from tank. Refer to DRAINING  
instructions in Maintenance section of manual.  
No adjustment available. Contact a service agency  
to determine cause.  
Condensation dripping on burner.  
Sediment or calcium in bottom of heater tank.  
SOOTING  
Improper combustion.  
Lack of supply air.  
Improperly installed vent piping.  
Downdraft  
VENT GAS ODORS  
Contact a service agency to determine cause.  
Poor combustion.  
40  
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NOTES:  
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NOTES:  
42  
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NOTES:  
43  
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44  
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