John Wood 4040SN-PDV User manual

PART NO. 186723-000 REV. B (08-07)
GSW Water Heating is a division of
A. O. Smith Enterprises Ltd.
WARNING:
If the information in these instructions is
not followed exactly, a fire or explosion
may result causing property damage, per-
sonal injury or death.
WARNING:
Improper installation, adjustment, alter-
ation, service, or maintenance can cause
injury or property damage. Refer to this
manual. For assistance or additional infor-
mation, consult a qualified installer, serv-
ice agency, or the gas utility.
FOR YOUR SAFETY
• Do not store or use gasoline or other
flammable vapours and liquids in the
vicinity of this or any other appliance.
• Installation and service must be per-
formed by a qualified installer, service
agency or the gas utility.
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier from
a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
WHAT TO DO IF YOU SMELL GAS
POWER DIRECT VENT WATER HEATER
INSTALLATION AND OPERATING INSTRUCTIONS
Read and understand these instructions thoroughly before starting

– 2 –
This page intentionally left blank. May be used for notes or to record other installation information.

– 3 –
I) INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
User Responsibilities 4
II) SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
For Installations in Canada: 5
For Installations in the United States: 5
Safety Warning (Flammable Vapours) 5
Safety Warning (Scalding) 5
Relief Valve Requirements (T&P) 6
III) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking the Water Heater 6
Location Requirements 6
Site Location 6
Clearances and Accessibility 7
In Earthquake Zones
Gas Supply 7
Gas Requirements
Gas Piping
Gas Pressure
Gas Pressure Testing
Venting 8
Vent Pipe Material
Vent Pipe Connection to Blower
Vent Pipe Installation
Vent Pipe Length
Vent Pipe Runs
Vent Pipe Termination
Vent Terminal Installations
Side Wall Vent Terminal Installation
Vertical Vent Terminal Installation
Concentric Vent Termination Kit Installation
Water Supply 13
Piping Installation
Closed System/Thermal Expansion
Temperature and Pressure (T&P) Relief Valve 14
The Temperature and Pressure Relief Valve:
The Discharge Line:
Electrical Supply 14
Resettable Lockout 15
Installation Checklist 18
IV) LIGHTING & OPERATING INSTRUCTIONS . . . . 19
Lighting Instructions (Robertshaw) 19
First Lighting 20
Gas Control
Robertshaw 2000N WDER Operation
Temperature Adjustment
Lighting Instructions (White-Rodgers) 22
Gas Control/Thermostat
Putting the Heater into Service
Temperature Adjustment
Heater Shutdown
System Error Codes
Intelli-VentTM System Error Codes
V) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Water Heater Operation 26
Burner Flames 26
Stacking 26
Emergency Shut Down 26
Operational Conditions 26
Condensation
Water Heater Sounds
Smoke/Odour
Anode Rod/Water Odour
VI) MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Draining and Flushing 28
Routine Preventative Maintenance 28
Temperature and Pressure Relief Valve 28
Replacement Parts 28
VII) COMBO HEATING . . . . . . . . . . . . . . . . . . . . . . . . 29
System Requirements 29
Installation 30
VIII) TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 31
Robertshaw 2000N WDER and White-Rodgers
Intelli-VentTM 31
IX) PARTS REFERENCE ILLUSTRATION. . . . . . . . . 32
LIMITED WARRANTY. . . . . . . . . . . . . . . . . . . . . . 33
TABLE OF CONTENTS
RETAIN THESE INSTRUCTIONS IN A SAFE LOCATION FOR FUTURE REFERENCE

I) INTRODUCTION
Thank you for purchasing a GSW Power Direct Vented
Water Heater. Properly installed and maintained, it will pro-
vide years of trouble free service.
This gas-fired water heater has been developed to produce
potable hot water for normal residential demands and may
also be used in combination with space heating applica-
tions. Any deviation from these applications could affect
your warranty.
User Responsibilities
This manual has been prepared to acquaint you with the
installation, operation and maintenance of your gas water
heater and provide important safety information in these
areas. It is your responsibility to ensure that your water
heater is properly installed and cared for.
FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS
MANUAL MAY RESULT IN SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE. THOROUGHLY READ
AND UNDERSTAND ALL INSTRUCTIONS BEFORE YOU
ATTEMPT TO INSTALL, OPERATE OR MAINTAIN THIS
HEATER.
Installation and service requires trade knowledge in the
areas of plumbing, electricity, venting, air supply and gas
supply. If you lack these skills, or have difficulty under-
standing these instructions, you should not proceed. Enlist
the help of a qualified service technician to install this water
heater.
Examples of qualified service technicians include those
trained in the plumbing and heating industry, local gas utili-
ty personnel, or an authorized service person.
– 4 –
Your safety and the safety of others is very important.
We have provided many important safety messages in this manual and on your appliance.
Always read and obey all safety messages.
All safety messages will tell you what the potential hazard is, tell you how to reduce the
chance of injury, and tell you what can happen if the instructions are not followed.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word
“DANGER” or “WARNING”.
DANGER
WARNING
You can be killed or seriously injured if you don’t immediately follow
instructions.
You can be killed or seriously injured if you don’t follow instructions.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to
publish a list of substances known to the State of California to cause cancer, birth defects, or other
reproductive harm, and requires businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth
defects, or other reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formalde-
hyde, carbon monoxide, and soot.
CAUTION
Hydrogen gas can be produced in a hot water system served by this heater that has not been used
for a long period of time (generally two (2) weeks or more). Hydrogen gas is extremely flammable
and can ignite when exposed to a spark or flame. To reduce the risk of injury under these condi-
tions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink
before using any electrical appliance connected to the hot water system. Use caution in opening
faucets. If hydrogen is present, there will probably be an unusual sound such as air escaping through
the pipe as the water begins to flow. There should be no smoking or open flame near the faucet at
the time it is open.
Do not use this appliance if any part has been under water. Immediately call a qualified service tech-
nician. Water heaters subjected to flood conditions or anytime the gas controls, main burner or pilot
have been submerged in water require replacement of the entire water heater.

Service to the Power Direct Vent System should only be
performed by a qualified service technician.
The manufacturer and seller of this water heater will not
assume any liability for any property damage, personal
injury or death resulting from improper sizing, installation or
failure to comply with these instructions.
The warranty on this water heater is in effect only when the
water heater is installed and operated in accordance with
these instructions. A data plate identifying your water heater
can be found next to the gas control/thermostat. When
referring to your water heater, always have the information
listed on the data plate readily available.
Protect your warranty: Regularly service your water
heater as directed in the "Maintenance" section of this man-
ual.
Retain your original receipt as proof of purchase.
Do not discard this manual. You or future users of this
water heater will need it for reference.
II) SAFETY
This water heater is design-certified by CSA International as
a Category I, direct vented water heater which takes its
combustion air from the outside of the structure and
exhausts all products of combustion to the outside of the
structure.
In addition to the installation instructions found in this man-
ual, the water heater must be installed in accordance with
all local and provincial or state codes or, in the absence of
such, with the latest editions of the following specifications.
For Installations in Canada:
“Natural Gas and Propane Installation Code” CAN/CSA-
B149.1 and
“Canadian Electrical Code (CAN/CSA C22.1), Part I”
available from:
Canadian Standards Association,
5060 Spectrum Way,
Mississauga, Ontario, Canada
L4W 5N6
For Installations in the United States:
“National Fuel Gas Code” ANSI Z223.1 (NFPA 54) and
“National Electrical Code” (NFPA 70)” available from:
American National Standards Institute,
25 West 43rd Street,
New York, NY 10036
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing and
Fuel Gas Code 248 CMR Section 2.00 and 5.00.
Check your phone listings for the local authorities having
jurisdiction over your installation.
Safety Warning (Flammable Vapours)
There is a risk of property damage, personal injury or death
from the by-products of combustion (e.g., flue gases), in
using fuel-burning appliances such as water heaters. Areas
that may not be suitable for water heater installation include
those where flammable liquids, gasoline, solvents, adhe-
sives etc. are stored, or where engine-driven equipment or
vehicles are stored, operated or repaired. These, and simi-
lar products, should not be stored or used near the water
heater or air intake. Due to the nature of air movement,
flammable vapours can be carried some distance from the
point of storage. The gas-fired water heater igniter or burn-
er flame can ignite these vapours causing a flashback, fire
or explosion, which may result in severe property damage,
serious personal injury or death. If flammable liquids or
vapours have spilled or leaked in the area of the water
heater, leave the area immediately and call the fire depart-
ment from a neighbor’s home. Do not attempt to clean the
spill until all ignition sources have been extinguished.
Safety Warning (Scalding)
Hot water produced by this appliance can cause severe
burns due to scalding. The hazard is increased for young
children, the aged or the disabled when water temperatures
exceed 52°C (125°F). Use tempering valves, also known as
mixing valves, in the hot water system to reduce the risk of
scalding at point-of-use such as lavatories, sinks and
bathing facilities. Such precautions must be followed when
this heater is operated in combination with dishwashing or
space heating applications.
– 5 –
WARNING
Flammable Vapours
FLAMMABLES
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other flammable vapours and liquids
in the vicinity of this or any other appliance. Storage of or use of gasoline
or other flammable vapours or liquids in the vicinity of this or any other
appliance can result in serious injury or death.
DANGER