Lochinvar RESIDENTIAL GAS WATER HEATERS User manual

1
Instruction Manual
PRINTED 0911 322830-000
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
POWER VENTED GAS MODELS WITH HOT SURFACE IGNITION
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
ALLTECHNICALANDWARRANTYQUESTIONS:SHOULDBEDIRECTEDTOTHELOCALDEALERFROMWHOMTHEWATERHEATERWASPURCHASED.
IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICALASSISTANCE AT 1-615-889-8900 OR VIA E-MAILAT [e-mail].
RESIDENTIAL GAS WATER HEATERS
• For Your Safety •
AN ODORANT ISADDED TO THE GAS USED
BY THIS WATER HEATER.
GAMA certification applies
to all residential gas water
heaters with capacities of 20
to100gallons withinputrating
of 75,000 BTU/Hr. or less.
300 Maddox Simpson Parkway
Lebanon, TN 37090
Phone: [phone] • Fax: [phone]
Technical Services email: [e-mail]
www.lochinvar.com
LOW LEAD
COMPLIANT

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SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use or service this water heater.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or injury.
WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or injury.
CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, could result in property damage
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
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 included in the Act.
IMPORTANT DEFINITIONS
• Qualified Installer: Aqualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
designfeaturesanduseof flammable vaporignition resistant waterheaters, and havea thorough understandingof this
instruction manual.
• ServiceAgency: Aservice agency also must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understandingof thisinstruction manual,and beable toperform repairsstrictly inaccordance withthe serviceguidelines
provided by the manufacturer.
• Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of
gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also
offer service and inspection of appliances within the building.

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GENERAL SAFETY

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SAFE INSTALLATION, USE AND SERVICE............................2
GENERAL SAFETY..................................................................3
TABLE OF CONTENTS............................................................4
INTRODUCTION......................................................................4
Preparing for the New Installation.....................................4
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS...........................5
TYPICAL INSTALLATION..................................................... 6-7
LOCATING THE NEW WATER HEATER........................... 8-10
Facts to Consider About Location................................. 8-9
Insulation Blankets............................................................9
Combustion Air and Ventilation for Appliances
Located in Unconfined Spaces.........................................9
Combustion Air and Ventilation for Appliances
Located in Confined Spaces....................................... 9-10
INSTALLING THE WATER HEATER.................................11-21
Water Piping ..............................................................11-12
Temperature-Pressure Relief Valve................................12
Gas Piping ......................................................................13
Sediment Traps...............................................................14
Blower Assembly Installation ..........................................15
Vent Pipe Connection to Blower Assembly.....................16
Venting and Installation............................................. 16-17
LIGHTING & OPERATING LABEL.........................................21
TEMPERATURE REGULATION ............................................22
FOR YOUR INFORMATION...................................................23
Start Up Conditions.........................................................23
Condensate.....................................................................23
Smoke/Odor....................................................................23
Thermal Expansion.........................................................23
Strange Sounds..............................................................23
Operational Conditions ...................................................23
Smelly Water...................................................................23
“Air” in Hot Water Faucets ..............................................23
High Temperature Shut Off System................................23
PERIODIC MAINTENANCE...................................................24
Venting System Inspection..............................................24
Burner Inspection............................................................24
Burner Cleaning..............................................................24
Housekeeping........................................................... 24-25
Anode Rod Inspection.....................................................25
Temperature-Pressure Relief Valve Operation ...............25
Draining...........................................................................25
Drain Valve Washer Replacement............................ 25-26
Service............................................................................26
LEAKAGE CHECKPOINTS....................................................26
REPAIR PARTS......................................................................27
TROUBLESHOOTING ..................................................... 28-30
WARRANTY...........................................................................31
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
Abbreviations Found In This Instruction Manual:
• CSA - Canadian Standards Association
• ANSI -American National Standards Institute
• NFPA - National Fire Protection Association
• ASME -American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
• UL - Underwriters Laboratories Inc.
Thisgas-firedwater heaterisdesigncertifiedby Underwriters Laboratories
Inc. under American National Standard/CSA Standard for Gas Water
Heaters ANSI Z21.10.1 • CSA 4.1 (current edition).
PREPARING FOR THE INSTALLATION
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,
SERIOUS BODILY INJURYAND/OR PROPERTY DAMAGE.
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 INSTALL OR OPERATE THE WATER
HEATER.
2. Theinstallationmustconformwiththeseinstructionsandthe local code
authorityhavingjurisdiction.Intheabsenceoflocalcodes,installations
shall comply with the National Fuel Gas Code ANSI Z223.1/NFPA
54 and the National Electrical Code, NFPA 70. These publications
are available from The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
3. Thewater heater when installed must begroundedinaccordancewith
thelocal codes, or inthe absence oflocal codes: In theUnited States,
the National Electrical Code. ANSI/NFPA 70 (current edition).
4. 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.
5. 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.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
6. ForCaliforniainstallation this water heatermustbe 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 State Architect, 400 P Street,
Sacramento, CA 95814.
7. Massachusetts Code requires this water heater to be installed in
accordancewithMassachusetts248-CMR2.00:StatePlumbing Code
and 248-CMR 5.00. For more information see next page.
8. Complies with SCAQMD rule #1121 and districts having equivalent
NOx requirements.
INTRODUCTION
TABLE OF CONTENTS

5
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed
in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the
area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber
or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard
wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a bat-
tery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSAcertified.
SIGNAGE Ametal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appli-
ance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54
as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturerofProduct
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with
the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall
include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of
a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases,
but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe–Exhaust
B Vent Terminal
C Vent Adapter-Rubber Boot
D Blower Assembly
E Cold Water Inlet
F Inlet Water Shut-off Valve
G Union
H Inlet Dip Tube
J Anode**
K Hot Water Outlet
L Outlet Receptacle (115 VAC)
M Temperature-Pressure Relief Valve
FIGURE 1.
N Flue
O Flue Baffle Assembly**
P Insulation
Q Control Harness
R Rating Plate
S Gas Supply
T Manual Gas Shut-off Valve
U Ground Joint Union
V Drip Leg (Sediment Trap)
W Drain Valve
X Gas Control Valve / Thermostat
Y Metal Drain Pan
Z Air Intake Screen - Base Pan
AA Inner Door
B B Outer Door
CC HSI Burner Assembly
D D Air Intake Screen -
Blower Assembly
E E FV Sensor/Bracket Assembly
(40K & 50K Models Only)
F F FV Sensor/Bracket Assembly
(55K & 62.5K Models Only)
NATURAL HOT SURFACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITOR
SENSOR
PROPANE HOT SURFACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITOR
SENSOR
*CAUTION: 115 VAC IN CONTROL HARNESS
AND INSIDE OUTER DOOR
* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.
** LOCATED UNDER THE BLOWER ASSEMBLY.
GAS MODELS
WITH HOT SURFACE IGNITION
& 2", 3" OR 4" PVC VENT CAPABILITY
TEMPERATURE INDICATORS
TEMPERATURE ADJUSTMENT BUTTONS
GAS CONTROL VALVE-THERMOSTAT

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NON-SCALD
MIXING VALVE
METAL DRAIN PAN
TYPICAL INSTALLATION
FIGURE 2.
MIXING VALVE USAGE
This appliance has been design certified as complying with American
National Standard/CSAStandard for water heaters and is considered
suitable for:
Water (Potable) Heating and Space Heating: All models are
considered suitable for water (potable) heating and space heating.
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, 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
codeor statelaw requiring acertain temperaturewater atthe hot water
tap, then you must take special precautions. In addition to using the
lowestpossible temperature settingthat satisfies yourhot water needs,
a means such as a *Mixing Valve should be used at the hot water taps
usedbythese people oratthewater heater. Mixingvalvesare 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 Figure 19.

8
FACTS TO CONSIDER ABOUT THE LOCATION
Carefullychoose an indoor location forthe newwater 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. Select a location indoors as close as practical to the vent terminal
or location to which the water heater vent piping is going to be
connected, and as centralized with the water piping system as
possible.
2. Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
Installationofthewater heater mustbeaccomplishedin such amanner
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
thewater heater inan attic orupper floor. When such locationscannot
be avoided, a suitable metal drain pan should be installed under the
water heater. Metal drain pans are available at your local hardware
store. Sucha metaldrain panmust havea minimumlength andwidth
of at least 2" (5.1 cm) greater that the water heater dimensions and
must be piped to an adequate drain. The metal drain pan must not
restrict combustion air flow.
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 metal 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 metal 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 metal drain pan that trigger an alarm or
turn off the incoming water to the water heater when leakage is
detected.
• Sensorsmountedin themetaldrain pan thatturnoffthe water supply
to the entire home when water is detected in the metal 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.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS)ARE LIKELYTOBEPRESENTORSTORED(GARAGES,
STORAGEAND UTILITYAREAS, ETC.): Flammable liquids (such as
gasoline,solvents, propane(LPor butane, etc.)and othersubstances
(suchas adhesives,etc.) emitflammable vaporswhich can be ignited
by a gas water heater’s hot surface igniter or main burner. The
resultingflashbackandfirecancausedeathor serious burnstoanyone
in the area. This water is equipped with a FV sensor for detecting the
presenceof flammable vapors,seeFigure 3.Whenthe sensordetects
those vapors, the unit will shut down and not operate. Should this
happen, please refer to the troubleshooting guide on pages 28-30.
Eventhough thiswater heateris aflammable vaporsignition resistant
water heater and is designed to reduce the chances of flammable
vaporsbeingignited, gasoline andother flammable substances should
never be stored or used in the same vicinity or area containing a gas
water heater or other open flame or spark producing appliance.
LOCATING THE NEW WATER HEATER
FIGURE 3.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
Thiswaterheater must not beinstalleddirectly 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" (7.6 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.
Minimum clearances between the water heater and combustible
surfaces are 0 inch at the sides and rear, 5" (12.7 cm) from the front

9
and 12" (30.5 cm) from the top. (Standard clearance.) If clearances
stated on the heater differ from standard clearances, install water
heater according to clearances stated on the heater.
Adequateclearance forservicing this appliance should beconsidered
before installation, such as changing the anodes, etc.
A minimum clearance of 5" (12.7 cm) must be allowed for access
to replaceable parts such as the thermostats, drain valve and relief
valve.
When installing the heater, consideration must be given to proper
location.Locationselected should be ascloseto the wallaspracticable
and as centralized with the water piping system as possible.
FIGURE 4.
Agas waterheatercannot operate properlywithout the correctamount
ofairfor combustion. Donotinstall in aconfinedarea such asa closet,
unless you provide air as shown in the “Locating The New Water
Heater” section. Never obstruct the flow of ventilation air. If you have
anydoubts or questionsatall, callyourgas supplier. Failureto provide
the proper amount of combustion air can result in a fire or explosion
and cause death, serious bodily injury, or property damage.
FIGURE 5.
Ifthiswaterheater will beusedinbeauty shops, barbershops,cleaning
establishments,orself-servicelaundrieswith dry cleaningequipment,it
isimperative that thewater heateror water heatersbe installedso that
combustion and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorinebased chemicals, refrigerants, etc.) inaddition tobeing highly
flammableinmany cases, willalso react toformcorrosive hydrochloric
acid when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure.
INSULATION BLANKETS
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the National Appliance Energy Conversation Act standards
with respect to insulation and standby loss requirements, making an
insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the draft hood.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
• Do not allow insulation to come within 2" (5.1 cm) of the floor to
prevent blockage of combustion air flow to the burner.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Doobtain newwarning andinstruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air flow.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 cubic meters per kW) of the
aggregateinput rating of all appliancesinstalled in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of tight construction (for example, weather
stripping,heavily insulated,caulked, vaporbarrier,etc.), additionalair
mayneed to beprovided using themethods describedin “Combustion
Air and Ventilation for Appliances Located in Confined Spaces.”
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SPACES
CONFINED SPACE is a space whose volume is less than 50 cubic
feet per 1,000 Btu per hour (4.8 cm per kW) of the aggregate input
rating of all appliances installed in that space.

10
Chemical vapor corrosion of the flue, blower assembly 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.
A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 5 and 6)
The confined space shall be provided with two permanent openings
communicatingdirectly with an additional room(s)of sufficientvolume
so that the combined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utilization equipment
installed in the combined space shall be considered in making this
determination. Each opening shall have a minimum free area of one
squareinchper1,000Btuperhour(22cm2/kW)ofthetotalinputratingof
allgasutilizationequipmentintheconfinedspace, butnot less than100
squareinches(645cm2).Oneopeningshallcommencewithin12inches
(31 cm) of the top and one commencing within 12 inches (31 cm) of
the bottom of the enclosures.
FIGURE 6.
B. ALL AIR FROM OUTDOORS: (See Figures 7, 8 and 9)
The confined space shall be provided with two permanent openings,
one commencing within 12 inches (31 cm) of the top and one
commencing within 12 inches (31 cm) from the bottom of the
enclosure. The openings shall communicate directly, or by ducts,
with the outdoors or spaces (crawl or attic) that freely communicate
with the outdoors.
1. Whendirectly communicating withtheoutdoors,each opening shall
have a minimum free area of 1 square inch per 4,000 Btu per hour
(5.5 cm2/kW)of totalinput ratingof allequipment inthe enclosure,
see Figure 7.
FIGURE 7.
2. Whencommunicating with the outdoorsthroughverticalducts,each
openingshall have aminimum freearea of 1square inchper 4,000
Btu per hour (5.5 cm2/kW) of total input rating of all equipment in
the enclosure, see Figure 8.
3. When communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 square inch
per 2,000 Btu per hour (11 cm2/kW)) of total input rating of all
equipment in the enclosure, see Figure 9.
FIGURE 8.
4. When ducts are used, they shall be of the same cross-sectional
area as the free area of the openings to which they connect. The
minimum short side dimension of rectangular air ducts shall not
be less than 3 inches (7.6 cm), see Figure 9.
FIGURE 9.
5. Alternatively a single permanent opening may be used when
communicatingdirectly with theoutdoors,or withspacesthat freely
communicatewiththe outdoors.Theopening shall haveaminimum
free area of 1 square inch per 3,000 BTU per hour (8.3 cm2/kW)
of total input rating of all equipment in enclosure. See Figure 9A.
FIGURE 9A.
6. Louversand Grilles: Incalculating freearea, consideration shallbe
given to the blocking effect of louvers, grilles or screens protecting
openings. Screens used shall not be smaller than 1/4 inch
(6.4 mm) mesh. If the free area through a design of louver or
grille is known, it should be used in calculating the size opening
required to provide the free area specified. If the design and free
area is not known, it may be assumed that wood louvers will be
20-25 percent free area and metal louvers and grilles will have
60-75 percent free area. Louvers and grilles shall be fixed in the
open position or interlocked with the equipment so that they are
opened automatically during equipment operation.
7. SpecialConditionsCreatedbyMechanicalExhaustingorFireplaces:
operation of exhaust fans, ventilation systems, clothes dryers or
fireplacesmaycreateconditions requiring specialattentionto avoid
unsatisfactory operation of installed gas utilization equipment.

11
WATER PIPING
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,cleaningandother sanitizing needscanscaldand permanently
injureyouupon contact. Somepeopleare more likelytobe permanently
injuredby hot waterthan others. Theseinclude the elderly,children, the
infirm,or physically/mentallyhandicapped. If anyone using hot waterin
yourhome fitsinto one of these groupsor ifthere 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 should be used at the hot water taps used by these
people or at the water heater, see Figure 2. Valves for reducing point
of use temperature by mixing cold and hot water are also available:
Consulta 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 mixing valve
must be installed. Please refer to Figure 2 for suggested piping
arrangement.
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or such
conditions as high line pressure, among others, have installed devices
such as pressure reducing valves, check valves, and back flow
preventers. Devices such as these cause the water system to be a
closed system.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed system
thevolumeof water willgrow.As the volumeofwater grows therewillbe
a corresponding increase in water pressure due to thermal expansion.
Thermalexpansioncancausepremature tank failure (leakage). This type
of failure is not covered under the limited warranty. Thermal expansion
can also cause intermittenttemperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure build up.
The temperature-pressure relief valve is not intended for the constant
relief of thermal expansion. This condition is not covered under the
limited warranty.
A properly sized thermal expansion tank should be installed on all
closed systems to control the harmful effects of thermal expansion.
Contact a local plumbing service agency to have a thermal expansion
tank installed.
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.
All gas piping must comply with local codes and ordinances or with
the National Fuel Gas Code (ANSI Z223.1/ NFPA-54)(current edition)
whichever applies. Copper and brass tubing and fittings (except tin
lined copper tubing) shall not be used.
INSTALLING THE NEW WATER HEATER
FIGURE 10.

12
Figure 10 shows the typical attachment of the water piping to the
water heater. The water heater is equipped with 3/4 inch NPT water
connections.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the cold water inlet connection. Do not
solder the cold water supply line directly to the cold water inlet.
It will harm the dip tube and damage the tank.
T & P Valve and Pipe Insulation (if supplied)
1. Locate the temperature and relief valve on the water heater (also
known as a T&P Relief Valve, Figure 11).
2. Locate the slit running the length of the insulation.
3 Spread this slit open and slip it up under the T&P Relief Valve.
See Figure 11. Apply gentle pressure to the insulation to ensure it
is fully seated on the T&P Relief Valve. Once sealed secure the
insulation with a section of duct tape, elecrical tape, or equivalent.
IMPORTANT: The insulation or tape must not block the discharge
opening or hinder access to the manual relief lever. Ensure a
discharge pipe is installed into the T&P valve discharge opening
per the instructions manual.
4. Locate the hot water (outlet) & cold water (inlet) pipes to the water
heater.
5. Locate the slit running the length of a section of pipe insulation.
6. Spread the slit open and slip the insulation over the cold water
(inlet) pipe. Apply gentle pressure along the length of the
insulation to ensure it is fully seated around the pipe. Also ensure
that the base of insulation is flush with the water heater. Once
seated, secure the insulation with duct tape, electrical tape, or
equivalent.
7. Repeat steps 5 through 6 for the hot water (outlet) pipe.
8. Add additional sections of pipe insulation as needed.
T&P Relief Valve Insulation
Manual Relief Lever
T&P Relief Valve
T&P Relief Valve
Drain Line
FIGURE 11.
TEMPERATURE-PRESSURE RELIEF VALVE
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 for Hot Water
Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements
of ASME.
Ifreplaced, the valvemust meet therequirements of localcodes, butnot
less than a combination temperature and pressure relief valve certified
as indicated in the above paragraph.
The valve must be marked with a maximum set pressure not to
exceed the marked hydrostatic working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity not less than the water
heater input rate as shown on the model rating plate.
For safe operation of the water heater, the relief valve must not be
removed from its designated opening nor plugged.
The temperature-pressure relief valve must be installed directly into
the 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 (15.2 cm) 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 Figures 10 or 14.
No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect tubing directly to discharge drain unless
a 6" (15.2 cm) air gap is provided. To prevent bodily injury, hazard to
life, or property damage, the relief valve must be allowed to discharge
waterin quantities should circumstances demand. Ifthe discharge pipe
is not connected to a drain or other suitable means, the water flow may
cause property damage.
The Discharge Pipe:
•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.
•Must terminate a maximum of six inches above a floor drain or
external to the building. In cold climates, it is recommended that
the discharge pipe be terminated at an adequate drain inside the
building.
•Shall not have any valve between the relief valve and tank.

13
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 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 gas pressure must not exceed 14 inch water
column (3.5 kPa) 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.
All gas piping must comply with local codes and ordinances or with
theNational FuelGas Code(ANSI Z223.1/NFPA-54)(current edition)
whichever applies. Copper and brass tubing and fittings (except tin
lined copper tubing) shall not be used.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(14 inches water column) (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.
A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas CodeANSI Z223.1/NFPA 54
and your gas supplier concerning pipe size.
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 asoapy water solution, not amatch oropen flame. Rinse
off soapy solution and wipe dry.
When installed at elevations above 7,700 feet (2,347 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
burnerorificeinaccordancewithNational Fuel Gas CodeANSI Z223.1/
NFPA 54. Contact your local gas supplier for further information.
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,
whichcould resultin serious injuryor death.Contact yourgas supplier
for any specific changes which may be required in your area.
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 (14
incheswatercolumn) (3.5 kPa). Itshallbe isolated fromthegas supply
piping system by closing its individual manual Shut-off valve during
anypressure testingof thegas supply piping system at test pressures
equal to or less than 1/2 pound per square inch (3.5 kPa).
Connecting the gas piping to the gas control valve of the water heater
can be accomplished by either of the two methods shown in Figures
12 and 13.

14
FIGURE 12. GAS PIPING WITH
FLEXIBLE CONNECTOR.
FIGURE 13. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL VALVE.
SEDIMENT TRAPS
Asediment trap (drip leg) 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
bottomoutlet orother device recognized as aneffectivesediment trap
(drip leg). If a tee fitting is used, it shall be installed in conformance
with one of the methods of installation shown in Figures 12 and 13.
Contaminants in the gas lines may cause improper operation of the
gascontrol valve that may result in fireor explosion. Before attaching
thegas linebe sure that all gaspipe isclean onthe inside. To trapany
dirt or foreign material in the gas supply line, a drip leg (sometimes
calledasediment trap) mustbe incorporated inthepiping. The drip leg
mustbe readily accessible. Installin accordance withthe “Gas Piping”
section. Refer to the current edition of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54.
FIGURE 14.
FILLING THE WATER HEATER
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.
BLOWER ASSEMBLY INSTALLATION
SEQUENCE OF INSTALLATION
1. This power vented water heater comes with the blower assembly
installed.
2 After the unit is set in place, make sure the blower assembly is still
mounted securely and the air intake screen of the blower assembly
is installed in the dilution air opening. Also make sure the drain port
ofthe rubber bootvent adapter is cappedoff.Lastly,make sure there
is no damage to the blower.
3. Makesure there isno packing material inthe discharge ofthe blower
or the intake of the dilution air restrictor, see Figure 15.
4. Makesurethattheplastictubingisstillattachedfromtheairpressureswitch
totheportontheblower housing.Makesurethe plastictubingis notfolded
anywhere between the pressure switch and the blower housing.

15
5. MakesuretheON/OFFswitchisintheOFF position and that the outer
harness is connected from the blower control box to the connector
on the bottom side of the gas control valve.
6. If the outer harness is not factory installed, make sure the ON/OFF
switch is in the OFF position and then connect the outer harness
from the blower control box to the connector on the bottom side of
the gas control valve.
7. This water heater is a poloarity sensitive appliance and will not operate if
the power supply polarity is reversed. The power supply or outlet providing
power to this water heater must be wired properly (correct polarity).
8. Do not plug in power cord until vent system is completely installed. This
powered vent heater operates on 110-120 Vac, therefore a grounded
outlet must be within reach of the six (6) foot (1.8 m) flexible power cord
supplied with the unit (see Figure 1). The power cord supplied may be
used onlywhere local codes permit.If local codesdo not permitthe use
of a flexible power supply cord:
a.) Make sure the unit is unplugged from wall outlet. Remove screws
and open panel on front of control box.
b.) Cut the flexible power cord, leaving enough to be able to make
connections, the remove the strain relief fitting from box.
c.) Install suitable conduit fitting in side of enclosure and then follow (d.)
and (e.) below.
d.) Splice field wiring into existing wiring using code authorized method
(wire nuts, etc.).
e.) Be certain that neutral and live connections are not reversed when
making these connections.
f.) Close panel on the side of control box, make sure that access panel
is secured shut.
DIAGRAM 1

16
VENT CONNECTIONS TO BLOWER ASSEMBLY
Figure 15 shows the optimal placement of the 2" to 3" or 3" to
4" reducer; however, the vent can be reduced at any point in the
vent system as long as the maximum and minimum vent length
requirements are met.
FIGURE 15.
VENTING AND INSTALLATION
Planthelayoutof the vent systemfromtheventtermination to thewater
heater considering all of the 90° and 45° elbows plus the number of
feet of pipe that would be needed to install the total vent system. The
water heater must be vented to the outdoors as described in these
instructions. DO NOT connect this water heater to an existing vent
or chimney. It must be vented separately from all other appliances.
The fittings, other than the supplied Vent Termination should be
equivalent to the following: PVC (Schedule 40, DWV,ASTM D-2665),
CPVC (Schedule 40, DWV, ASTM F-438), ABS (Schedule 40 DWV,
ASTM D-2661).
The cement used should be as recommended by the vent pipe
manufacturer. See the instructions on pages 18 and 19 for the proper
method of cutting and cementing the PVC pipe and fittings.
Theunit may beventedhorizontally throughawall orverticallythrough
the roof. Pipe runs must be adequately supported along both vertical
and horizontal runs as follows:
• For Schedule 40, 2" PVC,ABS vent pipe: Every 3 feet (0.9 m).
• For Schedule 40, 3" PVC,ABS vent pipe: Every 3.5 feet (1.1 m).
• For Schedule 40, 4" PVC,ABS vent pipe: Every 4 feet (1.2 m).
• For Schedule 40, 2" CPVC vent pipe: Every 5 feet (1.5 m).
• For Schedule 40, 3" CPVC vent pipe: Every 6 feet (1.8 m).
• For Schedule 40, 4" CPVC vent pipe: Every 6.5 feet (2.0 m).
It is imperative that the first hanger (or support) be located on the
horizontal run immediately adjacent to the first 90-degree elbow from
theverticalrise. Supportmethodused should isolatetheventpipefrom
thefloor joists orother structuralmembers to preventthe transmission
of noise and vibration. Do not support, pin, or otherwise secure the
venting system in a way that restricts the normal thermal expansion
and contraction of the chosen venting material.
If the water heater is being installed as a replacement for an existing
power vented heater in pre-existing venting, a through inspection of
theexisting venting system must beperformed priorto any installation
work. Verify that thecorrectmaterial asdetailedabove has beenused,
and that the minimum or maximum vent lengths and terminal location
asdetailed in this manual have been met. Carefullyinspect theentire
venting system for any signs of cracks or fractures, particularly at
the joints between elbows and other fittings and the straight runs of
vent pipe. Check the system for signs of sagging or other stresses
in the joints as a result of misalignment of any components in the
system. If any of these conditions are found, they must be corrected
in accordance with the venting instructions in this manual before
completing the installation and putting the water heater into service.
Except where instructed in this manual, the mixing of 2", 3" and 4"
vent pipe is NOTALLOWED. If 2" pipe is to be used, then a 2" to 3"
bell reducer is recommended. Figure 15 shows the recommended
location for the bell reducer. If the bell reducer is located at the
rubber boot on the blower assembly, then a short section of 3" vent
pipe needs to be installed in the rubber boot for proper connection of
the 2" to 3" bell reducer. That length can be of the minimum length
required for the connection.
If 4" pipe is to be used, then a 3" to 4" bell reducer is recommended.
Figure 15 shows the recommended location for the bell reducer. If
the bell reducer is located at the rubber boot on the blower assembly,
then a short section of 3" vent pipe needs to be installed in the rubber
boot for proper connection of the 3" to 4" bell reducer. That length
can be of the minimum length required for the connection.
The 40,000, 50,000, 55,000 and 62,500 BTU units are supplied with
a 2" Schedule 40 PVC 22.5° Vent Terminal. If you decide to vent with
3" or 4" pipe, a Schedule 40 DWV 45° Vent Terminal must be used.
For your convenience, we have included a screen for both 3" and 4"
Vent Terminals.
The vent piping should be connected to the blower with a rubber
adapter and secured with hose clamps. The adapter and clamps are
provided with the heater.
Even the flue gas temperature leaving the blower is between
140°F (69°C) and 175°F (79°C), some installations will have water
condensate in the vent piping. If this occurs, then adequate means
of draining and disposing of the condensate needs to be made by
the installer.
CONDENSATE
Condensateformation doesnotoccurinallinstallationsofpowervented
waterheaters, but shouldbeprotected againstoninstallations where it
canform in the venting system.Condensation in the venting systemof
powervented waterheaters isdependent uponinstallation conditions
including, but not limited to ambient temperature and humidity of
installationlocation,ambienttemperatureandhumidityofventingspace,
vent discharge and slope, and product usage. In certain conditions,
installationsinunconditionedspace or havinglonghorizontalor vertical
vent runs may accumulate condensate. In these conditions, the vent
pipe should be sloped downward away from the blower assembly
1/4"(6.4 mm)per fivefeet (1.5m) of pipe but not more than 1 1/2" (3.8
cm) in the total vent length. If the vent piping is vented level or sloped
upwards away from the blower assembly, then adequate means for
draining and disposing of the condensate needs to be made by the
installer (if condensate is detected). If you have condensate, then a
3/8"drain hose canbe connected tothe built-indrain port ofthe rubber
boot on the blower assembly. For your convenience, the rubber boot
is supplied with a removable cap on the built-in drain port. Prior to
operating the water heater, make sure the removable cap is installed
on the drain port (if a drain hose is not needed).

17
MAXIMUM AND MINIMUM VENT LENGTHS
40,000 BTU Units:
For 2" Venting, the maximum equivalent feet of pipe allowed is 40
feet (12.2 m). This does not include the supplied vent termination for
the water heater. For the 2" venting, one 90° elbow is approximately
equal to 5 feet (1.5 m). One 45° elbow is approximately equal to 2.5
feet (0.8 m). It is recommended that at least 2 feet (0.6 m) of spacing
be used in between all 45° elbows and all 90°elbows.
For 3" Venting, the maximum equivalent feet of pipe allowed is
120 feet (36.6 m). Thisdoesnot include theVentTermination(supplied
locally) for the water heater. For the 3" venting, one 90° elbow is
approximatelyequal to 5feet (1.5m). One 45° elbowis approximately
equalto 2.5feet (0.8 m). It is recommendedthat atleast 2 feet (0.6 m)
of spacing be used in between all 45° elbows and all 90°elbows.
For 4" Venting, the maximum equivalent feet of pipe allowed is
160 feet (48.8 m). Thisdoesnot include theVentTermination(supplied
locally) for the water heater. For the 4" venting, one 90° elbow is
approximatelyequal to 8feet (2.4m). One 45° elbowis approximately
equal to 4 feet (1.2 m). It is recommended that at least 2 feet (0.6 m)
of spacing be used in between all 45° elbows and all 90°elbows.
50,000 BTU Units:
For 2" Venting, the maximum equivalent feet of pipe allowed is 40
feet (12.2 m). This does not include the supplied Vent Termination for
the water heater. For the 2" venting, one 90° elbow is approximately
equal to 5 feet (1.5 m). One 45° elbow is approximately equal to 2.5
feet (0.8 m). It is recommended that at least 2 feet (0.6 m) of spacing
be used in between all 45° elbows and all 90°elbows.
For 3" Venting, the maximum equivalent feet of pipe allowed is
120 feet (36.6 m). Thisdoesnot include theVentTermination(supplied
locally) for the water heater. For the 3" venting, one 90° elbow is
approximatelyequal to 5feet (1.5m). One 45° elbowis approximately
equalto 2.5feet (0.8 m). It is recommendedthat atleast 2 feet (0.6 m)
of spacing be used in between all 45° elbows and all 90°elbows.
For 4" Venting, the maximum equivalent feet of pipe allowed is
160 feet (48.8 m). Thisdoesnot include theVentTermination(supplied
locally) for the water heater. For the 4" venting, one 90° elbow is
approximatelyequal to 8feet (2.4m). One 45° elbowis approximately
equal to 4 feet (1.2 m). It is recommended that at least 2 feet (0.6 m)
of spacing be used in between all 45° elbows and all 90°elbows.
55,000 and 62,500 BTU Units:
NOTE: The 55,000 and 62,500 BTU Units are not approved for 2"
venting.
For 3" Venting, the maximum equivalent feet of pipe allowed is 80
feet (24.4 m). This does not include the supplied Vent Termination for
the water heater. For the 3" venting, one 90° elbow is approximately
equal to 5 feet (1.5 m). One 45° elbow is approximately equal to 2.5
feet (0.8 m). It is recommended that at least 2 feet (0.6 m) of spacing
be used in between all 45° elbows and all 90°elbows.
For 4" Venting, the maximum equivalent feet of pipe allowed is
120 feet (36.6 m). Thisdoesnot include theVentTermination(supplied
locally) for the water heater. For the 4" venting, one 90° elbow is
approximatelyequal to 8feet (2.4m). One 45° elbowis approximately
equal to 4 feet (1.2 m). It is recommended that at least 2 feet (0.6 m)
of spacing be used in between all 45° elbows and all 90°elbows.
VENTING
The vent system must terminate so that proper clearances are
maintainedas cited in local codesor thecurrent edition ofthe National
FuelGas Code,ANSIZ223.1/NFPA54, 7.3.4eand 7.8a,b,as follows:
1. The exit terminals of a mechanical vent system shall be not less
than 7 feet (2.13 m) above grade when located adjacent to public
walkways, see Figure 16.
2. Aventing system shall terminate at least 3 feet (0.91 m)above any
forced air inlet located within 10 feet (3.1 m), see Figure 16.
3. The venting system shall terminate at least 4 feet (1.2 m) below,
4 feet (1.2 m) horizontally from or, 1 foot (0.31 m) above any door,
window or gravity air inlet into any building.
The manufacturer also recommends that the vent termination
should not be installed closer than 18" (45.7 cm) from an inside
corner of an L shaped structure and not be less than 1 foot (0.31
m) above grade.
The vent shall terminate a minimum of 12'' (30.5 cm) above
expected snowfall level to prevent blockage of vent termination,
see Figure 16.
4. In cold climates, it is recommended that vent termination not be
mounted directly above or within 3 feet (0.91 m) horizontally from
an oil tank vent or gas meter to avoid potential freeze-up from
condensation, see Figure 16..
Plan the vent system layout so that proper clearances are maintained
from plumbing and wiring.
Vent pipesserving powervented appliancesare classified by building
codes as “vent connectors”. Required clearances from combustible
materials must be provided in accordance with information in this
manual under LOCATION OF HEATER and VENT TERMINAL
INSTALLATIONS, and with the National Fuel Gas Code and local
codes.

18
FIGURE 16.
This unit can vent through 2", 3" or 4" nonmetallic pipe and fittings.
The vent pipe installation can be started from either the blower
discharge or the termination wall. Keep in mind the total vent system
(pipe and elbows) when installing the vent system, see VENTING
AND INSTALLATION, pages 15 - 17.
FIGURE 17.
The vent terminal should be kept as close as possible to the outside
wall, but you need to allow at least 1.5" (3.8 cm) of pipe past the wall,
for the wall flange and vent terminal to mount on the pipe.
Before the vent terminal is installed, caulk (not supplied) around the
pipeon theexterior wall and install theoptional wallflange.The flange
can be held to the outside wall by placing some of the caulking on the
backof theflange.The wall flange is supplied for decorative purposes
only and is not a requirement for the vent termination (if not needed
by the installer).
VERTICAL VENT THROUGH ROOF
This unit is approved for venting through the roof with the type vent
terminal that is included with the unit. A proper flashing or “BOOT”
should be used to seal the pipe where it exits the roof.
The total vent system should not exceed that which is specified, see
VENTING AND INSTALLATION, pages 15 - 17.
All of the pipe should be secured as per the instructions in the
instructions in the VENTING AND INSTALLATION, pages 15 - 17.
VERTICAL VENT TERMINATION RESTRICTIONS
1. Minimum of twelve 12" (30.5 cm) above the roof or twelve 12"
(30.5cm)above the anticipatedsnowlevel. Provideproper support
for all pipe protruding through the roof.
FIGURE 18.
2. 4' (1.2 m) from or 1' (0.3 m) above any gable, dormer, or other
roof structure with access to interior of building (i.e.-vent, window
etc.).
3. 3' (0.9 m) above any forced air inlet located within 10' (3.0 m).

19
VENT PIPE PREPARATION
1. INITIAL PREPARATION
A. Make sure the solvent cement you are planning to use is
designed for the specific application you are attempting.
B. Knowthephysicaland chemical characteristicsandlimitations
of the PVC and CPVC piping materials that you are about to
use.
C. Know the reputation of your manufacturer and their
products.
D. Knowyour own qualificationsor thoseof your contractor.The
solvent welding technique of joining PVC and CPVC pipe is
a specialized skill just as any other pipe fitting technique.
E. Closely supervise the installation and inspect the finished
job before start-up.
F. Contact the manufacturer, supplier, or competent consulting
agency if you have any questions about the application or
installation of PVC and CPVC pipe.
G. Take the time and effort to do a professional job. Shortcuts
will only cause you problems and delays in start-up. By far,
the majority of failures in PVC and CPVC systems are the
result of shortcuts and/or improper joining techniques.
2. SELECTION OF MATERIALS
• Cutting Device - Saw or Pipe Cutter
• Deburring Tool, Knife, File, or Beveling Machine (2" and above)
• Brush - Pure Bristle
• Rag - Cotton (Not Synthetic)
• Primer and Cleaner
• SolventCement -PVCforPVC Components andCPVCfor CPVC
Components
• Containers - Metal or Glass to hold Primer and Cement. Select
the type of PVC or CPVC materials to be used on the basis of their
application with respect to chemical resistance, pressure rating,
temperature characteristics, etc.
• InsertionTool -Helpful for largerdiameter pipeand fittings 6inches
(15.2 cm) and above.
PRIMER
It is recommended that Tetrahydrofuran (THF) be used to prepare the
surfaces of pipe and fittings for solvent welding. Do not use water,
rags, gasoline or any other substitutes for cleaning PVC or CPVC
surfaces. A chemical cleaner such as MEK may be used.
CEMENT
The cement should be a bodied cement of approximately 500 to
1600 centipoise viscosity containing 10-20% (by weight) virgin PVC
material solvated with tetrahydrofuran (THF). Small quantities of
dimethyl formamide (DMF) may be included to act as a retarding
agent to extend curing time. Select the proper cement; Schedule 40
cement should be used for Schedule 40 pipe. Never use all-purpose
cements,commercial glues andadhesives orABS cementto join PVC
or CPVC pipe and fittings.
APPLICATORS
Selectasuitablepure bristle typepaintbrush.Use a properwidthbrush
or roller to apply the primer and cement (see chart below). Speedy
applicationof cement isimportant dueto its fastdrying characteristics.
IMPORTANT NOTE: A dauber type applicator should only be used
on pipe sizes 2" and below. For larger diameter pipe, a brush or roller
must be used.
RECOMMENDED BRUSH* SIZE FOR PRIMER
AND CEMENT APPLICATIONS
Nominal Pipe
(IPS) Size Brush Width (INS.)
2 1-1/2
3 1-1/2 - 2-1/2
*USE ONLY NATURAL BRISTLE
TABLE 1
3.MAKING THE JOINT
A. Cutting
Pipe must be squarely cut to allow for the proper interfacing of the
pipe end and the fitting socket bottom. This can be accomplished
with a miter box saw or wheel type cutter. Wheel type cutters are
not generally recommended for larger diameters since they tend
to flare the corner of the pipe end. If this type of cutter is used, the
flare on the end must be completely removed.
NOTE: Power saws should be specifically designed to cut plastic
pipe.

20
STEP A
B. Deburring
Use a knife, plastic pipe deburring tool, or file to remove burrs
from the end of small diameter pipe. Be sure to remove all burrs
from around the inside as well as the outside of the pipe. A slight
chamfer (bevel) of about 10°-15° should be added to the end to
permiteasier insertionof the pipe into the end ofthe fitting. Failure
tochamfer the edgeof the pipemay remove cementfrom thefitting
socket, causing the joint to leak.
STEP B
C. Test dry fit of the joint
Tapered fittingsockets are designedso thataninterfaced fitshould
occur when the pipe is inserted about 1/3 to 2/3 of the way into
the socket. Occasionally, when pipe fitting dimensions are at the
tolerance extremes, it will be possible to fully insert dry pipe to the
bottomofthefittingsocket. Whenthis happens, asufficientquantity
of cement must be applied to the joint to fill the gap between the
pipeand fitting. Thegap must be filled to obtain astrong, leak-free
joint.
D. Inspection, cleaning, priming
Visually inspect the inside of the pipe and fitting sockets and
remove all dirt, grease or moisture with a clean dry rag. If wiping
fails to clean the surfaces, a chemical cleaner must be used.
Check for possible damage such as splits or cracks and replace
if necessary.
Depth-of-entry
Markingthe depth ofentry is away tocheck if thepipe has reached
the bottom of the fitting socket in Step F. Measure the fitting depth
and mark this distance on the pipe O.D. You may want to add
several inches to the distance and make a second mark as the
primer and cement will most likely destroy your first one.
Apply primer to the surface of the pipe and fitting socket with a
natural bristle brush. This process softens and prepares the PVC
orCPVC for the solvent cementingstep. Move quicklyand without
hesitation to the cementing procedure while the surfaces are still
wet with primer.
E. Application of solvent cement
• Applythe solvent cementevenly andquickly around theoutside
of the pipe at a width a little greater than the depth of the fitting
socket.
• Apply a light coat of cement evenly around the inside of the
fitting socket. Avoid puddling.
• Apply a second coat of cement to the pipe end.
STEP E
F. Joint assembly
Working quickly, insert the pipe into the fitting socket bottom and
give the pipe or fitting a 1/4 turn to evenly distribute the cement.
Do not continue to rotate the pipe after it has hit the bottom of the
fitting socket. A good joint will have sufficient cement to make a
bead all the way around the outside of the fitting hub. The fitting
will have a tendency to slide back while the cement is still wet so
hold the joint together for about 15 seconds.
STEP F
G. Cleanup and joint movement
Remove all excess cement from around the pipe and fitting with a
dry cotton rag. This must be done while the cement is still soft.
The joint should not be disturbed immediately after the cementing
procedure,andsufficienttimeshouldbe allowed for propercuringof
thejoint. Exactdrying timeis difficult to predict because it depends
on variables such as temperature, humidity and cement integrity.
For more specific information, you should contact your solvent
cement manufacturer.
STEP G