American Water Heater 40 Gallon 36000 BTU UltraLow Nox Direct Vent Natural Gas Water Heater DVUG6240S36NV user manual

							1
Do not store or use gasoline or other 
flammable vapors and liquids in the 
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
  •  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.
Installation and service must be performed 
by a qualified installer, service agency or 
the gas supplier.
WARNING:  If the information in these
instructions is not followed exactly, a fire 
or explosion may result causing property 
damage, personal injury or death.
INSTALLER:
•  AFFIX THESE INSTRUCTIONS TO OR ADJACENT   
TO THE WATER HEATER.
OWNER:
•  RETAIN THESE INSTRUCTIONS AND WARRANTY 
FOR FUTURE REFERENCE. RETAIN THE ORIGINAL 
RECEIPT AS PROOF OF PURCHASE.Table of Contents   ......................................................    2
325002-000
January 2013
Direct Vent
Residential Gas 
Water Heater
To obtain technical, warranty, or service assistance during or after 
the installation of this water heater, visit our website at:
http://www.americanwaterheater.com
or call toll free
1-800-999-9515
When calling for assistance, please have the following 
information ready:
1. Model number
2.  7 digit product number
3. Serial number
4.  Date of installation
5.  Place of purchase
Ultra Low NOx MODELS
Installation
Instructions and
Use & Care Guide
LOW LEAD
CONTENT 
						

							2
Table Of Contents
Water Heater Safety .............................................................................. 1-3
Installing Your Gas Water Heater ........................................................ 4-16
  Unpacking the Water Heater ........................................................... 4
 Location Requirements ................................................................ 5-6
 Gas Supply .................................................................................. 7-8
  Combustion Air Supply and Ventilation ...................................... 8-12
  Water System Piping ............................................................... 13-14
  Temperature & Pressure Relief Valve ........................................... 15
 Special Applications ...................................................................... 16
 Installation Checklist ..................................................................... 17
Operating Your Water Heater ............................................................ 18-22
 Lighting Instructions ...................................................................... 18
  Operating the Temperature Control System ................................. 21
 Operational Conditions ................................................................. 22
Maintenance of Your Water Heater ................................................... 23-27
Troubleshooting Charts ..................................................................... 27-29
Repair Parts Illustration ..................................................................... 30-31
PAGE
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all 
safety messages.
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.” These words mean:
Indicates an imminently hazardous situation which, if 
not avoided, will result in death or injury.
Indicates a hazardous situation which, if not avoided, 
could result in death or serious injury.
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.
Important Instructions
•  Do not use this appliance if any part has been under water. Immediately call a qualified person. Water heaters sub-
jected to flood conditions or any time the gas controls, main burner or pilot have been submerged in water require 
replacement of the entire water heater.
•  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 can ignite when exposed to a spark or flame. To 
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several 
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If 
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water 
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
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 product is certiflied to comply with a maximum weighted average of 0.25% lead content as required in some areas.
WATER HEATER SAFETY 
						

							3
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 satis-
fied: 
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 
battery 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 CSA certified. 
SIGNAGE A metal 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 heat-
ing appliance 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 manufacturer of Product 
 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 
						

							4
INSTALLING YOUR GAS WATER HEATER
Important Information About 
This Water Heater
This gas water heater was manufactured to voluntary 
safety standards to reduce the likelihood of a flammable 
vapor ignition incident. New technology used in meeting 
these standards makes this product more sensitive to  
installation errors or improper installation environments.  
Please review the Installation Checklist found at the end of 
the installation instructions section and make any required 
installation upgrades or changes.
Consumer Information
This water heater is design-certified by CSA International as 
a Category I, direct vented water heater which takes its com-
bustion air from the outside of the structure and exhausts all 
products of combustion to the outside of the structure.
This water heater must be installed according to all local 
and state codes or, in the absence of local and state codes, 
the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-
current edition. This is available from the following:
CSA  America, Inc.
8501 East Pleasant Valley Road
Cleveland, OH 44131
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
Check your phone listings for the local authorities having 
jurisdiction over your installation.
Consumer 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. 
Read all of the instructions thoroughly before attempting 
the installation or operation of this water heater. 
Do not discard this manual. You or future users of this 
water heater will need it for future reference.
IMPORTANT: The manufacturer and seller of this water 
heater will not be liable for any damages, injuries, or 
deaths caused by failure to comply with the installation and 
operating instructions outlined in this manual. 
If you lack the necessary skills required to properly install 
this water heater, or you have difficulty following the 
instructions, you should not proceed but have a qualified 
person perform the installation of this water heater. 
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. 
A data plate identifying your water heater can be found next 
to the gas control valve/thermostat. When referring to your 
water heater, always have the information listed on the data 
plate readily available. 
Retain your original receipt as proof of purchase.
Unpacking the Water Heater
WARNING
Excessive Weight Hazard
Use two or more people to move and install 
water heater.
Failure to do so can result in back or 
other injury.
IMPORTANT: Do not remove any permanent instructions, 
labels, or the data label from either the outside of the water 
heater or on the inside of water heater panels.
•  Remove exterior packaging and place installation com-
ponents aside.
•  Inspect all parts for damage prior to installation and 
start-up.
•  Completely read all instructions before attempting to 
assemble and install this product.
•  After installation, dispose of/recycle all packaging 
materials. 
						

							5
Location Requirements
This water heater design has been tested by CSA 
International and complies with ANSI Z21.10.1, Section 
2.35 Flammable Vapors Resistance. Therefore this water 
heater does not need to be installed 18 inches above the 
floor unless specifically required by state or local codes. 
The water heater  must be located or protected to avoid 
physical damage by vehicles or flooding.
Do not use or store flammable products such as gasoline, 
solvents, or adhesives in the same room or area near the 
water heater. If such flammables must be used, all gas 
burning appliances in the vicinity must be shut off and their 
pilot lights extinguished. Open the doors and windows for 
ventilation while flammable substances are in use. 
If flammable liquids or vapors have spilled or leaked in the 
area of the water heater, leave the area immediately and 
call the fire department from a neighbor’s home. Do not 
attempt to clean the spill until all ignition sources have been 
extinguished.
Keep combustibles such as boxes, magazines, clothes, 
etc. away from the water heater area.
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
        Do not store or use gasoline or other 
flammable vapors and liquids in the 
vicinity of this or any other appliance. 
Storage of or use of gasoline or other 
flammable vapors or liquids in the vicinity 
of this or any other appliance can result in 
serious injury or death.
Fl ammable VaporsFLAMMABLES
Read and follow water heater warnings and 
instructions.
WARNING
Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Doing so can result in death or 
carbon monoxide poisoning.
WARNING
Site Location
•  Select a location near the center of the water piping 
system. The water heater must be installed indoors 
and in a vertical position on a level surface. DO NOT 
install in bathrooms, bedrooms, or any occupied room 
normally kept closed. Note: The water heater may 
be  installed in a closet with a door off a bedroom or 
bathroom providing the units are installed and vented 
per the manufacturer’s instructions..
•  Consider the vent piping and vent cap termination  
location.  This is a direct vent water heater and    
may be vented through-the-wall.  See the “Vent Cap  
Termination” section of this manual for the  proper vent 
cap locations. 
•  Locate the water heater near the existing gas piping. 
If installing a new gas line, locate the water heater to 
minimize the pipe length and elbows.
NOTE:  This water heater must be installed according to all 
local and state codes or, in the absence of local and state 
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 
54)-current edition. 
						

							6
IMPORTANT: The water heater should be located 
in an area where leakage of the tank or connections 
will not result in damage to the area adjacent to the 
water heater or to lower floors of the structure. Due 
to the normal corrosive action of the water, the tank 
will eventually leak after an extended period of time. 
Also any external plumbing leak, including those from 
improper installation, may cause early failure of the tank 
due to corrosion if not repaired.  If the homeowner is 
uncomfortable with making the repair a qualified person 
should be contacted.  A suitable metal drain pan should 
be installed under the water heater as shown below, 
to help protect the property from damage which may 
occur from condensate formation or leaks in the piping 
connections or tank. The pan must limit the water level 
to a maximum depth of 1-3/4” and be two inches wider 
than the heater and piped to an adequate drain. 
NOTE: The pan must not restrict combustion air flow. 
Locate the water heater near a adequate indoor drain. 
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. 
Outside drains are subject to freezing temperatures 
which can obstruct the drain line. The piping should be 
at least 3/4” ID and pitched for proper drainage. Under 
no circumstances will the manufacturer or seller of this 
water heater be held liable for any water damage which 
is caused by your failure to follow these instructions.
•  The water heater should be located in an area not 
subject to freezing temperatures. Water heaters located 
in unconditioned spaces (i.e., attics, basements, 
etc.) may require insulation of the water piping and 
drain piping to protect against freezing. The drain and 
controls must be easily accessible for operation and 
service. Maintain proper clearances as specified on the 
data plate.
Clearances and Accessibility
NOTE: Minimum clearances from combustible surfaces are 
stated on the data plate adjacent to the gas control valve/
thermostat of the water heater.
The water heater is certified for installation on a 
combustible floor.
• IMPORTANT: If installing over carpeting, the carpeting 
must be protected by a metal or wood panel beneath 
the water heater. The protective panel must extend 
beyond the full width and depth of the water heater by 
at least three inches (76.2mm) in any direction; or if in an alcove or closet installation, the entire floor must be 
covered by the panel. 
• Figure 2 may be used as a reference guide to locate 
the specific clearance locations. A minimum of 24 
inches of front clearance should be provided for 
inspection and service.
State of California
NOTE: The water heater must be braced, anchored, or 
strapped to avoid moving during an earthquake. Correct   
installation procedure instructions may be obtained from 
California’s Office of the State Architect, 1102 Q street, 
Suite 5100, Sacramento, CA 95811. Instructions can be 
downloaded to your computer at www.dsa.dgs.ca.gov/
Pubs.
  METAL
DRAIN
PAN
AT LEAST 2” GREATER  THAN THE 
DIAMETER OF THE WATER HEATER.PIPED TO AN 
ADEQUATE DRAIN
6” MAXIMUM
AIR GAP  DISCHARGE PIPE
(DO NOT CAP OR PLUG) 
VAC
Figure 1
Drain Pan Installation
Back 0”
Sides 0”
Sides
   0”
To p
View
Front
24” minimum
for service
Vent 0”
Figure 2 
						

							7
Gas Supply
Gas Requirements
IMPORTANT: Read the data plate to be sure the water 
heater is made for the type of gas you will be using in 
your home. This information will be found on the data 
plate located near the gas control valve/thermostat. If the 
information does not agree with the type of gas available, 
do not install or light. Call your dealer.
NOTE: An odorant is added by the gas supplier to the gas 
used by this water heater. This odorant may fade over an 
extended period of time. Do not depend upon this odorant 
as an indication of leaking gas.
Gas Piping
The gas piping must be installed according to all local and state 
codes or, in the absence of local and state codes, the “National 
Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
Tables 1 on page 8 provides a sizing reference for commonly 
used gas pipe materials. Consult the “National Fuel Gas Code” 
for the recommended gas pipe size of other materials.
Refer to Figure 3
NOTE:  When installing gas piping, apply approved pipe joint 
compound.
1.  Install a readily accessible manual shut-off valve in the 
gas supply line as recommended by the local utility. 
Know the location of this valve and how to turn off the 
gas to this unit.
2.  Install a drip leg (if not already incorporated as part of 
the water heater) as shown. The drip leg must be no 
less than three inches long for the accumulation of dirt, 
foreign material, and water droplets.
3.  Install a ground joint union between the gas control 
valve/thermostat and the manual shut-off valve. This 
is to allow easy removal of the gas control valve/ 
thermostat.
4.  Turn the gas supply on and check for leaks. Test all 
connections by brushing on an approved noncorrosive 
leak-detection solution. Bubbles will show a leak. 
Correct any leak found.
Gas Pressure
IMPORTANT: The gas supply pressure must not exceed the 
maximum supply pressure as stated on the water heater’s data 
plate. The minimum supply pressure is for the purpose of input 
adjustment.
Gas Pressure Testing
IMPORTANT: This water heater and its gas connection must 
be leak tested before placing the appliance in operation.
•  If the code requires the gas lines to be tested at a pressure 
exceeding 14” W.C., the water heater and its manual shut-
off valve must be disconnected from the gas supply piping 
system and the line capped.
•  If the gas lines are to be tested at a pressure less than 
14” W.C., the water heater must be isolated from the gas 
supply piping system by closing its manual shut-off valve
U.L. recognized fuel gas and carbon monoxide (CO) detectors 
are recommended in all applications and should be installed 
using the manufacturer’s instructions and local codes, rules, or 
regulations.
NOTE: Air may be present in the gas lines and could prevent 
the pilot from lighting on initial start-up. The gas lines should 
be purged of air by a qualified person after installation of the 
gas piping system. While purging the gas piping system of air, 
make sure that the fuel is not spilled in the area of the water 
heater installation, or any source of ignition. If the fuel is spilled 
while purging the piping system of air follow the “WHAT TO DO 
IF YOU SMELL GAS” instructions on the cover of this manual.
Explosion Hazard
Use a new CSA approved gas supply line.
Install a shut-off valve.
 
  Failure to follow these instructions can 
result in death, explosion, or 
carbon monoxide poisoning.
WARNING
Do not connect a natural gas water heater to
an L.P. gas supply.
Do not connect an L.P. gas water heater to
a natural gas supply.
Manual Gas
Shut-off Valve
Ground
Joint
Union
Drip Leg
3” Minimum
Check with local
utility for
minimum height Figure 3
Gas Piping 
						

							8
Combustion Air Supply and 
Ventilation
IMPORTANT:  Air for combustion and ventilation must 
not come from a corrosive atmosphere. Any failure due 
to corrosive elements in the atmosphere is excluded from 
warranty coverage.
IMPORTANT:  Do not common vent this water heater with 
any power vented appliance.
Vent Pipe System
This is a direct vent water heater which draws its 
combustion air from outside of the structure and exhausts 
all products of combustion to the outside of the structure.
Carbon Monoxide Hazard
Water heater must be vented to outdoors.
Vent must be installed by a qualified person 
using the installation instructions.
Examples of a qualified person include:   
gas technicians, 
authorized gas company personnel, 
and authorized service persons.
Failure to follow these instructions can result 
in death or carbon monoxide poisoning.
WARNING
Through-the-wall installations require locating the water 
heater next to an outside wall.  All necessary components 
are supplied for the standard through-the-wall installation.  
Optional vertical and horizontal extension kits are available 
for installations that exceed the standard horizontal and 
vertical distances (see table at right).  Only one vertical and 
one horizontal kit can be used on the same installation.
Through the Wall Flex Pipe Venting
1.  Make sure a proper location has been selected for the   
water heater installation.  Consider the following:
•   Water piping
•   Gas Piping
•    Access for service
•    Proper clearance for combustibles
•    Drainage for the temperature and pressure 
relief valve and drain pan.
•    Vent cap termination
2.  Determine the “A” dimension for your specific water 
heater by referencing figure 4A.  Cut a 6 inch opening 
through the  wall in the location as shown.  Determine 
the location of electrical wiring, pipes, or wall studs 
before cutting.
NOTE:  Installations requiring an “A” dimension (vertical 
height) greater than what is shown will require the use of a 
Optional vertical extension kit (See “Vertical Install Kit” on 
Page 11). 
						

							9
Optional through the Wall Venting
1.  Make sure a proper location has been selected for the   
water heater installation.  Consider the following:
•   Water piping
•   Gas Piping
•    Access for service
•    Proper clearance for combustibles
•    Drainage for the temperature and pressure 
relief valve and drain pan.
•    Vent cap termination
2.  Determine the “A” dimension for your specific water 
heater by referencing figure 4B.  Cut a 6 inch opening 
through the  wall in the location as shown.  Determine 
the location of electrical wiring, pipes, or wall studs 
before cutting.
NOTE:  Installations requiring an “A” dimension (vertical 
height) greater than what is shown as standard in the table 
will require the use of a vertical extension kit (See “Vertical 
Install Kit” on Page 11).
“B”
“A”
NOTE:
1. Dim. “A” measured from center of cutout to bottom of heater.
    Maximum height for all water heaters 90”,  
    Minimum for 40 Gallon water heaters 68”,
    Minimum for 50 Gallon water heaters 76”.
2. Dim. 
“B” measured from center of heater to outside of wall.
    Minimum horizontal of 22“ for all water heaters at Maximum height of 90”.
Figure 4A
Installation Flex Vent Pipe
Outer Wall PlateSmall
Clamp
Large Clamp
Inner Wall
Plate
Upper Air Box
ReducerVent Cap
Assembly
Large Clamp
Small ClampSecure Flex Vent Pipe to Vent 
Cap with Small Clamp. Apply 
silicone sealant to all connections 
making sure all joints are tight 
and leak proof
.
Secure Flex Vent Pipe to 
Reducer with Small Clamp. 
Apply silicone sealant to all 
connections making sure all 
joints are tight and leak proof
.
1. 
2. 
3.  Uncompressing the corrugated Flex piping by pulling 
the piping to the length as required. Make sure there 
are two springs evenly spaced at the bend in the pipe.
4.  Determine the  “A” and “B” dimensions for the 
size of the water heater being installed (Figure 4A).                                                                         
Dim. “A” is measured from the center of cutout 
to the bottom of heater. Maximum height for all 
water heaters is 90”. Minimum height for 40 
Gallon water heaters 68” and minimum height 
for 50 Gallon water heaters is 76”  (Figure  4A).                                                                
Dim. “B” is measured from the center of water heater 
to the outside of the exterior wall. Minimum horizontal 
is 22” for all water heaters at the maximum height of 
90” (Figure 4A).
5.  Cut a 6” opening through the wall in the location as 
shown. Note: location is determine first by locating all  
electrical wiring, pipes, and wall studs before cutting. 
6.  Metal hangers may be used to keep the pipe level or 
with a slope upward from the water heater through the 
wall to Vent Cap.
7.  At the water heater: Pull the inner 3” corrugated pipe 
to the water heater’s flue reducer and attached using 
the Small Clamp included in kit. Apply hi-temp silicone 
sealant around the connection making sure joint is tight 
and leak proof (Figure 4A). 
8.  Pull the outer corrugated Flex Vent pipe down covering 
the connection and secure using the Large Clamp 
included in kit to the collar at the Upper Air Box 
(Figure 4A). Apply hi-temp silicone sealant around the 
connection making sure joint is tight and leak proof.
9.  At the exterior wall: Pull the Flex Vent piping through 
the Inner Wall Plate through the clearance hole from 
the exterior wall to the Outer Wall Plate. Secure Inner 
Wall Plate to the inside wall with 1/2” screws.
10.  Pull the outer corrugated Flex Vent pipe out to the 
Outer Wall Plate, secure with Large Clamp. Pull the 
inner 3” corrugated pipe out from the Flex Vent pipe 
through the Outer Wall Plate and attached to the end of 
the 3” tube at the Vent Cap and secure using the Small 
Clamp included in kit. Apply hi-temp silicone sealant 
around the connection making sure the joint is tight and 
leak proof (Figure 4A).
11.  Secure Vent Cap Assembly to the Outer Wall Plate to 
the exterior wall with four 1-1/2” screws provided in kit 
(Figure 4A). Note: varying wall structures may require a 
different type of screw anchor.
12.  Apply hi-temp silicone sealant around the connection 
making sure the joint is tight and leak proof (Figure 4A).  
						

							10
“B”
“A”
Figure 4B
Optional Installation
NOTE:
1. Dim. “A” measured from center of cutout to bottom of heater.
2. Dim. “B” measured from center of heater to outside of wall.
3” Elbow
Screws 
& 
Sealant
   1
   2
5” Pipe
3” Elbow
Inside Cover 
Plate
Screws 
& Sealant
Figure 5
Vertical Installation
4.  Extend the 3” telescoping pipe to its maximum length.   
Place the smaller section onto the 3” elbow at least 1 
and 1/2 inches (See Figure 6).  Drill two holes 180° 
apart and secure with the two #8 sheet metal screws 
provided. Apply silicone sealant to the joint.
5.  Attach the larger section of the 5” telescoping pipe to 
the flange on the outer wall plate (See Figure 6).  Drill 
holes 90° apart with a 1/8” drill bit and fasten with 
four #8 sheet metal screws (provided).  Apply silicone 
sealant to the seam.
6.  Extend the 5” telescoping tube to its maximum length.     
From outside of the building, insert a 5” tube/outer wall  
plate assembly through the opening in the exterior wall  
and onto the 5” elbow (See Figure 6). Seat the base of 
the outer wall plate onto the exterior wall.  Apply silicone 
sealant between the plate and the exterior wall.
3” Pipe Inner Wall 
Plate
Screws 
& Sealant
3” Telescoping 
Pipe
Wall
5” Elbow
Inner Wall 
Plate
Screws 
& Sealant
3” Telescoping      
Pipe5” Telescoping Pipe
Outer Wall Plate
Figure 6:
Vertical Installation
7.  Place the 3” tube located in the vent cap into the end 
of the 3” telescoping tube (See Figure 7).  Drill two 
holes 180° apart with a 1/8” drill bit and secure with 
two #8 sheet metal screws.  Apply sealant to the joint.  
Seat the cap against outer wall plate with the word 
“HOT” in an upright position.
8.  Secure the vent cap/outer wall plate assembly to the  
exterior wall with the four 1 and 1/2” screws provided  
(See Figure 7).  Varying wall structures may require a  
different type of screw anchor.  To prevent rain from  
entering the water heater vent pipe, the 5” tube should  
be sloped downward towards the wall 1/4” per foot.
KITCAPACITY
40 GALLON  50 GALLONABAB
STANDARD 62.75”18.00” - 24.50” 71.00” 18.00” - 24.50”
HORIZONTAL 62.75”27.00” - 38.00” 71.00” 27.00” - 38.00”
VERTICAL62.75” - 89-75” 18.00” - 24.50” 71.00” - 98.00” 18.00” - 24.50”
BOTH62.75” - 89-75” 27.00” - 38.00” 71.00” - 98.00” 27.00” - 38.00”
3.  If you are not using the vertical extension kit, place the 
3” elbow on the flue pipe reducer on the air box and 
point it in the desired direction (See Figure 8).  Press 
it firmly downward until seated.  Drill 4 holes 90° apart 
with a 1/8” drill bit and fasten the four #8 sheet metal 
screws provided. Apply silicone sealant to the joint.  
Install the 5” elbow over the 3” elbow and seat it into 
the collar on the air box. Drill 4 holes 90° apart with a 
1/8” drill bit and fasten the four #8 sheet metal screws 
provided.  Apply silicone sealant to the joint.  Place the 
inner wall cover plate over the 5” elbow.  This plate will 
be positioned later.
Table 2