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John Wood 5040SN-PDV - User Manual

John Wood 5040SN-PDV
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POWER DIRECT VENT WATER HEATER
INSTALLATION AND
OPERATING INSTRUCTIONS
Read these instructions thoroughly before starting
PART No. 324330-001 (13-08)
WARNING:
If the information in these instructions is
not followed exactly, a fire or explosion
may result causing property damage, per-
sonal injury or death.
WARNING:
Improper installation, adjustment, altera-
tion, service, or maintenance can cause
injury or property damage. Refer to this
manual. For assistance or additional infor-
mation, consult a qualified installer, ser-
vice agency, or the gas utility.
FOR YOUR SAFETY
• Do not store or use gasoline or other
flammable vapours and liquids in the
vicinity of this or any other appliance.
• Installation and service must be per-
formed by a qualified installer, service
agency or the gas utility.
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier from
a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
WHAT TO DO IF YOU SMELL GAS

Table of Contents

Questions and Answers

  • R
    rebecca31Aug 18, 2025
    Why John Wood 5040SN-PDV blower will not start?
    • B
      Brittney RobbinsAug 18, 2025
      The blower might not start due to several reasons. First, ensure the unit is receiving power by checking the power cord, fuses, and supply voltage. Then, make sure the thermostat setting isn't too low; increase the temperature setting if needed. A defective air pressure switch (it must be open at start-up) could also be the cause, in which case you should replace it. Other potential issues include a defective blower (replace the blower), disconnected or loose wiring (repair or reconnect the wires), or a control lockout (reset the control and determine the cause of the lockout).
  • Y
    Yolanda RichardsonAug 25, 2025
    What to do if hot surface igniter is not glowing on John Wood Water Heater?
    • D
      Dana GordonAug 26, 2025
      If the hot surface igniter isn't glowing after the warm-up, the 120VAC polarity might be reversed at the outlet. Reverse the polarity at the 120VAC outlet receptacle. Also, the hot surface igniter could be defective, so replace it and check for 120VAC across I1 & I2 (Robertshaw only). Finally, the control itself might be defective, requiring replacement.
  • K
    Kendra CamposSep 4, 2025
    How to fix a John Wood 5040SN-PDV blower that will not start?
    • K
      Kathleen MartinezSep 4, 2025
      If the blower on your John Wood Water Heater isn't starting, here are a few things to check: First, make sure the power cord is plugged in and check the fuses and supply voltage. You might also want to increase the thermostat temperature setting. If those aren't the problem, consider replacing the air pressure switch or the blower itself. Also, check for any damaged or disconnected wires and repair or reconnect them. Finally, try resetting the system, but be sure to determine the cause of the lockout first.
  • A
    Anthony SantosSep 7, 2025
    What to do if the hot surface igniter is not glowing on my John Wood 5040SN-PDV Water Heater?
    • E
      Elizabeth ThompsonSep 7, 2025
      If the hot surface igniter on your John Wood Water Heater isn't glowing after the warm-up period, the 120VAC polarity might be reversed at the outlet. Try reversing the polarity at the 120VAC outlet receptacle. If that doesn't work, consider replacing the igniter, ensuring you check for 120VAC across I1 & I2 (Robertshaw models only). As a last resort, you may need to replace the control.
  • J
    james59Sep 12, 2025
    Why is the control locked-out with a solid green LED on my John Wood 5040SN-PDV Water Heater?
    • P
      Patrick ValenciaSep 12, 2025
      If the control on your John Wood Water Heater is locked out and shows a solid green LED, the suggested solution is to replace the control. This could also be due to ECO failure from excessive water temperature, in which case you should replace the control. Another possibility is excessive humidity or a damp environment; in this case, allow the control to dry.
  • J
    Jeffrey AndersonNov 14, 2025
    What to do if John Wood 5040SN-PDV control locked-out?
    • R
      Robert BowenNov 14, 2025
      If the control is locked out, there could be several reasons. First, check and turn on the gas supply. If the control switch is in the “OFF” position, turn it to “ON”. Ensure the gas supply is sufficient and at the correct pressure for your gas type (Nat Gas 7.0 in. w.c. (1.74 kPa), Propane 11.0 in. w.c. (2.74 kPa)). Verify and adjust for the correct manifold gas pressure (NG 3.5 in. w.c.(0.87 kPa), Propane 10.0 in. w.c. (2.49 kPa)). Make sure you are using the correct gas type for your water heater model. Other potential causes include a defective igniter or loose wiring (replace the igniter or reconnect the wiring), an improperly positioned, dirty, or defective flame rod (reposition, clean, or replace the flame rod and reconnect any loose wires), a clogged burner orifice (remove the obst...
  • S
    Susan SandersNov 20, 2025
    How to stop John Wood Water Heater blower running continuously?
    • J
      Jamie BuchananNov 21, 2025
      If the blower runs continuously, it might be due to several reasons. The air pressure switch may not be closing due to insufficient draft. Check for a blocked vent piping, excessive piping length, a frozen vent termination or a clogged/dirty blower. Determine the cause of the insufficient draft and check the draft with a manometer at the pressure switch. Remove any blockage, reduce the vent length or increase the vent size, clear the termination of snow or ice, and clean the blower wheel. Also, inspect the pressure sensing tubing from the air pressure switch to the blower housing for disconnections, tears, or blockages; reconnect or replace the tubing as necessary. A defective air pressure switch may also cause this problem, so replace it if needed. Finally, check the high limit switch for...
  • D
    David AndradeNov 27, 2025
    What to do if the control is locked-out on my John Wood 5040SN-PDV Water Heater?
    • B
      Brandi RodriguezNov 27, 2025
      If the control on your John Wood Water Heater is locked-out, you can try the following: First, check and turn on the gas supply. Then, if it's a Robertshaw model, turn the control switch to the “ON” position. Ensure the supply pressure is correct for your gas type (Natural Gas should be at 7.0 in. w.c. (1.74 kPa), and Propane at 11.0 in. w.c. (2.74 kPa)). Also, check and adjust the manifold gas pressure (NG 3.5 in. w.c.(0.87 kPa), Propane 10.0 in. w.c. (2.49 kPa)). Make sure you're using the correct gas type for your water heater model. Other solutions include replacing a defective igniter or reconnecting its wiring, repositioning, cleaning, or replacing a defective flame rod and reconnecting its wiring, removing any obstruction, removing blockage or cleaning the flue, or replacing the con...
  • G
    Gregory JensenDec 1, 2025
    Why does the blower run continuously on my John Wood 5040SN-PDV Water Heater?
    • P
      prattevanDec 1, 2025
      The blower in your John Wood Water Heater might run continuously due to several reasons. One cause could be an air pressure switch not closing because of insufficient draft. To solve this, determine the cause of the insufficient draft and check it with a manometer at the pressure switch. You may need to remove blockages, reduce the vent length or increase its size, clear the termination of snow or ice, or clean the blower wheel. Other potential solutions include reconnecting or replacing the pressure sensing tubing, replacing a defective pressure switch, or addressing a high limit switch that's open due to excessive vent temperature or a defective switch. If overheating is the cause, check for overfiring, insufficient air supply, or high ambient air temperature. Note that once activated, t...

Summary

INTRODUCTION TO YOUR WATER HEATER

User Responsibilities

Outlines the user's role in ensuring proper installation, operation, and maintenance of the gas water heater.

CRITICAL SAFETY INFORMATION

Flammable Vapours Hazard

Warns about storing flammable liquids near the appliance and potential ignition hazards.

Hot Water Scald Hazard

Advises on the risk of severe burns from hot water and the use of tempering valves.

INSTALLATION GUIDELINES

Unpacking and Inspection

Provides instructions for safely unpacking the water heater and inspecting for damage.

Location and Site Requirements

Details safe placement, clearances, and ambient temperature requirements for installation.

GAS SUPPLY AND PIPING INSTALLATION

Clearances and Accessibility

Shows diagrams and lists minimum clearances required around the water heater for safe operation and maintenance.

Earthquake Zone Anchoring

Notes the requirement to brace or anchor the water heater in earthquake-prone areas.

Gas Type, Pressure, and Piping Codes

Instructs on gas type verification, pressure safety, and adherence to piping installation codes.

VENTING SYSTEM INSTALLATION

Gas Pressure Testing and Leak Checks

Details procedures for leak testing gas lines and the water heater's connection to ensure safety.

Vent Pipe Material and Approved Codes

Specifies approved plastic materials for vent systems and adherence to local and national codes.

VENT PIPE CONFIGURATION

Vent Pipe Connections and Installation Guidelines

Describes connecting vent pipes to the blower and general installation guidelines, including supports and condensation traps.

Maximum Vent Pipe Lengths

Details maximum allowable vent pipe lengths and factors affecting them, referencing a table of equivalent lengths.

Vent Pipe Routing and Termination Screens

Advises on proper vent pipe routing, slopes, and using appropriate termination screens based on vent length.

VENT TERMINAL INSTALLATIONS

Side Wall and Vertical Vent Terminal Requirements

Covers requirements for side wall and vertical roof vent terminals, including clearances and positioning.

Multiple Concentric Vent Termination Spacing

Provides spacing guidelines for multiple concentric vent terminations to prevent exhaust cross-circulation.

WATER SUPPLY AND CONNECTIONS

Water Piping Installation and Material

Guides on installing water piping, including pressure-reducing valves, expansion tanks, and material compatibility.

Closed System Expansion Tank Requirements

Explains the need for expansion tanks in closed water systems due to thermal expansion and potential relief valve discharge.

Temperature and Pressure Relief Valve Installation

Details the installation and importance of the T&P relief valve for safety against excessive pressure and temperature.

ELECTRICAL SUPPLY AND GROUNDING

Resettable Lockout and Control Reset

Explains how to reset the gas control/thermostat after a lockout condition for both control types.

Robertshaw Control Wiring Diagram

Illustrates the wiring diagram for the Robertshaw gas control/thermostat.

Robertshaw Gas Control;Thermostat Details

Provides details on the Robertshaw gas control/thermostat components and their functions.

White-Rodgers Control Wiring and Operation

Shows the White-Rodgers Intelli-Vent control details and wiring diagram for system operation.

PRE-OPERATION INSTALLATION CHECKLIST

LIGHTING AND OPERATING PROCEDURES

Robertshaw Control Lighting Instructions

Step-by-step guide for safely lighting the water heater with Robertshaw controls, including safety warnings.

Initial Lighting and Gas Control Functions

Provides initial lighting steps, safety warnings, and explains the gas control/igniter functions.

Robertshaw Operation and Temperature Setting

Details operational sequences, status codes, and guides on setting water temperature for Robertshaw controls.

White-Rodgers Control Lighting Instructions

Step-by-step guide for safely lighting the water heater with White-Rodgers controls, including safety warnings.

White-Rodgers Control Operation and Temp Adjustment

Explains the White-Rodgers Intelli-Vent control, its operation, and how to adjust water temperature settings.

Heater Shutdown and System Error Codes

Provides instructions for safely shutting down the heater and explains system error codes and their meanings.

Intelli-Vent System Error Code Diagnosis

Lists specific error codes for Intelli-Vent systems and their possible causes and corrective actions.

WATER HEATER OPERATION DETAILS

Water Heater Operation Sequence

Describes the sequence of operation for the water heater during a call for heat, including ignition and blower cycles.

Burner Flame Inspection

Guides on inspecting burner flames for proper characteristics and identifying issues like contamination.

Stacking, Emergency Shutdown, and Condensation

Explains stacking, emergency shutdown procedures, and normal condensation conditions.

Water Heater Sounds and Anode Rod

Lists common noises, smoke/odour causes, and anode rod inspection/replacement for tank protection.

ROUTINE MAINTENANCE AND CHECKS

Draining, Flushing, and Preventative Maintenance

Provides instructions for draining/flushing the tank and outlines annual preventative maintenance checks.

T&P Relief Valve Test Procedure

Details the manual operation of the T&P relief valve to ensure it functions correctly and safely.

COMBO HEATING SYSTEM INSTALLATION

Combo Heating System Requirements

Lists requirements for installing Combo Heating Systems, including component compatibility, sizing, and safety precautions.

Combo Heating Installation Options and Loops

Describes installation options for heating modes (air handler or baseboard) and loop requirements, including isolation and draining.

TROUBLESHOOTING COMMON ISSUES

Blower and Igniter Troubleshooting

Addresses common issues like the blower not starting or running continuously, and the hot surface igniter not glowing.

Control Lockout and Gas Supply Problems

Provides troubleshooting for control lockouts, gas supply problems, and incorrect manifold gas pressure.

PARTS REFERENCE AND ILLUSTRATION

LIMITED WARRANTY INFORMATION

John Wood 5040SN-PDV Specifications

General IconGeneral
BrandJohn Wood
Model5040SN-PDV
CategoryWater Heater
LanguageEnglish

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