American Water Heater Residential Gas Water Heater Instruction manual

Installation and Operating Manual
RESIDENTIAL GAS WATER HEATERS
DIRECT VENTED GAS MODELS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
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• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1404
327544-000
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE . . . . . . . . . . . 3
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Qualified Installer Or Service Agency . . . . . . . . . . . . 6
Preparing For The Installation . . . . . . . . . . . . . . . . . . 6
LIGHTING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . 28
TEMPERATURE REGULATION . . . . . . . . . . . . . . . . . . . 29
Temperature Regulation . . . . . . . . . . . . . . . . . . . . . 29
Temperature Adjustment
Operating The Temperature Control System. . . . . . 29
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS . . . . . . . . . . . 7
TYPICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water Temperature Adjustment
Operating Modes And Settings
FOR YOUR INFORMATION. . . . . . . . . . . . . . . . . . . . . . . 30
Get To Know Your Water Heater - Gas Models
(List Referencing Figures 1-5). . . . . . . . . . . . . . . . . . 9
Replacement Parts And Deliming Products . . . . . . 10
Combo Heating Inlet And Outlet Side Taps . . . . . . . 10
High Limit Controls (Energy Cut Off). . . . . . . . . . . . 10
External Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Start Up Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 30
Condensate
Smoke/Odor
Thermostat/Water Temperature
LOCATING THE NEW WATER HEATER . . . . . . . . . . . . . 11
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . 30
Strange Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operational Conditions . . . . . . . . . . . . . . . . . . . . . . 31
Facts To Consider About The Location . . . . . . . . . . .11
External/Internal Damage . . . . . . . . . . . . . . . . . . . . .11
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Confined Space Installations. . . . . . . . . . . . . . . . . . 12
Smelly Water
“Air” In Hot Water Faucets
High Water Temperature Shut Off System
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Clearances To Combustibles
Floors With Carpeting
Clearance For Servicing
Chemical Vapor Corrosion . . . . . . . . . . . . . . . . . . .
Storage Of Flammable Liquids . . . . . . . . . . . . . . . .
Insulation Blankets . . . . . . . . . . . . . . . . . . . . . . . . .
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
13
14
Water Pressure
Mixing Valves
INSTALLING THE NEW WATER HEATER . . . . . . . . . . . 15
Water Piping Installation . . . . . . . . . . . . . . . . . . . . .
Closed Water Systems . . . . . . . . . . . . . . . . . . . . . .
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature-Pressure Relief Valve. . . . . . . . . . . . .
15
15
15
16
T&P Valve Discharge Pipe Requirements:
Temperature-Pressure Relief Valve And
Pipe Insulation
Filling The Water Heater . . . . . . . . . . . . . . . . . . . . . 17
Space Heating And Potable Water Systems . . . . . . 18
Combo Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Requirements
Installation
Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sediment Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude Installations . . . . . . . . . . . . . . . . . . . .
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent Terminal Clearances . . . . . . . . . . . . . . . . . . . .
DV Termination Safety Cover . . . . . . . . . . . . . . . . .
Vent Connections . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating Clearance Hole For Vent . . . . . . . . . . . . .
Standard Vent Arrangement . . . . . . . . . . . . . . . . . .
Vent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing Vent Termination Assembly To
The Exterior Wall. . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent Restricter Plate . . . . . . . . . . . . . . . . . . . . . . . .
Uncompressing The Corrugated Tubing . . . . . . . . .
Vent Connection To The Water Heater . . . . . . . . . .
Offset Vent Arrangement . . . . . . . . . . . . . . . . . . . . .
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . .
2
20
21
21
22
22
23
23
23
23
24
Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flood Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting System Inspection . . . . . . . . . . . . . . . . . . .
Pilot And Main Burner . . . . . . . . . . . . . . . . . . . . . . .
Burner Flames. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing The Water Heater . . . . . . . . . . . . . . . . . .
Removing And Replacing The Gas Control Valve/
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
32
32
32
33
33
33
Removing The Gas Control Valve/Thermostat:
Replacing The Gas Control Valve/Thermostat:
Removing The Manifold/Burner Assembly . . . . . . . 33
Removing The Burner From The Manifold/Burner
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Natural Gas (Low Nox) & Propane (LP) Gas Burner
Replacing The Pilot/Thermopile Assembly . . . . . . .
Replacing The Manifold/Burner Assembly . . . . . . .
Piezoelectric Igniter System . . . . . . . . . . . . . . . . . .
Testing The Igniter System . . . . . . . . . . . . . . . . . . .
Temperature-Pressure Relief Valve Test . . . . . . . . .
Draining, Refilling And Flushing . . . . . . . . . . . . . . .
34
35
36
36
36
36
To Drain The Water Heater Storage Tank
To Refill The Water Heater Storage Tank
To Flush The Water Heater Storage Tank
Drain Valve Washer Replacement . . . . . . . . . . . . . 37
Anode Rod Maintenance. . . . . . . . . . . . . . . . . . . . . 37
To Remove The Anode Rod:
To Install The Anode Rod:
LEAKAGE CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . 39
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REFERENCE PARTS LISTING . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING GUIDELINES. . . . . . . . . . . . . . . . 42
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
24
24
24
25
25
27
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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.
This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.
This appliance can cause low level exposure to some of the substances listed in the Act.
IMPORTANT DEFINITIONS
Qualified Installer: A qualified 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
design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this
Installation and Operating manual.
Service Agency: A service 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 understanding
of this Installation and Operating manual, and be able to perform repairs strictly in accordance with the service guidelines
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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3
GENERAL SAFETY
WARNING
Fire or Explosion Hazard
• Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this water
heater, the vent termination hood or any other
appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive
gas pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after
extended period of non-use.
Read instruction manual before
installing, using or servicing
water heater.
4
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GENERAL SAFETY
DANGER
FLAMMBLE
Vapors from flammable
liquids may explode and
catch fire causing death or
severe burns.
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with codes.
• Do not operate water heater if flood damaged.
• For operation above 7,700’, a high altitude
orifice must be installed.
• Do not operate if soot buildup is present.
Do not use or store
flammable products such as
gasoline, solvents or adhesives in the same room or
area near the water heater or
the vent termination hood.
Keep flammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
4. out of children's reach.
Flammable Vapors
Water heater has a main
burner and pilot. While
operating, the pilot flame:
1. is in continuous operation
and
2. will ignite flammable
vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the floor
and
4. can be carried from other
rooms by air currents.
Installation: Do not install the water heater or the vent termination hood where flammable products will be stored or used.
• Do not place chemical vapor emitting products
near water heater or vent termination hood.
• Gas and carbon monoxide detectors are
available.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
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5
INTRODUCTION
Thank You for purchasing this water heater. Properly
installed and maintained, it should give you years of trouble
free service.
This water heater is suitable for potable water heating
and space heating applications but not for space heating
only applications.
Abbreviations found in this Installation and Operating
manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• UL - Underwriters Laboratories Inc.
• AHRI - Air Conditioning, Heating and Refrigeration
Institute.
This gas-fired water heater is design certified by CSA
International, under Water Heater Standard ANSI
Z21.10.1 • CSA 4.1 (current edition).
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualified Agency (as defined by
ANSI below) in the field involved. Installation skills such
as plumbing, air supply, venting, gas supply and electrical
supply are required in addition to electrical testing skills
when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any
individual, firm, corporation or company that either in
person or through a representative is engaged in and is
responsible for (a) the installation, testing or replacement
of gas piping or (b) the connection, installation, testing,
repair or servicing of appliances and equipment; that
is experienced in such work; that is familiar with all
precautions required and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualified (as defined by ANSI above) and
licensed or certified as required by authority having
jurisdiction to perform a given task, do not attempt to
perform any of the procedures described in this manual.
If you do not understand the instructions given in this
manual do not attempt to perform any procedures outlined
in this manual.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section of this manual
first and then entire manual carefully. If you don’t
follow safety rules, the water heater will not operate
properly. It could cause DEATH, SERIOUS BODILY
INJURY AND/OR PROPERTY DAMAGE. This manual
contains instructions for installation, operation,
and maintenance of the gas-fired water heater. It
6
also contains warnings throughout the manual that
you must read and be aware of. All warnings and
instructions are essential to proper operation of the
water heater and your safety. Since we cannot put
everything on the first few pages, READ ENTIRE
MANUAL BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
2. The installation must conform with these instructions
and local code authority having jurisdiction. In absence
of local codes, installation must comply with current
editions of the “National Fuel Gas Code”, ANSI
Z223.1/NFPA 54 and “National Electrical Code”,
NFPA 70. All documents are available from:
CSA International,
8501 East Pleasant Valley Road,
Cleveland, Ohio, United States
44131-5575.
NFPA documents are also available from:
National Fire Protection Association,
1 Batterymarch Park,
Quincy, MA 02269.
3. If after reading this manual you have any questions or
do not understand any portion of the instructions, call
the local gas utility or the manufacturer whose name
appears on the rating plate.
4. Carefully plan the place where you are going to put
the water heater. Correct combustion, vent action, and
vent pipe installation are very important in preventing
death from possible carbon monoxide poisoning and
fires (see Figure 6). Examine the location to ensure
the water heater complies with the “Locating The New
Water Heater” section in this manual.
5. NOTE: For California installation, this water heater
must be braced, anchored, or strapped to avoid falling
or 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 also be downloaded to your computer
at www.dsa.dgs.ca.gov..
6. Massachusetts Code requires this water heater to be
installed In accordance with Massachusetts 248-CMR
2.00: State Plumbing Code and 248-CMR 5.00.
7. This product is certified to comply with a maximum
weighted average of 0.25% lead content as required
in some areas.
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INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS
COMMONWEALTH OF MASSACHUSETTS
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 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 heating
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 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.
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7
INSTALLATION GRAPHIC: GAS-FIRED POTABLE
WATER HEATING/SPACE HEATING SYSTEM
•
If your water heater will be installed in the Commonwealth of Massachusetts, refer to the following
graphic during installation and during modifications to the water supply system.
TYPICAL MIXING VALVE INSTALLATION
COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM
EXPANSION TANK
TEMPERED WATER
TO FIXTURES
(MUST MEET TEMPS LISTED
IN MASS. CODE 248 CMR † )
CHECK
VALVE †
COLD WATER INLET
CHECK VALVE †
(1/8” HOLE
DRILLED IN CLAPPER)
VACUUM
RELIEF
VALVE
SHUT-OFF
VALVE
FLOW CONTROL
VALVE
UNION
HOT
WATER
OUT
OUT
SHUT-OFF
VALVE *
MASSACHUSETTS INSTALLATION REQUIREMENTS:
IN
COIL
TO
AIR
HANDLER
SEE
NOTE ‡
WATER HEATER ACCEPTED
BY THE BOARD FOR
INSTALLATION IN
MASSACHUSETTS. †
*
PUMP *
TEMP/
PRESSURE
RELIEF
VALVE
MUST BE VERTICAL TO
REMOVE AIR BUBBLES
MIXING VALVE
(MUST BE INSTALLED BELOW
TOP OF WATER HEATER
AS PER MANUFACTURER’S
RECOMMENDATIONS)
UNION
AIR
HANDLER
100’-0” MAXIMUM DISTANCE
FROM WATER HEATER TO FAN
COIL AND BACK. (DEVELOPED
LENGTH) NOT INCLUDING COIL
IN HEATING UNIT †
1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS
FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.
2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR
& 780 CMR).
3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.
8
†
REQUIRED FOR MASSACHUSETTS.
‡
PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS (LIST REFERENCING FIGURES 1-5)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Vent Termination Hood
Wall Plate
***Vent Pipe
Cold Water Inlet Nipple/Diptube
**Combo Heating System Supply
Outlet (Optional)
T&P Valve
Gas Control Valve/Thermostat
(Honeywell)
**Combo Heating System Return
Inlet (Optional)
*Discharge Pipe
Drain Valve
Outer Gas Door
Manifold Door Assembly (behind
outer door) (see Figure 3 &
Figure 4)
*Floor Drain
*Metal Drain Pan
Flexible Manifold Tube (see
Figure 3 & Figure 4)
1
2
16 *Sediment Trap
17 *Ground Joint Union (gas
connection)
18 *Main Manual Gas Shut-off Valve
19 *Gas Supply
20 Baffle Assembly
21 Rating Plate
22 Anode (under cap)
23 Hot Water Outlet Nipple (or
Optional Nipple/Anode)
24 *Inlet Water Shut-off Valve
25 *Union (water connection)
26 Air Inlet Snorkel
27 Air Tower
28 ***Airbox
29 *Thermal Expansion Tank (required
for all closed systems)
30 Sheet Metal Burner (see Figure 3 &
Figure 4)
31 Gas Orifice (see Figure 3 &
Figure 4)
3
32 Gas Manifold (see Figure 3 &
Figure 4)
33 Manifold Door Gasket (see Figure 3
& Figure 4)
34 Manifold Door (see Figure 3 &
Figure 4)
35 Two Piece Grommet With Clip (see
Figure 3 & Figure 4)
36 Viewport (see Figure 3 & Figure 4)
37 Flexible Manifold Tube (see
Figure 3 & Figure 4)
38 Pilot (see Figure 3 & Figure 4)
39 Thermopile (see Figure 3 &
Figure 4)
40 Pilot Shield (see Figure 3 &
Figure 4)
*, **, *** see notes on following page
24
1
2
4
5
23
29
25
25
6
22
4
21
7
20
27
8
26
19
9
18
10
17
28
11 12
16
15
13
14
Rear View
Front View
Figure 1
Figure 2
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30
39
37
40
31
38
Vacuum relief valve
install per local
codes (not supplied
with heater).
36
Figure 5
32
35
33
Natural gas and Propane (LP)
main burner with igniter assembly
for 38k to 42k Btu/hr models
34
REPLACEMENT PARTS AND DELIMING PRODUCTS
Replacement parts and recommended delimer may be
ordered through authorized servicers or distributors. When
ordering parts, provide complete model and serial numbers
(see rating plate), quantity and name of part desired.
Standard hardware items may be purchased locally.
Figure 3
Natural gas and Propane
(LP) main burner with igniter
assembly for 47k Btu/hr
models
39
40
30
38
31
37
32
33
36
Notes:
* Items not supplied with the water heater.
** The side recirculation loop connections may not be
used as the primary water inlet and outlet connections.
See “Combo Heating Inlet And Outlet Side Taps”
below.
*** During operation the vent pipe and airbox can get hot.
34
COMBO HEATING INLET AND OUTLET SIDE TAPS
Models equipped with Combo Heating capabilities are
shipped with the two side plumbing taps OPEN (items 5
and 8 in Figure 1 and see also Figure 8). If the heater is to
be operated without using the side taps, these openings
must be closed with the two pipe plugs supplied with
the heaters.
HIGH LIMIT CONTROLS (ENERGY CUT OFF)
Thermostat/Water Temperature
This feature is a part of the gas control valve/thermostat
(see Figure 1, item 7) and limits the maximum water
temperature. In the event of the water overheating, this
safety feature shuts off the fuel supply to the burner.
35
Figure 4
10
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LOCATING THE NEW WATER HEATER
FACTS TO CONSIDER ABOUT THE LOCATION
Carefully choose an indoor location for the new water
heater because the placement is a very important
consideration for the safety of the occupants in the building
and for the most economical use of the appliance. This
water heater is not for use in manufactured (mobile) homes
or outdoor installation.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must
be observed:
1. Select a location indoors as close as practical to the
vent termination position. Figure 28 shows the venting
distances that the heater can be from the outside wall.
Ensure the vent termination position maintains the
clearances as outlined in Figure 28 thru Figure 30.
2. Selected location must provide adequate clearances
for servicing and proper operation of the water heater.
3. Avoid locations that could cause the water heater to
freeze from outside air.
4. Avoid locations that expose the water heater to direct
sunlight.
5. Keep combustibles such as boxes, magazines,
clothes, etc., away from the water heater area.
• 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.
EXTERNAL/INTERNAL DAMAGE
Do not operate the water heater until it has been fully
checked out by a qualified technician, if the water heater:
• Has been exposed to fire or damage.
• Displays evidence of sooting.
• Produces steam or unusually hot water.
If the water heater has been flooded it must be replaced.
CAUTION
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage.
Installation of the water heater must be accomplished in
such a manner that if the tank or any connections should
leak, the flow of water will not cause damage to the
structure. For this reason it is not advisable to install the
water heater in an attic or upper floor. In all cases, a metal
drain pan should be installed under the water heater. Metal
drain pans are available at your local hardware store. Such
a metal drain pan must have a clearance of at least 1”
greater than any point on the water heater’s outer jacket
and must be piped to an adequate drain. The pan must
have a maximum depth of 1.75”.
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.
• Sensors mounted in the metal drain pan that turn off
the water supply to the entire building when water is
detected in the metal drain pan.
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11
AIR REQUIREMENTS
For safe operation an adequate supply of fresh,
uncontaminated air must be provided for combustion.
This gas-fired water heater is a direct vent model. It
connects directly to the outside of the building through
the vent termination hood. The hood operates as both
the combustion air intake and the heater exhaust port
(see Figure 16).
All combustion air is obtained from outside the building
through this hood. Ensure the area around the termination
hood is always kept clear and that the air supply is not
exposed to contamination or flammable vapors.
CONFINED SPACE INSTALLATIONS
This water heater connects to the vent termination hood
using the sealed air intake and exhaust piping (see Figure
1 and Figure 2).
During operation this piping can become hot, especially in
areas experiencing high ambient temperatures.
When installed in a confined space such as a closet, it is
recommended that the confined space be ventilated to
minimize the buildup of heat around the heater. Figure 6
and Figure 7 show an examples of ventilating a confined
space.
TOP VIEW
OF CLOSET
WITHOUT DOOR
TOP VIEW OF
CLOSET WITH
DOOR
0” MIN.
0” MIN.
5.5” MIN.
0” MIN.
Figure 6
ROOM AIR
FLOW
VENTILATION
AIR
OPENING
FRONT VIEW
OF DOOR
Clearance For Servicing
Adequate clearance of 24” for servicing this appliance
should be considered before installation, such as changing
the anodes, etc.
A minimum clearance of 5.5” must be allowed for access
to replaceable parts such as thermostats, drain valve and
relief valve.
When installing the heater, consideration must be given to
proper location. Location selected should be as close to
the wall as practicable and as centralized with the water
piping system as possible.
CHEMICAL VAPOR CORROSION
CORROSION OF THE FLUEWAYS AND VENT SYSTEM
MAY OCCUR IF AIR FOR COMBUSTION CONTAINS
CERTAIN CHEMICAL VAPORS. SUCH CORROSION
MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and
air conditioning refrigerants, swimming pool chemicals,
calcium and sodium chloride (water softener salt), waxes,
and process chemicals are typical compounds which are
potentially corrosive. Do not store products of this sort
near the heater or the vent termination hood. Air which is
brought in contact with the heater or the vent termination
hood should not contain any of the chemicals. The Limited
Warranty is voided when failure of water heater is due
to a corrosive atmosphere. See “Limited Warranty” for
complete terms and conditions.
WARNING
Fire or Explosion Hazard
ROOM AIR
FLOW
Figure 7
Clearances To Combustibles
Minimum clearances between water heater and
combustibles are 0” at the sides and rear, 5.5” from the
front and 12” from top. Minimum clearances from vent
piping to combustibles is 1” except as noted in Figure
21. If clearances stated on the heater differ from these
clearances, install water heater according to clearances
stated on the heater (see Figure 6).
12
Floors With Carpeting
This water heater must not be installed directly on
carpeting. Carpeting must be protected by a metal or
wood panel beneath the appliance extending beyond
the full width and depth of the appliance by at least 3” in
every 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.
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this water heater, the vent termination hood, or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
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Read instruction manual before
installing, using or servicing
water heater.
WARNING
FLAMMABLES
Flammable Vapors
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 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.
WARNING
Fire Hazard
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 standby heat loss encountered with storage
tank heaters. Your water heater meets or exceeds
the current 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 thru Figure 5). Failure to follow these instructions
will restrict the air flow required for proper combustion and
dilution, potentially resulting in fire, asphyxiation, serious
personal injury or death.
• Check local codes to determine if insulation blankets
are allowed.
• Do not cover the outer door, thermostat or T&P relief
valve.
For continued protection against
risk of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
• Do not cover the “Installation And Operating manual”.
•
Keep it on the side of the water heater or nearby for
future reference.
Do obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over
the existing labels.
STORAGE OF FLAMMABLE LIQUIDS
Flammable liquids (such as gasoline, solvents, propane
(LP or butane, etc.) and other substances (such as
adhesives, paints, etc.) emit flammable vapors which can
be ignited by a gas water heater’s pilot or main burner. The
resulting flashback and fire can cause death or serious
burns to anyone in the area.
Even though this water heater is a flammable vapors
ignition resistant (FVIR) water heater and is designed to
reduce the chances of flammable vapors being ignited,
gasoline and other flammable substances should never
be stored or used in the same vicinity or area containing a
gas water heater, the vent termination hood, or other open
flame or spark producing appliance. Examples of such
locations are garages, storage and utility areas.
FLAMMABLE
The water heater must be located and/or protected so it
is not subject to physical damage by a moving vehicle.
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
react to form corrosive hydrochloric acid when exposed to
the combustion products of the water heater. The results
can be hazardous, and also cause product failure.
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13
WATER PIPING
Water Pressure
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures. See also “Closed Water
Systems” and “Thermal Expansion” sections.
DANGER
Children, the elderly and the
disabled and are at highest
risk of scald injury.
Feel water before bathing or
showering.
Mixing Valves
HOT WATER CAN SCALD:
Water heaters are intended to heat water. Water heated
to a temperature which will satisfy space heating, clothes
washing, dish washing, cleaning and other sanitizing
needs can scald and permanently injure you upon contact.
Short repeated heating cycles caused by small hot water
uses can cause a temperature increase of the hot water
by 20F° higher than the heater’s temperature settings.
TEMPERED
POTABLE WATER
SUGGESTED PIPING
ARRANGEMENT FOR
TOP CONNECTIONS
SHUT-OFF
VALVE
COLD WATER
INLET
MIXING VALVE
CERTAIN
MODELS ARE
EQUIPPED WITH
SIDE PLUMBING
CONNECTIONS
FOR SPACE
HEATING. THE HOT
AND COLD FITTING
ASSEMBLIES
(PART #9001262)
CAN BE ORDERED
THROUGH THE
MANUFACTURER
TEMPERATUREPRESSURE
RELIEF VALVE
DISCHARGE
PIPE (DO NOT
CAP OR PLUG)
METAL DRAIN
PAN
GAS
SUPPLY
HOT
BURN
Temperature limiting devices
such as mixing must be
installed when required by
codes and to ensure safe
temperatures at fixtures.
Some people are more likely to be permanently injured
by hot water than others. These include the elderly,
children, the infirm and the physically/mentally disabled.
Table 1 (published by U.S. Government Memorandum,
1978) shows the approximate time-to-burn relationship
for normal adult skin. If anyone using hot water provided
by the water heater being installed fits into one of these
groups or if there is a local code or state law requiring a
certain water temperature at the point of use, then special
precautions must be taken (see Figure 8).
Water
Temperature
°F
Time for 1st
Degree Burns
(Less Severe Burns)
110
(normal shower temp.)
116
(pain threshold)
Time for Permanent
Burns 2nd & 3rd
Degree (Most
Severe Burns)
116
35 minutes
45 minutes
122
1 minute
5 minutes
131
5 seconds
25 seconds
140
2 seconds
5 seconds
149
1 second
2 seconds
154
instantaneous
1 seconds
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)
Table 1
6” MAX.
AIR GAP*
DRAIN
VALVE
MASSACHUSETTS: INSTALL A VACUUM RELIEF IN COLD-WATER LINE
PER SECTION 19 MGL 142.
Figure 8
14
Water temperature over
125°F can cause severe
burns instantly resulting in
severe injury or death.
In addition to using lowest possible temperature setting
that satisfies demand of application, a mixing valve should
be installed at the water heater (see Figure 8) or at hot
water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply 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 “Operating The Temperature Control
System” section in this manual.
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INSTALLING THE NEW WATER HEATER
WATER PIPING INSTALLATION
Note: Water piping and vent piping occupy the space
above the water heater. Plan the water piping to ensure
it does not cause interference with the vent piping (see
“Venting”).
• The system should be installed only with piping that is
suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. This water heater must not be
installed using iron piping or PVC water piping.
• Use only pumps, valves, or fittings that are compatible
with potable water.
• It is recommend that only full flow ball or gate valves
are used in water piping installations. The use of valves
that may cause excessive restriction to water flow is
not recommended.
• Use only 95/5 tin-antimony or other equivalent solder.
Any lead based solder must not be used.
• Piping that has been treated with chromates, boiler
seal, or other chemicals must not be used.
• Chemicals that may contaminate the potable water
supply must not be added to the piping system.
Piping, fittings, and valves should be installed according
to the installation drawing (see Figure 9). If the indoor
installation area is subject to freezing temperatures, the
water piping must be protected by insulation.
Important: Heat must not be applied to the water fittings on
the heater as they may contain nonmetallic parts. If solder
connections are used, solder the pipe to the adapter before
attaching the adapter to the hot and cold water fittings.
Important: Always use a good grade of joint compound
and be certain that all fittings are drawn up tight.
1. Install the water piping and fittings as shown in Figure
9. Connect the cold water supply (3/4” NPT) to the cold
water inlet fitting. Connect the hot water supply (3/4”
NPT) to the hot water outlet fitting.
Important: These models may contain energy saving heat
traps to minimize the migration of heat to the pipes. Do
not remove the inserts within the heat traps.
2. The installation of unions in both the hot and cold water
supply lines is recommended for ease of removing the
water heater for service or replacement.
3. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as
specified under “Closed Water Systems” and “Thermal
Expansion”.
4. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve and
how to shut off the water to the heater.
5. After piping has been properly connected to the water
heater, remove the aerator at the nearest hot water
faucet. Open the hot water faucet and allow the tank
to completely fill with water. To purge the lines of
any excess air, keep the hot water faucet open for
3 minutes after a constant flow of water is obtained.
Close the faucet, reinstall the aerator and check all
connections for leaks. Repair as needed.
HOT WATER
OUTLET
SHUT-OFF
VALVE
COLD
WATER
INLET
UNION
3/4” SWEAT
FITTING
UNION
EXPANSION
TANK
3/4” SWEAT
FITTING
TEMPERATUREPRESSURE
RELIEF VALVE
SOME
COMPONENTS
NOT SHOWN
FOR CLARITY.
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
DRAIN
VALVE
6” MAX.
AIR GAP
METAL
DRAIN
PAN
FLOOR
DRAIN
Figure 9
Figure 9 shows typical attachment of water piping to the
water heater. The water heater is equipped with 3/4” NPT
water connections.
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, the volume of water will increase when
heated. As the volume of water increases, there will be a
corresponding increase in water pressure due to thermal
expansion. Thermal expansion can cause premature tank
failure (leakage). This type of failure is not covered under
the limited warranty. Thermal expansion can also cause
intermittent temperature-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.
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15
A properly-sized and charged thermal expansion tank must
be installed on all closed systems to control the harmful
effects of thermal expansion. Contact a plumbing service
agency or your retail supplier regarding the installation of
a thermal expansion tank.
Note: To protect against untimely corrosion of hot and cold
water fittings, it is recommended that di-electric unions or
couplings be installed on this water heater when connected
to copper pipe.
CAUTION
Property Damage Hazard
• Avoid water heater damage.
• Install thermal expansion tank if necessary.
• Do not apply heat to cold-water inlet or hot-water outlet.
• Contact qualified installer or service agency.
TEMPERATURE-PRESSURE RELIEF VALVE
designated opening nor plugged. The T&P valve must be
installed directly into the fitting of the water heater designed
for the relief valve. Install discharge piping so that any
discharge will exit the pipe within 6”above an adequate
floor drain, or external to the building. In cold climates it is
recommended that it be terminated at an adequate drain
inside the building. 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’), or use of more than four elbows can cause restriction
and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
T&P valve and the tank. Do not connect discharge piping
directly to the drain unless a maximum of 6”air gap is
provided. To prevent bodily injury, hazard to life, or property
damage, the relief valve must be allowed to discharge
water in adequate quantities should circumstances
demand. If the discharge pipe is not connected to a drain
or other suitable means, the water flow may cause property
damage.
WARNING
CAUTION
Explosion Hazard
Water Damage Hazard
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA4.4 and ASME
code.
• Properly sized temperaturepressure relief valve must be
installed in opening provided.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
This water heater is provided with a properly rated/sized
and certified combination Temperature-Pressure Relief
Valve (T&P 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.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination temperaturepressure relief valve rated/sized and certified as indicated
in the above paragraph. The new valve must be marked
with a maximum set pressure not to exceed the marked
hydrostatic working pressure of the water heater (150 psi)
and a discharge capacity not less than the water heater
Btu/hr input rate as shown on the water heater’s model
rating plate.
• Temperature-pressure relief valve discharge pipe
must terminate at an adequate drain.
T&P Valve Discharge Pipe Requirements:
• 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 not be exposed to freezing temperatures.
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 6” 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 or other obstruction between
the relief valve and the drain.
DANGER
For safe operation of the water heater, the temperaturepressure relief valve must not be removed from its
16
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• Burn hazard.
• Hot water discharge.
HOT
BURN
• Keep clear of
temperature-pressure
relief valve discharge.
The T&P valve must be manually operated at least once
a year. Caution should be taken to ensure
1. no one is in front of or around the outlet of the
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 in this manual, and replace the temperaturepressure relief valve with a properly rated/sized new one.
Note: The purpose of a temperature-pressure relief valve
is to prevent excessive temperatures and pressures in
the storage tank. The T&P valve is not intended for the
constant relief of thermal expansion. A properly sized
thermal expansion tank must be installed on all closed
systems to control thermal expansion, see “Closed Water
Systems” and “Thermal Expansion” sections.
Temperature-Pressure Relief Valve And Pipe
Insulation
The T&P valve installed on this water heater is covered by
insulation to minimize heat loss. The insulation has a hole
on the bottom side to accommodate the valve outlet and
allow for the piping connection. Do not restrict the outlet
opening of the T&P valve.
T&P Relief Valve Insulation
(Outlet opening on underside)
Manual Relief Lever
T&P Relief Valve
T&P Relief Valve
Drain Line
Figure 10
Locate the temperature and pressure relief valve on the
water heater (also known as a T&P relief valve) (see
Figure 10).
1. Locate the slit running the length of the T&P relief
valve insulation.
2. Spread the slit open and fit the insulation over the T&P
relief valve (see Figure 10). Apply gentle pressure to
the insulation to ensure that it is fully seated on the
T&P Relief Valve. Once seated, secure the insulation
with duct tape, electrical tape, or equivalent.
Important: The insulation and tape must not block the
discharge opening or hinder access to the manual relief
lever (Figure 10). Ensure a discharge pipe is installed into
the T&P valve discharge opening per the instructions in
this manual.
1. Locate the hot water (outlet) and cold water (inlet)
pipes to the water heater.
2. Locate the slit running the length of a section of pipe
insulation.
3. 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 that it is fully
seated around the pipe. Also, ensure that the base
of the insulation is flush with the water heater. Once
seated, secure the insulation with duct tape, electrical
tape, or equivalent.
4. Repeat steps 2 and 3 for the hot water (outlet) pipe.
5. Add additional sections of pipe insulation as needed.
FILLING THE WATER HEATER
CAUTION
Property Damage Hazard
• Avoid water heater damage.
• Fill tank with water before operating.
• 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 handle
to the right (clockwise). The drain valve is on the lower
front of water heater (see Figure 9).
2. Important: If the heater is equipped with plumbing
side taps and they are not connected to piping, ensure
the side taps have been closed with pipe plugs.
3. Open all hot water faucets served by the water heater
to allow air to escape from the tank and the water
piping. Ensure any shut-off valves between the heater
and the faucets are in the open position.
4. Open the cold water supply valve to the water heater.
Notes:
• The cold water supply valve must be left open when
the water heater is in use.
• Avoid water leakage when filling the tank. Do not
allow the insulation of the water heater to get wet as
water can reduce the effectiveness of the insulation.
5. Allow water to run until a constant flow is obtained.
This will let air out of the water heater and the piping.
6. Check all water piping and connections for leaks.
Repair as needed.
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17
SPACE HEATING AND POTABLE WATER SYSTEMS
This appliance has been design certified as complying
with American National Standard/CSA Standard for water
heaters and are considered suitable for Water (Potable)
Heating and Space Heating. Note: This water heater
may be used in combination potable water/space heating
system. Do not use in a space heating only application.
WARNING
Toxic Chemical Hazard
• Do not connect to non-potable water system.
Note: Ensure the water heater has been properly sized
to accommodate the needs of the hot water demand and
space heating load. Undersizing the water heater can
result in insufficient hot water, excessive condensation
and inefficient operation.
• This water heater should not be connected to any
•
•
•
•
•
•
•
•
•
18
heating systems or components previously used with
a non-potable water heating appliance.
All piping components connected to this unit for space
heating applications should be suitable for use with
potable water.
Pumps, valves, piping and fittings must be compatible
with potable water.
Toxic chemicals, such as those used for boiler treatment
shall not be introduced into the potable water used for
space heating.
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 8 for suggested piping arrangement.
Be sure to follow the manual(s) shipped with the air
handler or other type heating system.
This water heater is not to be used as a replacement
for an existing boiler installation.
Do not use with piping that has been treated with
chromates, boiler seal or other chemicals and do not
add any chemicals to the water heater piping.
A properly installed flow control valve is required to
prevent thermosiphoning. Thermosiphoning is the
result of a continuous flow of water through the air
handler circuit during the off cycle. Weeping (blow off)
of the temperature-pressure relief valve (T&P) or higher
than normal water temperatures are the first signs of
thermosiphoning.
The hot water line from the water heater should be
vertical past any mixing valve or supply line to the
heating system to remove air bubbles from the system.
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COMBO HEATING
This section serves as a guide for the installation and use
of “Combo” heating systems utilizing a domestic water
heater that has been specifically approved for such use.
It is written for those knowledgeable in the required trades
and professionals involved in the design and installation
of Combo Heating Systems.
It is the responsibility of the installer/designer to follow all
applicable codes to ensure the effectiveness and safety
of the installation.
System Requirements
The following requirements must be met for the installation
of Combo Heating Systems:
1. All components used for the distribution of water in
the heating loop must be suitable for potable water.
These include all piping, fittings, solder and fluxes,
pumps for circulation of water, valves, etc.
2. The water heater must not be connected to a hydronic
heating system that has been used previously.
3. No boiler treatment chemicals of any kind shall be
introduced into the system.
4. The Combo System components must be selected
and sized to meet and maintain the total calculated
demands for both domestic service hot water
and space heating requirement. The sizing and
installation must be performed in accordance with
good engineering practice such as “ASHRAE
Handbooks”, HRAI’s Unified Combo Guidelines,
“Hydronics Institute Manuals”, ANSI Z223.1, CSA
F280, National/Provincial Building Codes, ANSI
and/or codes having jurisdiction.
5. The air handler (fan coil) and/or the circulating pump
in a baseboard hydronic loop will require a dedicated
120V circuit. This must be provided and identified for
this purpose.
6. All piping between the water heater and the air handler
or hydronic baseboard loop must be adequately
insulated to reduce heat loss.
7. If the local jurisdiction requires a back-flow preventer
in the cold water line, an expansion tank of adequate
size must be installed.
8. “Combo” Heating Systems require higher water
temperatures than other applications. When the
system is used to supply water for Combo Heating
applications, a means, such as mixing valve, must be
installed to temper the water in order to reduce scald
hazard potential (see Figure 11 & Figure 12).
2. Install a drain valve at the lowest point of the heating
loop so that water can be drained from the heating
module without affecting the water heater.
3. If the air handler does not have a venting means at
the highest point of the piping arrangement, install
an air bleed at the highest point of the plumbing
arrangement.
HOT WATER EXPANSION TANK (OPTIONAL)
(see also
TO HOUSE
COLD SUPPLY
Massachusetts
FIXTURE
CHECK VALVE (IF USED code requirements
on pg 8)
REQUIRES EXPANSION TANK)
MIXING
VALVE
M
8 in TO
12 in MAX.
COLD INLET
C
H
CHECK
FLOW
VALVE
CONTROL
HOSE BIB
(OPT.)
HOT
OUTLET
EXTERNAL
CIRCULATOR
RETURN
SUPPLY
WATER
HEATER
DRAIN/
PURGE
VALVE
INTERNAL
CIRCULATOR
AIR
HANDLER
Figure 11
HOT WATER EXPANSION TANK (OPTIONAL)
(see also
TO HOUSE
COLD SUPPLY
Massachusetts
FIXTURE
code requirements
CHECK VALVE (IF USED
on pg 8)
REQUIRES EXPANSION TANK)
MIXING
VALVE
M
8 in TO
12 in MAX.
COLD INLET
C
H
HOSE BIB
(OPT.)
HOT
OUTLET
Installation
The heating mode may be one of the following options:
A. A fan coil/air handler (Figure 11).
B. A hydronic baseboard (finned tube) loop/In floor heating
(Figure 12).
The following is a list of requirements for the installation
of option A or B.
1. Install shut-off valves and unions so that the water
heater can be isolated from the heating module should
servicing of the water heater become necessary.
www.americanwaterheater.com
CHECK
FLOW
VALVE
CONTROL
EXTERNAL
CIRCULATOR
RETURN
SUPPLY
WATER
HEATER
HYDRONIC
BASEBOARDS
(SERIES
CONNECTED
SHOWN)
Figure 12
19
There must be:
GAS PIPING
• A readily accessible manual shut-off valve in the gas
supply line serving the water heater, and
WARNING
• A sediment trap ahead of gas control valve/thermostat
Fire and Explosion Hazard
• Do not use water heater with
any gas other than the gas
shown on the rating plate.
• Excessive pressure to gas
control valve can cause serious
injury or death.
• Turn off gas lines during
installation.
• Contact qualified installer or
service agency.
•
to help prevent dirt and foreign materials from entering
the gas control valve/thermostat.
A flexible gas connector or a ground joint union between
the manual gas shut-off valve and gas control valve/
thermostat to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting
the water heater. Use a soapy water solution, not a match
or open flame. Repair and retest as required. When
finished, rinse off soapy solution and wipe dry.
WARNING
WARNING
Fire and Explosion Hazard
• Use joint compound or tape
compatible with propane.
• Leak test before operating
heater.
• Disconnect gas piping and
shut-off valve before pressure
testing system.
Explosion Hazard
Have a qualified technician make sure that the L.P.
gas operating pressure does not exceed 13" water
column.
Failure to do so can result in death, explosion, or
fire.
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
13 inch w.c. for natural gas and propane (LP) gas. 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 the “National Fuel Gas Code” (ANSI Z223.1/NFPA
54). Copper or brass tubing and fittings (except that which
is certified for gas usage) should not be used.
If the gas control valve/thermostat is subjected to
pressures exceeding 1/2 psi (14 inch w.c.), the damage
to the gas control valve/thermostat could result in a fire or
explosion from leaking gas.
Use pipe joint compound or Teflon tape marked as being
resistant to the action of gases.
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
The appliance and its individual manual gas shut-off
valve should be disconnected from the gas supply piping
system during any pressure testing of that system at test
pressures in excess of 1/2 psi. It should be isolated from
the gas supply piping system by closing its individual
manual gas shut-off valve during any pressure testing of
the gas supply piping system at test pressures equal to
or less than 1/2 psi.
Connecting gas piping to the gas control valve/thermostat
of water heater can be accomplished by either of two
methods shown in Figure 13 & Figure 14.
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 the “National Fuel Gas
Code” (ANSI Z223.1/NFPA 54) and your gas supplier
concerning pipe size.
20
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CERTIFIED GAS
SUPPLY FLEX PIPE
(PROPERLY SIZED
FOR THE HEATER
INPUT RATE)
GROUND
JOINT
UNION
(OPTIONAL)
SEDIMENT
TRAP
3”
MIN.
GAS
CONTROL
VALVE
CAP
HIGH ALTITUDE INSTALLATIONS
Installations above 7,700’. require replacement of the
burner orifice in accordance with the current edition of
the “National Fuel Gas Code” (ANSI Z223.1/NFPA 54).
Failure to replace the orifice could result in improper and
inefficient operation of the appliance, producing carbon
monoxide gas in excess of safe limits, which could result
in serious personal injury or death. Contact your gas
supplier for any specific changes which may be required
in your area.
Figure 13
WARNING
BLACK PIPE
Breathing Hazard - Carbon Monoxide Gas
• High altitude orifice must be
installed for operation above
7,700 ft.
SEDIMENT
TRAP
3” MIN.
GROUND
JOINT
UNION
(OPTIONAL)
• Contact a qualified installer or
service agency.
GAS
CONTROL
VALVE
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
CAP
Figure 14
SEDIMENT TRAP
WARNING
Fire and Explosion Hazard
• Contaminants in gas lines can
cause fire or explosion.
• Clean all gas piping before
installation.
• Install sediment trap in accordance with NFPA54.
A sediment trap should be installed as close to the inlet of
the water heater as practical at the time of water heater
installation. The sediment trap should be either a tee fitting
with a capped nipple in the bottom outlet or other device
recognized as an effective sediment trap. If a tee fitting is
used, it should be installed in conformance with one of the
methods of installation shown in Figure 13 & Figure 14.
Contaminants in the gas lines may cause improper
operation of the gas control valve/thermostat that may
result in fire or explosion. Before attaching the gas line be
sure that all gas pipe is clean on the inside. To trap any
dirt or foreign material in the gas supply line, a sediment
trap (sometimes called a dirt leg) must be incorporated in
the piping. The sediment trap must be readily accessible.
Install in accordance with the “Gas Piping” section. Refer
to the current edition of the “National Fuel Gas Code”
(ANSI Z223.1/NFPA 54) .
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21
VENTING
This direct vent water heater uses a sealed venting
system to supply fresh combustion air to the heater and
to exhaust the products of combustion (flue gases) to the
outdoors. The venting is a “pipe in a pipe” system. The
inner (3”) piping carries out the exhaust flue gases while
the outer (6”) piping carries in fresh combustion air. The
corrugated end of the vent piping connects to the top of
the water heater and the opposite end connects to the vent
termination hood which will be mounted on the exterior wall
(see Figure 16). Figure 16 shows the hot exhaust gas exit
and the location of the combustion air intake.
Figure 19 thru Figure 26 show how to assemble and
connect the venting system.
Figure 28 thru Figure 30 show various installation options.
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY
OF THE VENT TERMINATION HOOD.
NEVER OPERATE THE WATER HEATER UNLESS IT IS
VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR
SUPPLY TO AVOID RISKS OF IMPROPER OPERATION,
FIRE, EXPLOSION OR ASPHYXIATION.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION
AND VENTILATION MUST BE PROVIDED FOR SAFE
OPERATION.
*Minimum 9 in. to
a window or door
that may be opened
WARNING
Breathing Hazard - Carbon Monoxide Gas
• Install vent system In accordance with codes.
• Do not operate water heater if flood damaged.
• Install water heater in accordance with the
instruction manual.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake.
• Do not place chemical vapor emitting products near
water heater or vent terminal hood.
• Gas and carbon monoxide detectors are available.
• Never operate the heater unless it is vented to the
outdoors and has adequate air supply to avoid risks
of improper operation, fire, explosion or asphyxiation.
• Analyze the entire vent system to make sure that
condensate will not become trapped in a section of
vent pipe and therefore reduce the open cross
sectional area of the vent.
• Chemical corrosion of flue and vent system can
cause serious injury or death.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
VENT TERMINAL CLEARANCES
The vent system must terminate so that proper clearances
are maintained as cited in local codes or the current edition
of the “National Fuel Gas Code”, ANSI Z223.1/NFPA
54 as follows:
**Minimum 12 in.
Minimum 12 in.
above grade or
anticipated snow
level
Minimum 12 in.
from soffit
** Or as required by local authorities.
Minimum
3 ft.
clearance to a
service regulator
vent outlet
**Minimum
18 in.
from outside
corner
Minimum 12 in.
under veranda, porch,
deck or balcony
(see footnote 1)
Minimum
3 ft.
above if within
10 ft.
horizontally to
a mechanical air
supply inlet
Minimum 9 in. to a non mechanical air supply inlet
into building or combustion air inlet to another appliance
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
1. Permitted only if veranda, porch, deck or balcony is fully opened on a minimum of two sides beneath the floor.
2. A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
Figure 15
22
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HOT
EXHAUST
GAS OUT
FRESH
COMBUSTION
AIR IN
Figure 18
VENT CONNECTIONS
After the location for the vent terminal has been selected
as outlined in Figure 6 & Figure 15, use the following
illustrations for installation:
SCREW
Figure 16
Be sure venting is properly connected to prevent escape
of dangerous flue gases which could cause deadly
asphyxiation.
DV TERMINATION SAFETY COVER
When the heater is in operation the vent termination hood
will be hot (see Figure 16).
A Safety cover (see Figure 17) is available to prevent
accidental contact with the vent terminal. Contact your
Customer Service Department for ordering information.
LOCATING CLEARANCE HOLE FOR VENT
Cut a clearance hole, approximately 7” in diameter, through
the exterior wall for the vent assembly. The recommended
height is 64” for 40 gal. models, 73” for 50 gal. models
and 74” for 50 gal. Hi-Input models, as measured from
the hole center to bottom of water heater. Where the
wall is combustible and the wall thickness is over 14”, 1”
clearance to combustible surfaces around the vent terminal
is needed. The first 14” is zero clearance (see Figure 21).
STANDARD VENT ARRANGEMENT
* If the horizontal length of the venting is less than 30”
the restricter plate must be installed (see Figure 22, Figure
28 thru Figure 30).
• Do not use the restricter plate in an offset installation
(see Figure 26).
• Do not use the restricter plate the horizontal length of
the venting is greater than 30”.
Note: The length of “unstretched” corrugated tube could
cause the length of the vent run to exceed the minimum. In
this case cut off a piece of the corrugated tube to achieve
the 17” minimum vent length.
Figure 17
Alternatively, a wire mesh or louvered fencing guard can
be built around the termination as shown in Figure 18.
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23
VENT ASSEMBLY
The vent piping and the vent termination hood are to be
connected as shown in Figure 20.
Maintain vent clearances to combustibles as shown in
Figure 21.
Depending on your access to where the vent termination
passes through the wall, you may wish to connect the
piping and vent termination hood together first.
Inside the vent piping there are springs that hold the two
corrugated pipes in position. When the pipes are stretched
to the required length, the springs will remain properly
spaced.
To connect the vent piping to the vent termination hood,
first slide the inner (3”) corrugated pipe over the inner vent
termination pipe. Continue this action until the locking
clip on the corrugated pipe snaps into position in the
corresponding groove (see Figure 19). Secure corrugated
pipe with screw (supplied) inserted through hole opposite
the locking clip.
Repeat this process with the outer (6”) corrugated pipe and
lock it into position on the outer pipe on the vent termination
(see Figure 19). Secure corrugated pipe with screw
(supplied) inserted through hole opposite the locking clip.
Note: To reduce the friction between the corrugated pipe
and the O-rings, it is recommended to dampen the O-rings
with water.
The completed connection is shown in Figure 20.
OUTER
CORRUGATED
PIPE
LOCKING
INNER VENT
CLIP
TERMINATION PIPE
O-RING
INNER
CORRUGATED PIPE
OUTER VENT
TERMINATION PIPE
LOCKING CLIP
GROOVE
junction of the vent terminal base plate and the exterior
wall with exterior type sealant (not included). Slide the trim
plate (inside) over the outer corrugated tube and fasten the
trim plate to the interior wall. Caulk the junction of the outer
corrugated tube and the trim plate (inside) with suitable
sealant. The vent termination hood attaches to the vent
piping as shown in Figure 20.
1”
CLEARANCE
SPRING
14” ZERO
CLEARANCE
TRIM PLATE
(OUTSIDE)
TRIM PLATE
(INSIDE)
CUTAWAY TO
SHOW SPRING
PLACEMENT
APPLY
SEALANT
APPLY
SEALANT
Figure 21
VENT RESTRICTER PLATE
The vent restricter plate (see Figure 22) is required for
short horizontal runs on low vent installations (see Figure
29) and high vent installations (see Figure 30).
For short horizontal vent runs (see Figure 29) place the
restricter plate over the flue tube reducer before connecting
the inner corrugated tube to the flue tube reducer. DO
NOT use the restricter plate if the horizontal run is greater
than 30”.
For high vertical runs use the restricter plate only when
the vertical run of the venting above the heater is greater
than 48” (see Figure 30).
FLUE TUBE
REDUCER
UPPER AIR
INLET BOX
Figure 19
RESTRICTER
PLATE
SCREW
Figure 20
Figure 22
SECURING VENT TERMINATION ASSEMBLY TO
THE EXTERIOR WALL
Some models are supplied with trim plates which may
be used to cover the holes in the wall (see Figure 1 and
Figure 21). Slide one trim plate (if supplied) over the outer
corrugated tube, then insert the outer corrugated tube
through the clearance hole from exterior wall. Secure
the trim plate to the exterior wall, then secure the vent
terminal to the exterior wall with 4 screw anchors (included)
appropriate for the type of wall construction. Caulk the
UNCOMPRESSING THE CORRUGATED TUBING
1. Pull the inner corrugated tube towards the water heater
and leave some length over the water heater’s center
for bending (see Figure 23).
2. Pull the outer corrugated tube toward the water heater
and leave it 2” shorter than the inner corrugated tube.
3. Make sure there are two springs evenly spaced at the
bend in the tube.
4. Use metal hangers to keep venting level or with a
slope upward from the heater to terminal.
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SMOOTH,
EASY CURVE
OUTER
CORRUGATED PIPE
INNER
CORRUGATED
PIPE
RESTRICTER
PLATE
APPLY
SILICONE
TO AIRBOX
BEFORE
ATTACHING
PIPING
FLUE TUBE
REDUCER
APPLY
SILICONE
GEAR
CLAMP
SECURE
WITH A
SHEET METAL
SCREW
Figure 23
Figure 25
VENT CONNECTION TO THE WATER HEATER
Bend both the corrugated pipes toward the flue connection
on the water heater. Pull and connect the inner corrugated
pipe to the water heater’s flue tube reducer with hi-temp
red silicone (included) and gear clamp. Make sure this
connection is tight and leak proof (see Figure 24).
*The sealant between the inner corrugated pipe and water
heater’s flue tube reducer must be hi-temp red silicone
or other material suitable for 600°F continuous service.
OFFSET VENT ARRANGEMENT
Where a straight vent arrangement is impossible, a
horizontal 90° maximum bend can be made. Use the
water heater casing outer diameter as a template to form
the corrugated tube.
SMOOTH,
EASY CURVE
Note: If you are using the vent restricter plate, the inner
vent pipe is to go over the side legs and down the stops.
90°
MAXIMUM
BEND
SMOOTH,
EASY CURVE
RESTRICTER
PLATE STOP
GEAR
CLAMP
Figure 26
CUTAWAY TO
SHOW DETAILS
Figure 24
Apply hi-temp red silicone (included) around the collar on
air manifold box. Pull the outer corrugated pipe all the way
on to collar and secure with the gear clamp. Pull the free
end of the corrugated pipe past the gear clamp and secure
with one sheet metal screw (see Figure 25).
Figure 27
Note: To ensure good exhaust gas flow, bend vent piping
using a smooth, easy curve as shown in Figure 24 thru
Figure 26. Do not use reverse or compound curves as
shown in Figure 27.
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25
Low Vent installation
High Vent installation
1 5
9
6
1
A
B
8
7
C
12” MIN.
BELOW
SOFFIT
1 5
ABOVE
ANTICIPATED
SNOW
LEVEL OR
12” ABOVE
GRADE
17”
MIN.
1
6
72”
MAX.
Figure 28
2
DIM.
4038
5040
A
80” MAX.
B
9” MIN.
5047
C
(RECOMMENDED)
63.63”
73.00”
74.00”
C
(MINIMUM)
60.75
69.50
70.50
D
14.25” MIN.
NOTE: Dimension “C” is the height above to floor to the center of the
termination hole through the exterior wall.
Minimum Vent installation
4
3
D
9”
C
ABOVE
ANTICIPATED
SNOW
LEVEL OR
12” ABOVE
GRADE
Figure 30
NOTES: (applies to Figure 28 thru Figure 30)
1. In any installation the total of dimension “A” plus
dimension “B” must not exceed 89”.
2. This heater can be installed with 0” clearance to a wall.
3. Minimum vent pipe clearance to combustibles is 1”
(see Figure 21).
4. Minimum distance from center of heater to wall is
14.25”.
5. Dimension “A” includes wall thickness.
6. Hole diameter in wall is 7”.
7. Venting must slope up away from the heater a
minimum of 0.25” per foot of length to prevent
condensation from collecting and to provide
sufficient draft.
8. Distance above horizontal at full extension is 2”.
9. Use support stays to hold the venting to avoid sags
or valleys.
Figure 29
26
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INSTALLATION CHECKLIST
Note: Use and complete this checklist before lighting the
heater. Correct any conditions that do not meet these
instructions.
Water Heater Location
 Centrally located with the water piping system.
Located as close to gas piping and vent pipe system
as possible.

Located indoors and in a vertical position. Protected
from freezing temperatures.

Proper clearances from combustible surfaces
maintained and not installed directly on a carpeted
floor.

Provisions made to protect the area from water
damage. Metal drain pan installed and piped to an
adequate drain.

Installation area free of corrosive elements, flammable
material and flammable vapor emitting products.

Sufficient room to service the water heater.
Gas Supply and Piping
 Gas supply is the same type as listed on the water
heater data plate.

Gas line equipped with shut-off valve, union and
sediment trap.



Adequate pipe size and of approved material.
Approved pipe joint compound or tape used.
Vent Termination Hood
 Securely fastened to exterior wall.


Above anticipated snow level or 12” above grade.

Area around vent termination hood clear and
unobstructed.


No flammable vapor emitting products stored nearby.
Proper clearances from windows, doors, corners,
other vent openings etc.
Safety covers in place (when applicable).
Water System Piping
 Temperature-Pressure relief valve properly installed
with a discharge line run to an open drain and
protected from freezing.




All piping properly installed and free of leaks.
Heater completely filled with water.
Closed system pressure build-up precautions installed.
Mixing valve installed (when applicable).
After all actions on checklist are checked/
completed, read the Lighting Instructions and
proceed with lighting the heater.
Chloride-free soap and water solution or other
approved means used to check all connections and
fittings for possible gas leaks.
Vent Pipe System
 Evenly stretched out between water heater and vent
termination hood.

Smooth bend with adequate support to prevent
sagging, 0.25” per foot.

Inside pipe (3”) and outside pipe (6”) securely
fastened to vent termination hood.

Vent restricter plate installed on heater flue outlet as
applicable.

Inside pipe (3”) and outside pipe (6”) securely fastened
to water heater with silicone and gear clamps.

Not obstructed in any way.
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27
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED
WITH WATER AND AIR PURGED FROM ALL LINES
FLAMMABLE
A. This appliance has a pilot which is lit by a piezoelectric spark gas ignition system. Do not open the inner door
of the appliance and try to light the pilot by hand.
B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric 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.
C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a
fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately contact a qualified installer or service
agency to replace a flooded water heater. Do not attempt to repair the unit! It must be replaced!
LIGHTING INSTRUCTIONS
Gas Control &
Temperature Knob
Status
Light
FIGURE 'A'
120°F
Mark
FIGURE 'B'
120°F
Mark
FIGURE 'C'
120°F
Mark
Pilot Flame
FIGURE 'D'
Main Burner
Igniter
Button
"OFF" POSITION
GAS CONTROL
"PILOT" POSITION
"ON" POSITION
Thermopile
CONTROL KNOB
1.
STOP! It is imperative that you read all safety warnings before lighting the pilot.
2. Turn the gas control/temperature knob counterclockwise
to the "OFF" position.
3. Wait ten (10) minutes to clear out any gas. If you then smell gas,
STOP! Follow “ B” in the safety
information above on this label. If you do not smell gas, go to
the next step.
4. Turn the gas control/temperature knob clockwise
to “PILOT”. See Figure ‘B’.
5. Press the gas control/temperature knob all the way in and hold it in. The knob should travel in about 1/4 inch if
it is set to "PILOT" correctly. While holding the gas control/temperature knob in, click the igniter button
continuously (about once a second) for up to 90 seconds or until status light begins to blink. The pilot flame
should envelop the thermopile. See Figure ‘D’.
6. When the status light starts blinking, release the gas control/temperature knob. Set the gas
control/temperature knob to the desired setting. See Figure ‘C’.
• If the status light does not start blinking within 90 seconds, repeat steps 2 through 5 up to THREE (3) times,
waiting 10 minutes between lighting attempts.
• The circuitry in this advanced gas valve requires that you wait 10 minutes between lighting attempts.
• If the status light turns a solid color, release the gas control/temperature knob and repeat steps 2 through 5
(waiting 10 minutes before attempting to relight the pilot). If the status light does not start blinking after
three lighting attempts, turn the gas control/temperature knob to the "OFF" position and call a qualified
service technician or your gas supplier.
DANGER: Hotter water increases the risk of scald injury. Consult the instruction manual before
changing the temperature setting.
Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting information.
TO TURN OFF GAS TO APPLIANCE
1. Turn the gas control/temperature knob counterclockwise
to the "OFF" position. The status light will stop
blinking and stay on for a short time after the water heater is turned off. See Figure ‘A’.
329352-000
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TEMPERATURE REGULATION
TEMPERATURE REGULATION
Important: Adjusting the thermostat past the 120°F mark
on the temperature dial will increase the risk of scald injury.
Hot water can produce first degree burns within:
Temperature Adjustment
Valves for reducing the point-of-use temperature by mixing
cold and hot water are available (see Figure 8). Also
available are inexpensive devices that attach to faucets to
limit hot water temperatures. Contact a licensed plumber
or the local plumbing authority.
Note: During low demand periods, a lower thermostat
setting will reduce energy losses and may satisfy your
normal hot water needs. If hot water use is expected to
be more than normal, a higher thermostat setting may be
required to meet the increased demand. When leaving
your home for extended periods (e.g., vacations etc.) turn
the temperature dial to its lowest setting. This will maintain
the water at low temperatures with minimum energy losses
and prevent the tank from freezing during cold weather.
GAS CONTROL VALVE/THERMOSTAT
SETTINGS
GAS CONTROL/
TEMPERATURE KNOB
STATUS
LIGHT
130°F 140°F 150°F 155°F
MARK MARK MARK MARK
Time for Permanent
Burns 2nd & 3rd
Degree (Most
Severe Burns)
Water
Temperature
°F
Time for 1st
Degree Burns
(Less Severe Burns)
110
(normal shower temp.)
116
(pain threshold)
116
35 minutes
45 minutes
122
1 minute
5 minutes
131
5 seconds
25 seconds
140
2 seconds
5 seconds
149
1 second
2 seconds
154
instantaneous
1 seconds
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong,
Sept. 15,1978)
Table 2
Should overheating occur or the gas supply fail to shut off,
turn “OFF” the manual gas shut-off valve to the appliance
(see Figure 1, item 18).
OPERATING THE TEMPERATURE CONTROL
SYSTEM
Water Temperature Adjustment
The water temperature setting can be adjusted from 91°F
to 155°F. Turn the Gas Control Valve/Temperature Knob
to the desired setting/temperature.
Note: The temperatures indicated are approximates. The
actual temperature of the heated water may vary.
Operating Modes And Settings
Standard Mode - The controller adjusts the water heater
to maintain the temperature set by the user.
120°F
MARK
91°F
MARK
IGNITER
Figure 31
The thermostat is adjusted to the “OFF” position when
it is shipped from the factory. Water temperature can be
regulated by moving the temperature dial to the preferred
setting. The preferred starting point is 120°F at the “HOT”
setting. Align the knob with the desired water temperature
as shown in Figure 31. There is a hot water scald potential
if the thermostat is set too high.
Note: Temperatures shown on the gas control valve/
thermostat are approximates. The actual temperature of
the heated water may vary.
Setting for vacation - The “LOW” position sets the controller
at approximately 91°F. This setting is recommended for
times when the water heater will not be in use for an
extended period of time. It effectively turns the controller
temperature setting down to a temperature that prevents
the water in the water heater from freezing while still
conserving energy.
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FOR YOUR INFORMATION
EXTERNAL DAMAGE
Do not operate the water heater until it has been fully
checked out by a qualified technician, if the water heater:
• Has been exposed to fire or damage.
• Displays evidence of sooting.
• Produces steam or unusually hot water.
If the water heater has been flooded it must be replaced.
Smoke/Odor
It is not uncommon to experience a small amount of smoke
and odor during the initial start-up. This is due to burning off
of oil from metal parts, and will disappear in a short while.
THERMAL EXPANSION
START UP CONDITIONS
NEVER OPERATE THE HEATER WITHOUT FIRST
BEING CERTAIN IT IS FILLED WITH WATER AND A
TEMPERATURE AND PRESSURE RELIEF VALVE IS
INSTALLED IN THE RELIEF VALVE OPENING OF THE
HEATER. DO NOT ATTEMPT TO OPERATE HEATER
WITH COLD WATER INLET VALVE CLOSED.
Condensate
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water
heater may appear to be leaking when in fact the water is
condensate. This usually happens when:
a. A new water heater is filled with cold water for the
first time.
b. Burning gas produces water vapor in water heaters,
particularly high efficiency models where flue
temperatures are lower.
c. Large amounts of hot water are used in a short time
and the refill water in the tank is very cold.
Moisture from the products of combustion condense on
the cooler tank surfaces and form drops of water which
may fall onto the burner or other hot surfaces to produce
a “sizzling” or “frying” noise.
Because of the suddenness and amount of water,
condensate water may be diagnosed as a “tank leak”.
After the water in the tank warms up (about 1-2 hours),
the condition should disappear.
Do not assume the water heater is leaking until there has
been enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the
family’s demands for hot water including dishwashers,
washing machines and shower heads.
Water supply systems may, because of such events as
high line pressure, frequent cut-offs, the effects of water
hammer among others, have installed devices such
as pressure reducing valves, check valves, back flow
preventers, etc. to control these types of problems. When
these devices are not equipped with an internal by-pass,
and no other measures are taken, the devices cause the
water system to be closed. As water is heated, it expands
(thermal expansion) and closed systems do not allow for
the expansion of heated water.
As water is heated, it expands (thermal expansion). As the
volume of water increases, there will be a corresponding
increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure
(leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause
intermittent temperature-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 plumbing service
agency or your retail supplier regarding the installation of
a thermal expansion tank.
Excessive condensate may be noticed during the
winter and early spring months when incoming water
temperatures are at their lowest.
Good venting is essential for a gas fired water heater
to operate properly as well as to carry away products of
combustion and water vapor.
30
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STRANGE SOUNDS
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do
not necessarily represent harmful or dangerous conditions.
“Air” In Hot Water Faucets
Condensation causes sizzling and popping within the
burner area during heating and cooling periods and should
be considered normal. See “Condensate” in this section.
Sediment collecting over time in the bottom of the tank
can result in “rumbling” or “percolating” sounds. Follow
the directions given in “Draining, Refilling And Flushing”.
OPERATIONAL CONDITIONS
Smelly Water
In each water heater there is installed at least one anode
rod (see Figure 1, item 22) for corrosion protection of the
tank. Some models will have an additional anode which
is connected to the hot water outlet nipple (see Figure 1,
item 23). Certain water conditions will cause a reaction
between the anode rod and the water. The most common
complaint associated with the anode rod is one of a “rotten
egg smell” in the hot water. The smell is a result of four
factors which must all be present for the odor to develop:
1. A concentration of sulfate in the supply water.
2. Little or no dissolved oxygen in the water.
3. A sulfate reducing bacteria which has accumulated
within the water heater (this harmless bacteria is
nontoxic to humans).
4. An excess of active hydrogen in the tank. This is
caused by the corrosion protective action of the anode.
For certain water conditions, setting the gas control valve/
thermostat at 140°F can reduce the smell generated in
the water heater.
Note: Under these conditions install a mixing valve to limit
the temperature of the water delivered to the system (see
“Water Piping” section).
HYDROGEN GAS: Hydrogen gas can be produced in
a hot water system that has not been used for a long
period of time (generally two weeks or more). Hydrogen
gas is extremely flammable and explosive. To prevent the
possibility of injury under these conditions, we recommend
the hot water faucet, located farthest away, be opened for
several minutes before any electrical appliances which
are connected to the hot water system are used (such
as a dishwasher or washing machine). If hydrogen gas is
present, there will probably be an unusual sound similar
to air escaping through the pipe as the hot water faucet
is opened. There must be no smoking or open flame near
the faucet at the time it is open.
High Water Temperature Shut Off System
This water heater is equipped with an automatic gas
shut-off system. This system works when high water
temperatures are present. Turn “OFF” the entire gas supply
to the water heater. The high temperature shut-off is built
into the gas control valve. It is non-resettable. If the high
temperature shut-off activates, the gas control valve must
be replaced. Contact your gas supplier or service agency.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less
active material, and then chlorinating the water heater tank
and all water lines. Contact the local water heater supplier
or service agency for further information concerning an
Anode Replacement Kit and this chlorination treatment.
If the smelly water persists after the anode replacement
and chlorination treatment, we can only suggest that
chlorination or aeration of the water supply be considered
to eliminate the water problem.
Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
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31
MAINTENANCE
FOR YOUR SAFETY AND SATISFACTORY OPERATION,
IT IS RECOMMENDED THAT THIS HEATER BE
CHECKED ONCE A YEAR BY A COMPETENT SERVICE
PERSON.
USERS OF THIS WATER HEATER SHOULD BE AWARE
THAT GAS COMPONENTS WEAR OUT OVER A PERIOD
OF TIME. THE GAS CARRYING COMPONENTS OF
THIS WATER HEATER SHOULD BE INSPECTED FOR
PROPER OPERATION PERIODICALLY BY A QUALIFIED
SERVICE TECHNICIAN.
HOUSEKEEPING
DANGER
Be sure the vent piping is properly connected to prevent
escape of dangerous flue gasses which could cause
deadly asphyxiation.
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chemical
vapo rs. 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.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility
to correct the problem and clean or replace the flue and
venting before resuming operation of the water heater.
WARNING
Fire and Explosion Hazard
• Do not obstruct combustion air
openings at the vent termination
hood.
• Do not use or store flammable
vapor products such as gasoline,
solvents or adhesives in the same
room or area near water heater,
the vent termination hood, or other
appliance.
• Can cause serious injury or death.
INSTALLED IN SUITABLE AREA:
To ensure sufficient ventilation and combustion air
supply, proper clearances from the water heater must
be maintained. See “Locating The New Water Heater”
section. Combustible materials such as clothing, cleaning
materials, or flammable liquids, etc. must not be placed
against or adjacent to the water heater which can cause
a fire.
FLOOD DAMAGE
Flood damage to a water heater may not be readily visible
or immediately detectable. However, over a period of time
a flooded water heater will create dangerous conditions
which can cause DEATH, SERIOUS BODILY INJURY,
OR PROPERTY DAMAGE. Contact a qualified installer or
service agency to replace a flooded water heater. Do not
attempt to repair the unit! It must be replaced!
VENTING SYSTEM INSPECTION
At least once a year a visual inspection should be made
of the venting system. You should look for:
1. Obstructions which could cause improper venting.
The combustion and ventilation air flow must not be
obstructed.
2. Damage or deterioration which could cause improper
venting or leakage of combustion products.
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Breathing Hazard - Carbon Monoxide Gas
• Flue gases may escape if vent pipe is not
connected.
• Be alert for obstructed, sooted or deteriorated
vent system to avoid serious injury or death.
• Do not store corrosive chemicals in vicinity of
the water heater or the vent termination hood.
• Chemical corrosion of flue and vent system
can cause serious injury or death.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
PILOT AND MAIN BURNER
At least once a year a visual inspection should be made
of the main burner and the pilot assembly for proper flame
characteristics. This can be done by removing the Outer
Door and viewing the main burner operation through the
Viewport on the Inner Door (see Figure 38). The main
burner should provide complete combustion of gas, ignite
rapidly, give reasonably quiet operation, and cause no
excessive flame lifting from the burner ports. If the proper
flame characteristics are not evident (see Figure 32),
make sure that the flow of combustion and ventilation
air is not blocked in the venting system. You should also
check for sooting. Soot is not normal and will impair proper
combustion.
Soot build-up indicates a problem that requires correction
before further use. Turn “OFF” gas to water heater and
leave off until repairs are made, because failure to correct
the cause of the sooting can result in a fire causing death,
serious injury, or property damage.
If proper flame characteristics are not evident, call your
service agency to remove and clean the burner and correct
any operational problem.
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BURNER FLAMES
Inspect the burner flames through the viewport and
compare them to the drawings in Figure 32. A properly
operating burner should produce a soft blue flame. Blue
tips with yellow inner cones are satisfactory. The tips of the
flame may have a slight yellow tint. The flame should not be
all yellow or have a sharp blue-orange color. Contaminated
air may cause an orange colored flame. Contact a qualified
service technician if the flame is not satisfactory
TIPS MAY HAVE
A YELLOW TINT
YELLOW INNER
CONES ARE
SATISFACTORY
CORRECT FLAME
SOFT BLUE
INCORRECT
FLAME LAZY
YELLOW
Figure 32
SERVICING THE WATER HEATER
Servicing this water heater shall be done by qualified
service personnel only.
1. Before performing any maintenance, it is important
to turn “OFF” the gas supply to the water heater at
the manual gas shut-off valve. This valve is typically
located beside the water heater. Note the position of
the shut-off valve in the open/on position, then proceed
to turn it “OFF” (see Figure 1).
2. With the water heater shut-off, allow sufficient time for
the it to cool off before performing any service.
REMOVING AND REPLACING THE GAS CONTROL
VALVE/THERMOSTAT
Removing The Gas Control Valve/Thermostat:
1. Turn the gas control/temperature knob to the “OFF”
position (see Figure 31 and Figure 33).
2. Turn “OFF” the gas at the manual gas shut-off valve
(see Figure 1).
3. Drain the water heater. Refer to the “Draining, Refilling
And Flushing” section and follow the procedure.
4. Disconnect the igniter wire from the igniter lead wire.
Use needle nose pliers to disconnect the thermopile
connector. Disconnect the pilot tube (7/16” wrench)
and manifold tube (3/4” wrench) at the gas control
valve/thermostat (see Figure 33).
Note: Propane (LP) Gas systems use reverse (left-hand)
threads on the manifold tube.
5. Refer to “Gas Piping” and disconnect the ground joint
union in the gas piping (see Figure 13 & Figure 14).
Disconnect the remaining pipe from the gas control
valve/thermostat.
6. To remove the gas control valve/thermostat, thread a
4” section of gas pipe into the inlet and use it to turn
the gas control valve/thermostat (counterclockwise).
Do not use a pipe wrench or equivalent to grip body.
Damage may result, causing leaks. Do not insert
any sharp objects into the inlet or outlet connections.
Damage to the gas control valve/thermostat may
result.
Replacing The Gas Control Valve/Thermostat:
To replace the gas control valve/thermostat, reassemble
in reverse order. When replacing the gas control valve/
thermostat, thread a 4” section of gas pipe into the inlet and
use it to turn the gas control valve/thermostat (clockwise).
DO NOT OVER TIGHTEN; damage may result.
• Be sure to use approved Teflon® tape or pipe joint
compound on the gas piping connections and fitting
on the back of the gas control valve that screws into
the tank.
• Be sure to remove the pilot ferrule nut from the new gas
control valve/thermostat. Reconnect the manifold tube,
pilot tube, igniter wire and the thermopile connections.
• Turn the main gas supply “ON” and check the gas
supply connections for leaks. Correct any leak found.
• Light the pilot and main burner, then check the manifold
tube and pilot tube connections for leaks. Use an
approved noncorrosive leak detection solution. If such
a solution is not available, use a mixture of hand dish
washing soap and water (one part soap to 15 parts
water) or childrens’ soap bubble solution. Bubbles
forming indicate a leak. Correct any leak found.
• Be sure tank is completely filled with water before
lighting and activating the water heater. Follow the
lighting instructions on the label or see “Lighting
Instructions” to restart the water heater.
If additional information is required, reference the number
on the cover of this manual for service information.
TEFLON® is a registered trademark of E.I. Du Pont De Nemours and
Company
REMOVING THE MANIFOLD/BURNER ASSEMBLY
1. Turn the gas control/temperature knob to the “OFF”
position (see Figure 31 and Figure 33).
2. Turn “OFF” the gas at the manual gas shut-off valve
(see Figure 1).
GAS CONTROL/
TEMPERATURE
KNOB
THERMOPILE
CONNECTOR
IGNITER
BUTTON
IGNITER
LEAD
WIRE
IGNITER
WIRE
WHITE
WIRE
PILOT
TUBE
RED WIRE
MANIFOLD TUBE
Figure 33
3. Remove the outer door.
4. Disconnect the following from the gas control valve/
thermostat: pilot tube (7/16” wrench), igniter wire (from
the igniter lead wire), and manifold tube (3/4” wrench)
(see Figure 33).
Note: Propane (LP) Gas systems use reverse (left-hand)
threads on the manifold tube.
5. Use needle nose pliers to disconnect the thermopile
connector from the gas control valve/thermostat (see
Figure 33).
6. Grasp the manifold tube and push down slightly to
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33
free the manifold tube and pilot tube.
7. Remove the screws (1/4” nut driver) securing the
manifold/burner assembly to the combustion chamber
(Figure 34).
8. Carefully remove the manifold/burner assembly
from the combustion chamber. BE SURE NOT TO
DAMAGE ANY INTERNAL PARTS.
GAS CONTROL/
TEMPERATURE
KNOB
GAS CONTROL
VALVE/THERMOSTAT
THERMOPILE
WIRE
CONNECTIONS
PIEZO IGNITER
BUTTON
PILOT TUBE
VIEWPORT
MANIFOLD
TUBE
MANIFOLD
SCREW (2)
OUTER DOOR
NOT SHOWN
MANIFOLD
DOOR
MANIFOLD COMPONENT
BLOCK
THERMOPILE PILOT
CONNECTOR TUBE
Figure 34
REMOVING THE BURNER FROM THE MANIFOLD/
BURNER ASSEMBLY
Natural Gas (Low Nox) & Propane (LP) Gas Burner
1. Take off the burner by removing the two (2) screws
located underneath the burner.
2. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water (see
Figure 35).
Important: DO NOT remove the orifice.
SCREWS
REPLACING THE PILOT/THERMOPILE ASSEMBLY
1. Remove the manifold door assembly as described in
“Removing The Manifold/Burner Assembly” section.
2. Remove the burner to access the pilot/thermopile
assembly. Remove and keep the screws securing the
burner to the manifold (see Figure 35).
Important: DO NOT remove the orifice.
3. Remove the screw securing the pilot/thermopile
assembly to the pilot bracket and keep for reuse later
(see Figure 36 & Figure 39).
4. Lift the retainer clip straight up from the back of
the manifold component block (using a flat-blade
screwdriver), then remove the manifold component
block from the manifold door (see Figure 36).
Important: Be careful not to bend or alter the position of
the pilot tube. It will be used as a bending template for the
new pilot assembly. Note the placement/order of the wires
in the manifold component block.
PILOT
ASSEMBLY
(BOTTOM VIEW)
RETAINER
CLIP
PILOT/THERMOPILE
ASSEMBLY SCREW
IGNITER
WIRE
PILOT/THERMOPILE
ASSEMBLY
SLOT
TAB
BRACKET
VIEWPORT
BURNER AND
OTHER FITTINGS
NOT SHOW FOR
CLARITY.
GASKET
MANIFOLD
COMPONENT
BLOCK
MANIFOLD
DOOR
Figure 36
5. Lift the pilot/thermopile assembly (including the igniter
wire) from the manifold assembly (see Figure 37).
6. Read this step carefully before proceeding. Using the
old pilot/pilot tube assembly as a guide, bend the new
pilot tube to match the old one. Make only the bends
closest to the pilot before going to the next step.
KEEP DRAIN
HOLE IN THIS
POSITION
BURNER
(BOTTOM VIEW)
Figure 35
3. When replacing the burner, ensure the drain hole is
in the position shown in Figure 35.
THERMOPILE
CONNECTOR
PILOT
IGNITER
CONNECTOR
THERMOPILE
PILOT/
THERMOPILE
ASSEMBLY
THERMOPILE
WIRES
PILOT TUBE NOT
SHOWN FOR CLARITY
Figure 37
7. Route the new pilot tube, igniter wire and thermopile
wires through the opening in the manifold door (see
Figure 36).
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8. Using the pilot screw removed earlier, attach the new
pilot/thermopile assembly. Reattach the burner to the
manifold using the screws removed earlier.
9. Reinstall the manifold component block in the
manifold door. Ensure that the pilot tube and wires
are positioned as shown in Figure 38.
MANIFOLD
COMPONENT
BLOCK
VIEWPORT
PILOT TUBE PASSES
THROUGH TOP
HOLE OF MANIFOLD
COMPONENT BLOCK
(LARGEST HOLE)
THERMOPILE WIRES
PASS THROUGH
BOTTOM HOLE
OF MANIFOLD
COMPONENT BLOCK
IGNITER WIRE
PASSES THROUGH
CENTER OF MANIFOLD
COMPONENT BLOCK
(SMALLEST HOLE)
Figure 38
10. Carefully bend the new pilot tube to match the bend
of the manifold tube.
Note: When bending, DO NOT crimp or crease the pilot
tube.
11. Before you proceed to the next step, install the new
brass ferrule nut in the gas control valve/thermostat’s
pilot tube opening, HAND TIGHT ONLY.
12. Install the manifold/burner assembly. Refer to the
“Replacing The Manifold/Burner Assembly” section
for instructions.
REPLACING THE MANIFOLD/BURNER ASSEMBLY
1. Check the door gasket for damage or imbedded debris
prior to installation (see Figure 36).
2. Inspect the viewport for damage and replace as
required (see Figure 36).
3. Insert the new manifold/burner assembly into the
burner compartment, making sure that the tab of the
manifold tube engages the slot of the bracket inside
the combustion chamber (see Figure 36).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber (see Figure 36).
5. Tighten the two screws that secure the manifold/burner
assembly to the combustion chamber. (Use a 1/4” nut
driver.) There should be no space between the gasket
part of the manifold door and combustion chamber.
Important: Do not operate the water heater if the door
gasket does not create a seal between the manifold door
and the combustion chamber.
6. Reconnect the manifold tube (3/4” wrench) and pilot
tube (7/16” wrench) to the gas control valve/thermostat
(see Figure 33). Do not cross-thread or apply any
thread sealant to the fittings.
Important: If you were supplied with a new ferrule nut in
a parts kit, follow these steps to connect the pilot tube:
1.) Install the ferrule nut into the gas valve at the pilot
tube location, hand tight only.
2.) Insert the pilot tube into the ferrule nut until the
tube bottoms out, then tighten the nut with a 7/16”
wrench until the crimp connection seals to the
pilot tube.
3.) Continue to tighten until the nut is tight in the gas
valve.
Note: Propane (LP) Gas systems use reverse (left-hand)
threads on the manifold tube.
7. Connect thermopile connector to the gas control valve/
thermostat (see Figure 33).
8. Reconnect the igniter wire (see Figure 33).
9. Turn “ON” the gas supply to the water heater at the
manual gas shut-off valve (see Figure 1).
10. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater. With
the main burner lit, check for leaks at the manifold
and pilot connections by brushing on an approved
noncorrosive leak detection solution. If such a solution
is not available, use a mixture of hand dish washing
soap and water (one part soap to 15 parts water)
or childrens’ soap bubble solution. Bubbles forming
indicate a leak. Correct any leak found.
11. Verify proper operation, then replace the outer door.
WARNING
Explosion Hazard
Tighten both manifold door screws securely.
Remove any fiberglass between gasket and
combustion chamber.
Replace viewport if glass is missing
or damaged.
Replace manifold component block if missing or removed.
Replace door gasket if damaged.
Failure to do so can result in death,
explosion, or fire.
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35
PIEZOELECTRIC IGNITER SYSTEM
The piezoelectric igniter system consists of the igniter
button, electrode, and wire. The pilot is ignited by an
electric spark generated when the igniter button is pressed
(see Figure 39).
THERMOPILE
PILOT
PILOT/
THERMOPILE
BRACKET
ELECTRODE
WIRE TO ELECTRODE
IGNITER BUTTON
Figure 39
TESTING THE IGNITER SYSTEM
Turn “OFF” the gas to the water heater at the manual gas
shut-off valve. Watch the electrode tip while activating the
igniter. A visible spark should jump from the electrode. To
avoid shock, do not touch the burner or any metal part
on the pilot or pilot assembly. If no spark is visible, check
the wire connections and make sure the electrode is not
broken. Replace the igniter if defective. Dirt and rust on the
pilot or electrode tip can prevent the igniter spark. Wipe
clean with a damp cloth and dry completely. Rust can be
removed from the electrode tip and metal surfaces by
lightly sanding with an emery cloth or fine grit sandpaper.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
It is recommended that the temperature-pressure relief
valve be checked to ensure it is in operating condition at
least once a year.
When checking the temperature-pressure relief valve
operation, make sure that (1) no one is in front of or around
the outlet of the T&P valve discharge line, and (2) that
water discharge will not cause any property damage, as
water may be extremely hot. Use care when operating
valve as the valve may be hot.
To check the relief valve, lift lever at the end of valve
several times (see Figure 40). The valve should seat
properly and operate freely.
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 and drain the
water heater, see “Draining, Refilling And Flushing”
section. Replace the T&P valve with a properly rated/
sized new one, see “Temperature-Pressure Relief Valve”
for instructions on replacement.
36
Figure 40
If the Temperature-Pressure Relief Valve on the water
heater weeps or discharges periodically, it may be due to
thermal expansion.
Note: Excessive water pressure is the most common
cause of temperature-pressure relief valve leakage.
Excessive water system pressure is most often caused
by “thermal expansion” in a “closed system.” See “Closed
Water Systems” and “Thermal Expansion” sections of this
manual. The T&P valve is not intended for the constant
relief of thermal expansion.
DANGER
• Burn hazard.
• Hot water discharge.
HOT
• Keep clear of
temperature-pressure
relief valve discharge.
BURN
DRAINING, REFILLING AND FLUSHING
Periodic draining and cleaning of sediment from the tank
maybe necessary. It is recommended that the tank be
drained and flushed every 6 months to remove sediment
which may build up during operation. The water heater
should be drained if being shut down during freezing
temperatures or for an extended period of time. See
“Typical Installation” section (Figure 1) in this manual for
location of the water heater components described below.
To Drain The Water Heater Storage Tank
1. Turn the gas control/temperature knob to the “OFF”
position (see Figure 31 and Figure 33).
2. Turn “OFF” the gas supply at the manual gas shut-off
valve.
3. Close the cold water inlet valve to the water heater.
4. Open a nearby hot water faucet and leave open to
allow for draining.
5. Connect a hose to the drain valve and terminate to
an adequate drain.
Note: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
6. Open the water heater drain valve.
7. Close the water heater drain valve when all water in
the storage tank has drained.
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To Refill The Water Heater Storage Tank
1. Close the water heater drain valve.
2. Remove the drain hose.
3. Open a nearby hot water faucet and leave open to
allow air to escape.
4. Open the cold water inlet valve to the water heater.
5. To purge the lines of any excess air, keep the hot
water faucet open for 3 minutes after a constant flow
of water is obtained.
6. Turn “ON” the gas supply at the manual gas shut-off
valve.
7. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
To Flush The Water Heater Storage Tank
1. Turn “OFF” the gas at the manual gas shut-off valve
(see Figure 1).
2. Ensure the cold water inlet valve is open.
3. Connect a hose to the drain valve and terminate it to
an adequate drain.
4. Ensure the drain hose is secured before and during the
entire flushing procedure. Flushing is performed with
system water pressure applied to the water heater.
5. Open the water heater drain valve to flush the storage
tank. Caution: Water will be hot.
6. Flush the water heater storage tank to remove
sediment and allow the water to flow until it runs clean.
7. Close the water heater drain valve when flushing is
completed.
8. Remove the drain hose.
9. Ensure the heater is full of water.
10. Turn “ON” the gas supply at the manual gas shut-off
valve.
11. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
12. Allow the water heater to complete several heating
cycles to ensure it is operating properly.
Caution: Do not turn on the gas to the water heater
unless the tank is full. Open a hot water faucet and allow
the water to run until the air is purged and the water flows
uninterrupted from the faucet.
Important: When operating a cold tank, condensation can
occur and drip on the burner. This should not be confused
with a tank leak.
7. Check for leaks. Repair as needed.
8. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
ALTERNATIVE
STEM HANDLE
HANDLE AND
CAP ASSEMBLY
WASHER
Figure 41
ANODE ROD MAINTENANCE
Each water heater contains at least one anode rod,
which will slowly deplete (due to electrolysis) prolonging
the life of the water heater by protecting the glass-lined
tank from corrosion. Adverse water quality, hotter water
temperatures, high hot water usage, hydronic heating
devices, and water softening methods can increase
the rate of anode rod depletion. Once the anode rod
is depleted, the tank will start to corrode, eventually
developing a leak.
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water. See “Operational Conditions”.
Important: Do not remove this rod permanently as it will
void any warranties. A special anode rod may be available
if water odor or discoloration occurs.
CAP
DRAIN VALVE WASHER REPLACEMENT
1. Turn “OFF” the gas at the manual gas shut-off valve
(see Figure 1).
2. Follow “Draining” instructions in the “Draining, Refilling
And Flushing” section.
3. Turning counterclockwise ( ), remove the hex cap
below the screw handle.
4. Remove the washer and put the new one in place.
5. Screw the handle and cap assembly back into the
drain valve and retighten using a wrench. DO NOT
OVER TIGHTEN.
6. Follow “Refilling” instructions in the “Draining, Refilling
And Flushing” section.
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* THE ANODE ROD IS COVERED
BY URETHANE FOAM LOCATED
UNDER THE CAP. CHIP AWAY
THE FOAM TO EXPOSE THE
TOP OF THE ANODE ROD
ANODE ROD *
Figure 42
37
Note: This rod may reduce but not eliminate water odor
problems. The water supply system may require special
filtration equipment from a water conditioning company to
successfully eliminate all water odor problems.
Artificially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease
the life of the water heater tank. The anode rod (see Figure
42) should be inspected after a maximum of three years
and annually thereafter until the condition of the anode
rod dictates its replacement (see Figure 43).
EXPOSED
SUPPORT
WIRE
PITTED ANODE ROD
EXPOSED
SUPPORT
WIRE
Figure 43
Note: Artificially softened water requires the anode rod to
be inspected annually. The following are typical (but not
all) signs of a depleted anode rod:
• The majority of the rods diameter is less than 3/8”.
• Significant sections of the support wire (approx. 1/3 or
more of the anode rod’s length) are visible.
If the anode rod show signs of either or both it should be
replaced.
Note: Whether re-installing or replacing the anode rod,
check for any leaks and immediately correct if found.
To Install The Anode Rod:
1. Use Teflon® tape or an approved pipe sealant on
threads of the new anode rod.
2. Place the anode rod in the spud (top of the tank) (see
Figure 42) and turn clockwise until the threads are
hand tight. Using a ratchet and 1-1/16” socket tighten
down water tight.
3. Open a nearby hot water faucet to purge air from
the water line. Fill water heater tank completely.
(Refer to “Draining, Refilling And Flushing” for proper
procedures).
Note: To assure the water heater tank is full, keep the hot
water faucet open for 3 minutes after a constant flow of
water is obtained.
4. After turning closing the hot water faucet, check for
water leaks around anode rod and immediately correct
any if found.
5. Reinstall the insulation and anode cap which were
removed in step 5 of removal process.
6. Turn “ON” the manual gas shut-off valve (see Figure
1).
7. Turn the gas control/temperature knob to the “ON”
position (see Figure 31 and Figure 33).
8. Follow the lighting instructions on the label or see
“Lighting Instructions” to restart the water heater.
To Remove The Anode Rod:
1. Turn the gas control/temperature knob to the “OFF”
position (see Figure 31 and Figure 33).
2. Turn “OFF” the gas at the manual gas shut-off valve
(see Figure 1).
3. Shut off the incoming water supply to the water heater
and open a nearby hot water faucet to depressurize
the water tank.
4. Connect a hose to the drain valve and terminate it to
adequate drain or to the exterior of the building. Open
the drain valve and drain approximately 5 gallons of
water from tank. (Refer to “Draining, Refilling And
Flushing” for proper procedures). Close drain valve
and remove hose.
5. Remove and retain the anode cap on top of the heater
and remove and retain just enough insulation so you
can access to the anode head (see Figure 42). Keep
in a safe place for reinstallation later.
6. Remove the anode rod by using a ratchet and a
1-1/16” socket turning counter-clockwise (see Figure
42).
38
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LEAKAGE CHECKPOINTS
SERVICE
If a condition persists or you are uncertain about the
operation of the water heater contact a service agency.
Use this guide to check a “Leaking” water heater (see
Figure 44). Many suspected “Leakers” are not leaking
tanks. Often the source of the water can be found and
corrected.
If you are not thoroughly familiar with gas codes, your
water heater, and safety practices, contact your gas
supplier or qualified installer to check the water heater.
• * To check where threaded portion enters tank, insert
cotton swab between jacket opening and fitting. If cotton
is wet, follow the draining instructions in this manual,
and then remove fitting. Put pipe dope or Teflon® tape
on the threads and replace. To refill the water heater
follow the instructions in “Draining, Refilling And
Flushing”.
A
B
B
C
Read this manual first. Then before checking the water
heater make sure the gas supply has been turned “OFF”,
and never turn the gas “ON” before the tank is completely
full of water.
Never use this water heater unless it is completely filled
with water. To prevent damage to the tank, the tank must
be filled with water. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
D. Water at the vent assembly is water vapor which has
condensed out of the combustion products. This is
caused by a problem in the vent. Contact the gas utility.
E. *Condensation may be seen on pipes in humid weather
or pipe connections may be leaking.
F. *The anode rod fitting may be leaking (anode is located
under the plastic plug and insulation).
G. Small amounts of water from temperature-pressure
relief valve may be due to thermal expansion or high
water pressure in your area.
H. *The temperature-pressure relief valve may be leaking
at the tank fitting.
I. Water from a drain valve may be due to the valve being
slightly opened.
J. *The drain valve may be leaking at the tank fitting.
K. Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets
form and drip onto the burner or run on the floor. This
is common at the time of start-up after installation and
when incoming water is cold.
L. Water in the water heater bottom or on the floor may
be from condensation, loose connections, or the relief
valve. DO NOT replace the water heater until a full
inspection of all possible water sources is made and
necessary corrective steps taken.
M. The combo heating system connections may be
leaking.
E
J
G
H
I
D
F
Figure 44
Leakage from other appliances, water lines, or ground
seepage should also be checked.
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39
REFERENCE PARTS LISTING
Replacement parts may be ordered
through your plumber or the local
distributor. When ordering replacement
parts, always have the following
information ready:
1. Model, Serial and Product number
2. Type of gas
3. Item number
4. Parts description
1 Vent Termination Hood
2 Wall Plate
3 ***Vent Pipe
4 Cold Water Inlet Nipple/Diptube
6 T&P Valve
7 Gas Control Valve/Thermostat
(Honeywell)
9 *Discharge Pipe
10 Drain Valve
11 Outer Gas Door
12 Manifold Door Assembly (behind
outer door) (see Figure 3 &
Figure 4) (see also Figure 47 &
Figure 48)
15 Flexible Manifold Tube (see
Figure 3 & Figure 4) (see also
Figure 47 & Figure 48)
22 Anode (under cap)
23 Hot Water Outlet Nipple (or Optional
Nipple/Anode)
26 Air Inlet Snorkel
27 Air Tower
28 ***Airbox
29 *Thermal Expansion Tank (required
for all closed systems)
30 Sheet Metal Burner (see Figure 3 &
Figure 4) (see see also Figure 47 &
Figure 48)
31 Gas Orifice (see Figure 3 &
Figure 4) (see also Figure 47 &
Figure 48)
32 Gas Manifold (see Figure 3 & Figure
4) (see also Figure 47 & Figure 48)
33 Manifold Door Gasket (see Figure 3 &
Figure 4) (see also
Figure 47 & Figure 48)
34 Manifold Door (see Figure 3 & Figure
4) (see also Figure 47 & Figure 48)
35 Two Piece Grommet With Clip (see
Figure 3 & Figure 4) (see also
Figure 47 & Figure 48)
36 Viewport (see Figure 3 & Figure 4)
(see also Figure 47 & Figure 48)
37 Flexible Manifold Tube (see
Figure 3 & Figure 4) (see also
Figure 47 & Figure 48)
38 Pilot (see Figure 3 & Figure 4) (see
also Figure 47 & Figure 48)
39 Thermopile (see Figure 3 &
Figure 4) (see also Figure 47 &
Figure 48)
40 Pilot Shield (see Figure 3 &
Figure 4) (see also Figure 47 &
Figure 48)
*
Items not supplied with the water
heater.
*** During operation the vent pipe and
airbox can get hot.
13 *Floor Drain
14 *Metal Drain Pan
1
2
3
1
2
4
6
23
22
22
28
4
27
7
9
26
10
11 12
15
13
14
Front View
Figure 45
40
Rear View
Figure 46
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30
39
37
36
40
†
38
31
Flare
Nut
††
39
38
37
35
Natural gas and Propane (LP)
main burner with igniter assembly
for 38k to 42k Btu/hr models
Natural gas and Propane
(LP) main burner with igniter
assembly for 47k Btu/hr
models
34
40
30
†
Flare
Nut
††
31
32
32
33
33
36
Figure 47
34
35
Figure 48
Notes:
† The orifice on Natural gas models has Right-hand
thread, the orifice on Propane (LP) models has Lefthand thread.
†† For Natural gas models the Flare Nut has Right-hand
thread. For Propane (LP) models the Flare Nut has
Left-hand thread.
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41
TROUBLESHOOTING GUIDELINES
PROBLEM
BURNER WILL NOT
IGNITE
POSSIBLE CAUSE(S)
1.
2.
3.
4.
5.
6.
7.
8.
Pilot not lit
Thermostat set too low
No gas
Dirt in the gas lines
Pilot line clogged
Main burner line clogged
Defective thermopile
Defective gas control/thermostat
PILOT WILL NOT LIGHT
OR REMAIN LIT
HIGH OPERATION
COSTS
PILOT FLAME TOO
SMALL
42
1.
2.
3.
4.
5.
6.
7.
8.
Light pilot
Turn temp. dial to desired temperature
Check with gas utility company
Notify utility-install trap in gas line
Clean, locate source and correct
Clean, locate source and correct
Replace thermopile
Replace gas control/thermostat
1. Sulfur in the water
1. Replace the anode with a special
anode
2. Raising the water heater temperature
setting to 140°F may help to eliminate
the odor (will require the use of a
mixing valve)
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
SMELLY WATER
BURNER FLAME
YELLOW-LAZY
CORRECTION
Low gas pressure
Flue clogged
Main burner line clogged
Obstruction in main burner orifice
Insufficient combustion air
1.
2.
3.
4.
5.
6.
7.
Check with gas utility company
Clean, locate source and correct
Clean, locate source and correct
Clean or replace orifice
Check that the vent termination hood
and venting pipe is not blocked
Air in gas line
No gas
Dirt in gas lines
Pilot line or orifice clogged
Defective thermopile
Insufficient combustion air
Gas control/thermostat ECO switch
open
8. Defective igniter or electrode
9. Low gas pressure
10. Incorrect gas
1. Bleed the air from the gas line
2. Check with gas utility company
3. Notify utility-install sediment trap (dirt
leg) in gas line
4. Clean, locate source and correct
5. Replace thermopile
6. Check that the vent termination hood
and venting pipe is not blocked
7. Replace gas control/thermostat
8. Replace igniter or pilot assembly
9. Check with gas utility company
10. Check rating plate for correct gas type.
Check with gas utility company
1.
2.
3.
4.
5.
6.
7.
8.
9.
Thermostat set too high
Sediment or lime in tank
Water heater too small for job
Wrong piping connections
Leaking faucets
Gas leaks
Wasted hot water
Long runs of exposed piping
Hot water piping in exposed wall
1. Set temperature dial to lower setting
2. Drain/Flush-Provide water treatment if
needed
3. Install adequate size heater
4. Correct piping-dip tube must be in cold
inlet
5. Repair faucets
6. Check with utility-repair at once
7. Advise customer
8. Insulate piping
9. Insulate piping
1.
2.
3.
4.
Pilot line or orifice clogged
Low gas pressure
Defective pilot
Incorrect gas
1.
2.
3.
4.
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Clean, locate source and correct
Check with gas utility company
Replace pilot
Check rating plate for correct gas type.
Check with gas utility company
PROBLEM
INSUFFICIENT HOT
WATER
SLOW HOT WATER
RECOVERY
DRIP FROM RELIEF
VALVE
POSSIBLE CAUSE(S)
CORRECTION
1. Thermostat set too low
2. Sediment or lime in tank
3. Water heater too small
4. Wrong piping connections
5. Leaking faucets
6. Wasted hot water
7. Long runs of exposed piping
8. Hot water piping in outside wall
9. Low gas pressure
10. Leaks or cracks in dip tube
11. Incorrect plumbing/plumbing crossover
1. Turn temperature dial to desired setting
2. Drain/flush-provide water treatment if
needed
3. Install adequate size heater
4. Correct piping-dip tube must be in cold
inlet
5. Repair faucets
6. Advise customer
7. Insulate piping
8. Insulate piping
9. Check with gas utility company
10. Check dip tube. Replace if faulty
11. Correct cold water crossover
1.
2.
3.
4.
5.
6.
7.
8.
9.
1. Check vent termination hood and
venting, flueway, flue baffle and burner
2. Clean flue, locate source and correct
3. Check with gas utility company
4. Replace gas control/thermostat
5. Turn temperature dial to desired
setting
6. Install adequate size heater
7. Correct piping-dip tube must be in
cold inlet
8. Advise customer
9. Drain/flush - provide water treatment if
needed
Insufficient combustion air
Venting/flue clogged
Low gas pressure
Improper calibration
Gas control/thermostat set too low
Water heater too small
Wrong piping connections
Wasted hot water
Sediment or lime in tank
1. Excessive water pressure
2. Heater stacking
3. Closed water system/thermal
expansion
THERMOSTAT FAILS TO 1. Defective gas control/thermostat
SHUT OFF
2. Improper calibration
COMBUSTION ODORS
1. Insufficient ventilation air
2. Flue clogged or vent system blocked
3. Heater installed in a confined area
1.
2.
SMOKING AND CARBON 3.
FORMATION (SOOTING) 4.
5.
CONDENSATION
Insufficient combustion air
Low gas pressure
Venting/flue clogged
Defective gas control/thermostat
Burner flame yellow-lazy
1. Temperature setting too low
2. Water heater too small
1. Orifice too large
BURNER FLAME
2. High gas pressure
FLOATS AND LIFTS OFF
3. Flue clogged
PORTS
BURNER FLAME TOO
HIGH
FLAME BURNS AT
ORIFICE
1. Use a pressure reducing valve and
relief valve
2. Lower the thermostat setting
3. See “Closed System/Thermal
Expansion”
1. Replace gas control/thermostat
2. Replace gas control/thermostat
1. Provide ventilation to the water heater.
Check flueway, flue baffle, burner
2. Clean, locate source and correct
3. Provide fresh air ventilation
1. Check vent termination hood and
venting, flueway, flue baffle and burner
2. Check with gas utility company
3. Clean, locate source and correct
4. Replace gas control/thermostat
5. See “Burner Flame Yellow-Lazy”
1. Increase the temperature setting
2. Install adequate size heater
1. Replace with correct orifice
2. Check with gas utility company
3. Clean flue and burner-locate source
and correct
1. Orifice too large
2. High gas pressure
1. Replace with correct orifice
2. Check with gas utility company
1. Defective gas control/thermostat
2. Low gas pressure
3. Orifice not properly installed
1. Replace gas control/thermostat
2. Check with gas utility company
3. Reinstall the orifice
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43
STATUS LIGHT AND DIAGNOSTIC CODE
TROUBLESHOOTING CHART
LED STATUS
PROBLEM
CORRECTIVE ACTION
0 FLASHES (LED NOT LIT)
Pilot light is not lit or
Turn Gas Control Valve/Thermostat knob to
thermopile has not yet reached “OFF”. Wait 10 minutes, then attempt to relight
normal operating temperature. Pilot by following the lighting instructions on the
water heater’s label. Until the thermopile reaches
its normal operating temperature, the Status Light
will not blink, even if the Pilot is lit. It may take
up to 90 seconds of continuous Pilot operation
before the thermopile reaches normal operating
temperature and the Status Light starts to blink.
If the Status Light does not blink after three
lighting attempts, check to make sure unit is
getting gas. Remove the outer door. Press reset
button. Replace outer door. Turn Gas Control
Valve/Thermostat knob to “OFF”. Wait 10 minutes,
then attempt to light Pilot by following the lighting
instructions on the water heater’s label. Look
through the view port for the Pilot flame. If Pilot is
not visible, the spark igniter or gas supply to the
Pilot should be checked.
If the Pilot is visible and the Status Light does
not blink after 90 seconds of continuous Pilot
operation, the Pilot flame may not be heating the
thermopile sufficiently (weak Pilot), the thermopile
may be defective, or wiring connectors may be
loose.
RED LIGHT ON (SOLID)
Pilot light was recently
extinguished and the
thermopile is cooling down.
Turn Gas Control Valve/Thermostat knob to
“OFF”. Wait 10 minutes for the thermopile to
cool, then attempt to relight Pilot by following the
lighting instructions on the water heater’s label.
NOTE: This gas control valve/thermostat has
built-in circuitry that requires waiting 10 minutes
between lighting attempts.
Until the thermopile reaches its normal operating
temperature, the Status Light will not blink, even
if the Pilot is lit. It may take up to 90 seconds of
continuous Pilot operation before the thermopile
reaches normal operating temperature and the
Status Light starts to blink.
1 FLASH (EVERY 3
SECONDS)
Normal operation.
No corrective action necessary.
2 FLASHES
Pilot is lit but the thermopile
is not producing the required
output voltage.
Turn Gas Control Valve/Thermostat knob to
“OFF”. The thermopile is probably defective, but
loose wiring connections or a weak Pilot flame
can also cause this symptom.
44
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LED STATUS
PROBLEM
CORRECTIVE ACTION
4 FLASHES
The Gas Control Valve’s
temperature sensor has
detected that the water
temperature was too high.
Once this condition occurs,
the Main Burner and the Pilot
Light will be shut off. Since the
Pilot light will be off, should
this condition occur, this Flash
Code will only be displayed
immediately after the Pilot has
been relit. Turn Gas Control
Valve/Thermostat knob to
“OFF”.
Relight pilot and verify 4 flashes. If 4 flashes are
observed, turn Gas Control Valve/Thermostat
knob to “OFF”. Turn Main Gas Supply “OFF.”
Replace the Gas Control Valve/Thermostat. See
“Removing and Replacing the Gas Control Valve/
Thermostat.”
5 FLASHES
The temperature sensor
(thermistor) is defective.
Turn Gas Control Valve/Thermostat knob
to “OFF”. Replace the temperature sensor
(thermistor).
7 FLASHES
Gas Control Valve failure.
Turn Gas Control Valve/Thermostat knob to
“OFF”. Turn Main Gas Supply “OFF”. Replace
the Gas Control Valve/Thermostat. See
“Removing and Replacing the Gas Control Valve/
Thermostat.”
8 FLASHES
This condition only appears if
the gas control/temperature
knob has been turned off
and the thermopile continued
to produce electric power.
This condition can occur if
the thermopile does not cool
down as quickly as expected
when the unit is shut off. This
condition can also occur if
the gas control/temperature
knob has been turned off and
the pilot continues to operate
because the pilot valve is
stuck in the open position.
Make sure that the gas control valve/thermostat
knob is set to “OFF”. Wait one minute. Remove
the outer door. Look through the sight glass for
a pilot flame. If a pilot flame is observed with
the gas control valve/thermostat knob set to the
“OFF” position, the pilot valve is stuck open. Turn
the main gas supply “OFF”. Replace the gas
control valve/thermostat. For instructions, see
“Removing and Replacing the Gas Control Valve/
Thermostat.”
If the pilot flame is not observed when the gas
control valve/thermostat knob is set to the “OFF”
position, wait 10 minutes for the thermopile to
cool, then attempt to relight the pilot by following
the lighting instructions on the water heater’s
label. If this condition returns, replace the gas
control valve/thermostat. See “Removing And
Replacing The Gas Control Valve/Thermostat” for
instructions.
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45
NOTES
46
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NOTES
www.americanwaterheater.com
47
500 Princeton Road, Johnson City, TN 37605
Phone: 800-999-9515 • Fax: 800-999-5210
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