Whirlpool AMERICAN WATERHEATERS Service manual

INSTALLATION, OPERATION, AND SERVICE MANUAL
RESIDENTIAL STORAGE TYPE GAS WATER HEATER
Recognize this symbol as an indication of Important
Safety Information.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED
SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT
AND OPERATION OF THIS WATER HEATER. READ THESE
INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION
OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN IMPROPER INSTALLATION, OPERATION, SERVICE OR
MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,
SCALD INJURY, CARBON MONOXIDE POISONING, EXPLOSION,
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING: If the information in these
instructions is not followed exactly, a fire or
explosion may result causing property damage,
personal injury or death.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
INSTALLER:
•
ATTACH THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER
HEATER.
•
BEFORE LEAVING THE PREMISES REVIEW THIS OPERATION AND
SERVICE MANUAL TO BE SURE THE HEATER HAS BEEN INSTALLED
CORRECTLY. START AND OPERATE THE UNIT FOR ONE COMPLETE
CYCLE AND MAKE SURE THE WATER TEMPERATURE IS ACCEPTABLE
TO THE CONSUMER AT THE FIXTURES.
OWNER:
• RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE
REFERENCE. RETAIN THE ORIGINAL RECEIPT AS PROOF OF
PURCHASE.
SE PUEDE OBTENER UNA VERSION ESPAÑOL DE ESTAS
INSTRUCCIONES SI ESCRIBE A LA FÁBRICA QUE APARECE EN LA
PLACA DE ESPECIFICATIONES
A SPANISH VERSION OF THESE INSTRUCTIONS MAY BE OBTAINED IF
YOU WRITE TO THE MANUFACTURER SHOWN ON THE RATING PLATE.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any telephone in your building.
• Immediately call your gas supplier from a
neighbor’s telephone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
THIS MANUAL IS NOT TO BE USED WITH GAS STORAGE TYPE WATER
HEATERS CERTIFIED FOR INSTALLATION IN MANUFACTURED HOMES
(MOBILE HOMES).
AN ODORANT IS ADDED BY THE GAS SUPPLIER TO THE GAS
USED BY THIS WATER HEATER. SEE WARNING BELOW.
WARNING
AN ODORANT IS ADDED BY THE GAS SUPPLIER TO THE GAS USED
BY THIS WATER HEATER. THIS ODORANT MAY FADE OVER AN
EXTENDED PERIOD OF TIME. DO NOT DEPEND UPON THIS
ODORANT AS AN INDICATION OF LEAKING GAS. IF A GAS LEAK IS
SUSPECTED, CHECK FOR LEAKS BY USING A CHLORIDE-FREE SOAP
AND WATER SOLUTION, OR OTHER APPROVED METHOD. IF A LEAK
CANNOT BE FOUND BUT IS STILL SUSPECTED, FOLLOW THE STEPS
UNDER "WHAT TO DO IF YOU SMELL GAS" AS OUTLINED ON THIS
PAGE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.
TO OBTAIN TECHNICAL, WARRANTY OR SERVICE
ASSISTANCE DURING OR AFTER THE INSTALLATION
OF THIS WATER HEATER, CALL TOLL FREE:
1-800-999-9515.
WHEN CALLING FOR ASSISTANCE, PLEASE HAVE THE
FOLLOWING INFORMATION READY:
1.
2.
3.
4.
MODEL NUMBER
7 DIGIT PRODUCT NUMBER
SERIAL NUMBER
DATE OF INSTALLATION
WARNING
THIS WATER HEATER MUST BE BRACED, ANCHORED, OR
STRAPPED TO AVOID FALLING OR MOVING DURING AN
EARTHQUAKE. CONTACT LOCAL UTILITIES FOR CODE
REQUIREMENTS IN YOUR AREA OR CALL THE 800 NUMBER
SHOWN ON FRONT OF THIS MANUAL AND REQUEST
INSTRUCTIONS 6600933 FOR EXAMPLES.
6510185
March 2000
Supersedes 6510160
Vapors from flammable liquids will explode
and catch fire causing death or severe burns.
Do not use or store flammable products such as
gasoline, solvents or adhesives in the same room or
area near the water heater.
Keep flammable products:
1. far away from the water heater.
2. in approved containers,
3. tightly closed and
4. out of children’s reach.
Water heater has a main burner and pilot flame.
The pilot flame:
1. is on all the time 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 to the pilot
flame by air currents.
Do not install this heater where flammable
products will be stored or used unless the main
burner and pilot flames are at least 18 inches
above the floor. This will reduce but not eliminate
the risk of vapors being ignited by the main burner
or pilot flame.
DANGER
DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE
ONE LISTED ON THE DATA PLATE. This water heater is equipped for
use with one type gas only. CHECK THE DATA PLATE NEAR THE GAS
CONTROL VALVE FOR THE CORRECT GAS. FAILURE TO USE THE
CORRECT GAS CAN CAUSE PROBLEMS WHICH CAN RESULT IN
DEATH, SERIOUS BODILY INJURY OR PROPERTY DAMAGE. If you
have any questions or doubts consult your gas supplier or gas utility
company. Water heaters using bottled propane or liquefied petroleum
gas (LPG) are different from natural gas models. A natural gas water
heater will not function safely on bottled propane or liquefied
petroleum gas (LPG) and a propane gas water heater will not function
safely on natural gas. Do not attempt to convert a water heater from
natural gas to LPG or from LPG to natural gas.
WHEN REMOVING PURGED
GASES FROM A PIPING
SYSTEM, DO NOT CREATE
A HAZARDOUS CONDITION
BY DISCHARGING THE
GASES INTO A CONFINED
AREA OR IN AN AREA THAT
CONTAINS AN IGNITION
SOURCE.
Water temperature over 125°F can cause severe
burns instantly or death from scalds.
Children, disabled and elderly are at highest risk of
being scalded.
See the instruction manual before setting the water
temperature at the water heater.
Feel the water before bathing or showering.
Temperature limiting valves are available for use.
2
GENERAL SAFETY WARNINGS
BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS WATER HEATER, MAKE SURE YOU READ AND UNDERSTAND THE ENTIRE INSTALLATION,
OPERATION AND SERVICE MANUAL. SPECIAL ATTENTION MUST BE GIVEN TO ALL THE SAFETY WARNINGS PROVIDED THROUGHOUT THIS MANUAL.
FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN A FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. IF YOU
HAVE DIFFICULTY UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL OR ARE NOT AN EXPERIENCED INSTALLER, DO NOT PROCEED, BUT GET HELP
FROM A QUALIFIED INSTALLATION OR SERVICE TECHNICIAN.
DANGER
•
•
•
•
•
•
•
•
•
•
•
TAMPERING WITH THE THERMOSTAT, IGNITER CONTROL, GAS VALVE
OR TEMPERATURE AND PRESSURE RELIEF VALVE IS DANGEROUS AND
MAY RESULT IN SERIOUS INJURY OR DEATH. TAMPERING VOIDS ALL
WARRANTIES. ONLY PROPERLY TRAINED, QUALIFIED SERVICE
PERSONNEL SHOULD SERVICE THESE COMPONENTS. DO NOT
ATTEMPT TO MODIFY OR CHANGE THIS WATER HEATER IN ANY WAY.
DO NOT ATTEMPT TO CONVERT THIS WATER HEATER FROM NATURAL
GAS TO L.P. OR FROM L.P. TO NATURAL GAS. THIS CAN RESULT IN
PROPERTY DAMAGE, FIRE, EXPLOSION, BODILY HARM OR DEATH.
DO NOT INSTALL THIS WATER HEATER IN A MOBILE HOME
DO NOT INSTALL THIS WATER HEATER OUTDOORS.
RESIDENTIAL AREAS WHERE FLAMMABLE LIQUIDS (GASOLINE,
SOLVENTS, LIQUID PROPANE, BUTANE, ETC.) OR OTHER SUBSTANCES
WHICH EMIT FLAMMABLE VAPORS ARE STORED MAY NOT BE
SUITABLE FOR WATER HEATER INSTALLATION. NATURAL AIR
MOVEMENTS CAN CARRY FLAMMABLE VAPORS SOME DISTANCE
FROM WHERE THEY ARE STORED OR USED. NEAR GROUND LEVEL
VENTS CAN DRAW THESE VAPORS INTO THE WATER HEATER WHERE
THE PILOT FLAME OR MAIN BURNER CAN IGNITE THEM CAUSING
PROPERTY DAMAGE, SERIOUS BURNS OR DEATH. NEVER STORE OR
USE FLAMMABLE SUBSTANCES IN THE SAME ROOM OR AREA
CONTAINING A GAS WATER HEATER. IF SUCH FLAMMABLES MUST BE
USED, ALL GAS BURNING APPLIANCES IN THE VICINITY MUST BE
SHUT OFF AND THEIR PILOT LIGHTS EXTINGUISHED. OPEN THE DOORS
AND WINDOWS FOR VENTILATION WHILE FLAMMABLE SUBSTANCES
ARE IN USE.
FLAMMABLE VAPORS MAY BE DRAWN TO THIS WATER HEATER FROM
OTHER AREAS OF THE STRUCTURE BY AIR CURRENTS.
WATER HEATERS INSTALLED IN RESIDENTIAL GARAGES MUST BE
INSTALLED SUCH THAT THE PILOT FLAME AND MAIN BURNER FLAME
ARE NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS TO
REDUCE BUT NOT ELIMINATE THE RISK OF LIGHTING FLAMMABLE
VAPORS WHICH MAY BE PRESENT IN A GARAGE. THIS WATER
HEATER MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL
DAMAGE BY VEHICLES OR FLOODING.
THE WATER HEATER IS CERTIFIED FOR INSTALLATION ON A
COMBUSTIBLE FLOOR. HOWEVER WHEN THIS WATER HEATER IS
INSTALLED OVER CARPETING, THE CARPETING MUST BE PROTECTED
BY A METAL OR WOOD PANEL BENEATH THE WATER HEATER AND
EXTENDING BEYOND THE FULL WIDTH AND DEPTH OF THE WATER
HEATER BY AT LEAST THREE INCHES IN ANY DIRECTION. IF THE
WATER HEATER IS INSTALLED IN A CARPETED ALCOVE OR CLOSET,
THE ENTIRE FLOOR MUST BE COVERED BY THE PANEL. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN A FIRE HAZARD.
THIS WATER HEATER AND ANY OTHER GAS FUEL BURNING
APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR
PROPER VENTILATION OF THE FLUE GASES.
REPAIR, REPLACEMENT, SERVICE AND CLEANING OF WATER HEATER
PARTS MUST ONLY BE PERFORMED BY A QUALIFIED SERVICE
TECHNICIAN.
DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK GAS
PIPING FOR LEAKS.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
DO NOT ATTEMPT TO LIGHT THIS WATER HEATER UNTIL IT IS
PROPERLY INSTALLED AND YOU UNDERSTAND ALL OF THE SAFETY
WARNINGS AND PRECAUTIONS.
VENTILATION AND COMBUSTION AIR SUPPLIES CANNOT BE TAKEN
FROM AREAS THAT CONTAIN NEGATIVE PRESSURE PRODUCING
DEVICES SUCH AS FIREPLACES, EXHAUST FANS AND AIR
CIRCULATION SYSTEMS. INLET AIR CANNOT BE TAKEN FROM AN
ATTIC EQUIPPED WITH POWER VENTILATION.
THE USE OF VENT DAMPERS IS NOT RECOMMENDED BY THE
MANUFACTURERS OF THIS WATER HEATER.
FAILURE TO PROPERLY VENT THIS WATER HEATER CAN CAUSE AN
EXPLOSION, FIRE, OR CARBON MONOXIDE POISONING WHICH MAY
RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
DO NOT VENT THIS WATER HEATER AND A FORCED DRAFT OR
POWER VENT APPLIANCE INTO THE SAME CHIMNEY OR GAS VENT.
MOISTURE IN THE FLUE GASES MAY CONDENSE AND FORM ON THE
EXTERIOR OF THE GAS VENT PIPE. IMPROPER LOCATION OR
INSTALLATION CAN CAUSE STRUCTURAL DAMAGE TO THE
RESIDENCE.
VENT CONNECTORS MAY NOT TERMINATE WITHIN A CHIMNEY
FLUE SERVING A FIREPLACE UNLESS THE FLUE OPENING IS
PERMANENTLY SEALED.
OBSTRUCTIONS OR HOLES IN THE VENT PIPE CAN CAUSE TOXIC
FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE
POISONING OR DEATH. THE VENT PIPE MUST BE REPLACED IF IT IS
LEAKING.
NEVER OPERATE AN EMPTY OR PARTIALLY FILLED WATER HEATER.
THIS CAN RESULT IN SERIOUS DAMAGE TO THE TANK.
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITH THE
COLD WATER SHUTOFF VALVE CLOSED.
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITHOUT A
PROPERLY INSTALLED TEMPERATURE AND PRESSURE RELIEF
VALVE. FAILURE TO INSTALL AND MAINTAIN A NEW AND
PROPERLY LISTED TEMPERATURE AND PRESSURE RELIEF VALVE
WILL RELEASE THE MANUFACTURER FROM ANY CLAIMS WHICH
MIGHT RESULT FROM EXCESSIVE TEMPERATURE OR WATER
PRESSURE.
WATER SUPPLY TO THIS HEATER MUST NOT EXCEED 180° F.
WATER TEMPERATURES IN EXCESS OF 180° F WILL CAUSE THE
HIGH LIMIT CONTROL (ECO) TO OPEN AND SHUT OFF THE GAS
SUPPLY TO THE UNIT. THE HIGH LIMIT CONTROL IS A SINGLE USE
TYPE THAT WILL REQUIRE THE REPLACEMENT OF THE
THERMOSTAT BEFORE THE BURNER CAN OPERATE.
THIS WATER HEATER IS EQUIPPED FOR ONE TYPE OF GAS ONLY. DO
NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE
ONE LISTED ON THE DATA PLATE LOCATED NEAR THE GAS
CONTROL. FAILURE TO USE THE CORRECT GAS CAN RESULT IN
PROPERTY DAMAGE, BODILY INJURY OR DEATH.
ADJUSTING THE THERMOSTAT PAST THE 120° F BAR ON THE
TEMPERATURE DIAL WILL INCREASE THE RISK OF SCALD INJURY.
3
GENERAL SAFETY WARNINGS (CONT.)
DANGER
•
CONTAMINANTS IN THE GAS PIPING MAY FOUL THE THERMOSTAT
CAUSING A MALFUNCTION, FIRE OR EXPLOSION. BE SURE ALL GAS
PIPING IS CLEAN AND CLEAR ON THE INSIDE BEFORE ATTACHING
THE GAS LINE.
•
HOT WATER CAN PRODUCE FIRST DEGREE BURNS WITHIN:
3 SECONDS AT 140°F (60°C)
20 SECONDS AT 130°F (54°C)
8 MINUTES AT 120°F (49°C)
•
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM THAT
HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY
TWO WEEKS OR MORE). HYDROGEN GAS IS EXTREMELY
FLAMMABLE AND CAN IGNITE WHEN EXPOSED TO A SPARK OR
FLAME. TO PREVENT THE POSSIBILITY OF INJURY UNDER THESE
CONDITIONS, WE RECOMMEND THE HOT WATER FAUCET BE OPENED
FOR SEVERAL MINUTES AT THE KITCHEN SINK BEFORE USING ANY
ELECTRICAL APPLIANCE WHICH IS CONNECTED TO THE HOT WATER
SYSTEM. IF HYDROGEN IS PRESENT, THERE WILL PROBABLY BE AN
UNUSUAL SOUND SUCH AS AIR ESCAPING THROUGH THE FAUCET
AS WATER BEGINS TO FLOW. DO NOT SMOKE OR HAVE ANY OPEN
FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
•
DO NOT ATTEMPT TO BYPASS OR JUMPER THE ECO. THIS WILL
VOID THE WARRANTY AND RELEASE THE MANUFACTURER FROM
ANY LIABILITY FOR ANY ACCIDENT RESULTING FROM ELIMINATING
THE ECO FROM THE WATER HEATER CIRCUIT.
•
HOUSEHOLDS WITH SMALL CHILDREN, ELDERLY, IMPAIRED OR
DISABLED MEMBERS AND ANYONE WITH TEMPERATURE SENSITIVE
SKIN MAY REQUIRE A LOW TEMPERATURE SETTING TO REDUCE THE
RISK OF SCALD INJURY.
•
THE GAS LINE MUST BE OF ADEQUATE SIZE SO AS TO PREVENT
UNDUE PRESSURE DROP AND NEVER SMALLER THAN THE PIPE SIZE
TO THE GAS VALVE ON THE WATER HEATER. FAILURE TO PROPERLY
SIZE THE GAS LINE CAN RESULT IN A FIRE OR EXPLOSION CAUSING
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
CONSUMER INFORMATION
This water heater is design-certified by CSA International as a Category I, nondirect vented water heater which takes its combustion air either from the
installation area or from air ducted to the unit from the outside.
This water heater should be installed in accordance with the latest edition of the
“National Fuel Gas Code”, ANSI Z223.1, NFPA 54 and the requirements and codes
of the local utilities or other authorities having jurisdiction. This is available from
the following:
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269
American Gas Association
1515 Wilson Boulevard
Arlington, VA 22209
Local Authorities (Check your telephone listings)
CONSUMER RESPONSIBILITIES
This manual has been prepared to acquaint you with the installation, operation and
maintenance of your gas water heater and to provide important safety information
in these areas.
We urge you to read all of the instructions thoroughly before attempting the
installation or operation of this water heater. This manual should be kept for
future reference.
The manufacturer of this water heater will not be liable for any damages caused
by failure to comply with the installation and operating instructions outlined in this
manual.
If you lack the necessary skills required to properly install this water heater or you
have difficulty following the directions, you should not proceed but have a
qualified person perform the installation of this water heater.
A data plate identifying your water heater can be found next to the gas control
valve/thermostat. When referring to your water heater always have the
information listed on the data plate readily available.
Retain your original receipt as proof of purchase.
HIGH ALTITUDE INPUT RATING
The input rating on the data plate of this water heater is for installations up to
2000 feet of elevation. For installations at elevations above 2000 feet, the rating
should be reduced by 4 percent for each 1000 feet above sea level.
4
WATER HEATER MODIFICATION/TAMPERING
DANGER
TAMPERING WITH THE THERMOSTAT, IGNITER CONTROL, GAS VALVE,
OR TEMPERATURE AND PRESSURE RELIEF VALVE IS DANGEROUS AND
MAY RESULT IN SERIOUS INJURY OR DEATH. TAMPERING VOIDS ALL
WARRANTIES. ONLY PROPERLY TRAINED, QUALIFIED SERVICE
PERSONNEL SHOULD SERVICE THESE COMPONENTS. DO NOT
ATTEMPT TO MODIFY OR CHANGE THIS WATER HEATER IN ANY WAY.
INSULATION BLANKET
Some governing bodies may require the use of external insulation blankets when
water heaters are installed in newly constructed homes and additions. If an
insulation blanket is applied to this water heater CAUTION must be exercised so
as to not restrict its proper function and operation. Please note the following:
•
•
•
•
The space between the base of the water heater and the floor must remain
unobstructed to allow for proper airflow. As time passes, the blanket may
sag and obstruct the air passage resulting in unsafe water heater operation.
Do not apply an insulation blanket to the top of the water heater as this may
obstruct the draft hood.
Do not cover the temperature and pressure relief valve, any labels or
instruction materials applied to the water heater. These labels must remain
visible for reference by the user. Do not remove these labels, as they are a
permanent part of the water heater as required by the certification agencies
and/or the Federal Government.
Do not cover any access panels leading to burner compartments. Do not cover
the thermostat controls, or doors on the water heater.
GAS CONVERSION
DANGER
DO NOT ATTEMPT TO CONVERT THIS WATER HEATER FROM
NATURAL GAS TO L.P. OR FROM L.P. TO NATURAL GAS. THIS CAN
RESULT IN PROPERTY DAMAGE, FIRE, EXPLOSION, BODILY HARM
OR DEATH.
5
TABLE OF CONTENTS
SAFETY PRECAUTIONS
.....................................................
GENERAL SAFETY WARNINGS
.......................................................
CONSUMER INFORMATION/RESPONSIBILITIES
............................
WATER HEATER MODIFICATION/TAMPERING
..............................
TABLE OF CONTENTS
.................................................................
LOCATION REQUIREMENTS AND CONSIDERATIONS
....................
VENTILATION AND COMBUSTION AIR SUPPLY
............................
VENT PIPE SYSTEM
.....................................................................
WATER SYSTEM PIPING
.................................................................
SPECIAL APPLICATIONS
.................................................................
GAS SUPPLY AND PIPING
.............................................................
INSTALLATION CHECK LIST
...........................................................
START-UP/OPERATION
.................................................................
OPERATIONAL CONDITIONS
...........................................................
MAINTENANCE
..............................................................................
BURNER ASSEMBLY REMOVAL, CLEANING, AND REPLACEMENT
.
THERMOCOUPLE AND PILOT ASSY. REPLACEMENT
.....................
GAS CONTROL VALVE/THERMOSTAT REPLACEMENT
.....................
TROUBLESHOOTING GUIDE
..............................................................
REPAIR PARTS LIST AND ILLUSTRATION
...................................
PAGE
1,2
3,4
4
4
5
5,6
7,8
9,10
11,12
13
14,15
15
16-19
19
20
20-21
21
22
22-23
24
IMPORTANT: TO INSURE PROPER INSTALLATION AND
OPERATION OF THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN
OR REPAIR THIS PRODUCT. UPON UNPACKING OF THE WATER HEATER INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND STARTUP. THIS WATER HEATER MUST BE INSTALLED ONLY BY QUALIFIED INSTALLATION PERSONNEL..
LOCATION REQUIREMENTS AND CONSIDERATIONS
GENERAL INFORMATION
WARNING
DO NOT INSTALL THIS WATER HEATER IN A MOBILE HOME. This water
heater is not approved for installation in a mobile home. DO NOT INSTALL
OUTDOORS. This water heater is certified for indoor installation only. Failure
to follow these instructions could result in FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
• Beauty shops, dry cleaning establishments, photo processing labs
• Liquid or powdered bleaches, swimming pool chemicals, spray can
propellants, cleaning solvents
• Refrigerants
• Calcium and sodium chloride
• Waxes and process chemicals
Products of this sort should not be stored near the water heater or air inlet.
DANGER
AREAS WHERE FLAMMABLE LIQUIDS (GASOLINE, SOLVENTS, LIQUID
PROPANE, BUTANE, ETC.) OR OTHER SUBSTANCES WHICH EMIT
FLAMMABLE VAPORS ARE STORED MAY NOT BE SUITABLE FOR
WATER HEATER INSTALLATION. NATURAL AIR MOVEMENTS CAN
CARRY FLAMMABLE VAPORS SOME DISTANCE FROM WHERE THEY
ARE STORED OR USED. NEAR GROUND LEVEL VENTS CAN DRAW
THESE VAPORS INTO THE WATER HEATER WHERE THE PILOT FLAME
OR MAIN BURNER CAN IGNITE THEM CAUSING PROPERTY DAMAGE,
SERIOUS BURNS OR DEATH. NEVER STORE OR USE FLAMMABLE
SUBSTANCES IN THE SAME ROOM OR AREA CONTAINING A GAS
WATER HEATER. IF SUCH FLAMMABLES MUST BE USED, ALL GAS
BURNING APPLIANCES IN THE VICINITY MUST BE SHUT OFF AND
THEIR PILOT LIGHTS EXTINGUISHED. OPEN THE DOORS AND
WINDOWS FOR VENTILATION WHILE FLAMMABLE SUBSTANCES ARE
IN USE.
WARNING
FLAMMABLE VAPORS MAY BE DRAWN TO THIS WATER HEATER FROM
OTHER AREAS OF THE STRUCTURE BY AIR CURRENTS.
IMPORTANT: This water heater should not be installed near a corrosive or
potentially corrosive air supply. Water heater corrosion and component failure
can be caused by the heating and breaking down of airborne chemicals. These
materials are corrosive at low concentration levels with little or no odor to
reveal their presence. Examples of potentially corrosive locations and
compounds are:
VAPORS FROM FLAMMABLE LIQUIDS WILL EXPLODE AND
CATCH FIRE CAUSING DEATH OR SEVERE BURNS.
WARNING
IT IS NOT DESIRABLE TO INSTALL A GAS FIRED WATER HEATER IN A
RESIDENTIAL GARAGE. IF INSTALLATION IN A RESIDENTIAL GARAGE IS
YOUR ONLY OPTION, THIS WATER HEATER MUST BE INSTALLED SUCH
THAT THE PILOT FLAME AND MAIN BURNER FLAME ARE NO LESS THAN
18 INCHES ABOVE THE FLOOR (SEE FIGURE 2, PAGE 6). THIS IS TO
REDUCE BUT NOT ELIMINATE THE RISK OF IGNITING FLAMMABLE
VAPORS WHICH MAY BE PRESENT IN A GARAGE. THE WATER HEATER
MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY
VEHICLES OR FLOODING. FAILURE TO FOLLOW THESE WARNINGS
CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
5
LOCATION REQUIREMENTS AND CONSIDERATIONS (CONT.)
SITE LOCATION
1.
Select a location near the center of the water piping system. It must
be installed indoors and in a vertical position on a level surface. DO
NOT install in bathrooms, bedrooms or any occupied room normally
kept closed.
2.
Locate the water heater as close to the chimney or gas vent as is
practical. Consider the vent system piping and combustion air supply
requirements when selecting the water heater location. The venting
system must be able to run from the water heater to the termination
with a minimal length and elbows. THE VENT PIPE CANNOT
EXCEED THE MAXIMUM ALLOWABLE LENGTH AS PERMITTED
IN THE “NATIONAL FUEL GAS CODE”.
3.
Locate the water heater near the existing gas piping. If installing a
new gas line, locate the water heater to minimize the pipe length and
elbows.
5.
The water heater should be located in an area not subject to freezing
temperatures. Water heaters located in unconditioned spaces (i.e.
attics, basements, etc.) may require the insulation of the water piping
and drain piping to protect against freezing. The drain and controls
must be easily accessible for operation and service. Maintain proper
clearances as specified.
6.
Do not locate the water
heater near an air-moving
device. The operation of airmoving devices such as
exhaust fans, ventilation
systems, clothes dryers, fireplaces, etc., can affect the
proper operation of the
water
heater.
Special
attention must be given to
conditions these devices
may create to avoid
unsatisfactory operation of
the equipment.
CLEARANCE/ACCESSIBILITY
Minimum clearances from combustible materials are stated on the data
plate adjacent to the thermostat of the water heater. REFER TO THE
DATA PLATE OF THE WATER HEATER FOR THE CORRECT
CLEARANCES FROM COMBUSTIBLE CONSTRUCTION MATERIALS.
Figure 3 may be used as a reference guide to locate the specific clearance
locations. A minimum of 24 inches of front clearance should be provided for
inspection and service.
IMPORTANT
4.
6
The water heater should be located in an area where leakage of the
tank or connections will not result in damage to the area adjacent to
the water heater or to lower floors of the structure. It is
recommended that a suitable metal drain pan be installed under the
water heater as shown below. This pan is to protect the property
from damage which may occur from normal condensate formation on
the tank jacket or leaks in the tank and pipe connections. The pan
must limit the water level to a maximum depth of 1 3/4 inches and be
two inches wider than the heater and piped to an adequate drain.
Locate the water heater near a suitable inside drain. Outside drains
are subject to freezing temperatures which can obstruct the drain line.
The piping should be at least 3/4” ID and pitched for proper drainage.
This pan must not restrict combustion air flow. UNDER NO
CIRCUMSTANCES IS THE MANUFACTURER TO BE HELD LIABLE
FOR ANY WATER DAMAGE IN CONNECTION WITH THIS WATER
HEATER.
WARNING
THE WATER HEATER IS CERTIFIED FOR INSTALLATION ON A
COMBUSTIBLE FLOOR. HOWEVER, WHEN THIS WATER HEATER IS
INSTALLED OVER CARPETING, THE CARPETING MUST BE
PROTECTED BY A METAL OR WOOD PANEL BENEATH THE WATER
HEATER AND EXTENDING BEYOND THE FULL WIDTH AND DEPTH
OF THE WATER HEATER BY AT LEAST THREE INCHES IN ANY
DIRECTION. IF THE WATER HEATER IS INSTALLED IN A CARPETED
ALCOVE OR CLOSET, THE ENTIRE FLOOR MUST BE COVERED BY
THE PANEL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN A FIRE HAZARD.
VENTILATION AND COMBUSTION AIR SUPPLY
GENERAL INFORMATION
WARNING
THIS WATER HEATER AND ANY OTHER FUEL BURNING APPLIANCE
MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER
VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT
OUTSIDE AIR BE SUPPLIED INTO THE WATER HEATER AREA. FAILURE
TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE,
CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH.
Adequate facilities for providing air for combustion and ventilation must be
provided in accordance with the “National Fuel Gas Code”, ANSI Z223.1-Latest
Edition, NFPA 54 or the applicable provisions of the local building codes.
IMPORTANT: Air for combustion and ventilation must not come from a
corrosive atmosphere. Any failure due to corrosive elements in the atmosphere
is excluded from warranty coverage.
IMPORTANT: Water heaters installed in open spaces in buildings with
unusually tight construction may still require outdoor air to function properly. In
this situation, outside air openings should be sized the same as for a confined
space.
MODERN HOME CONSTRUCTION USUALLY REQUIRES SUPPLYING OUTSIDE
AIR INTO THE WATER HEATER AREA.
CONSULT THE LOCAL CODES OF YOUR AREA FOR SPECIFIC VENTILATION
AND COMBUSTION AIR REQUIREMENTS.
CONFINED SPACES
For the correct and safe operation of this water heater, ample air must be
supplied for the combustion, ventilation and dilution of flue gases. Small
enclosures and confined areas must have two permanent openings so that
sufficient fresh air can be drawn from outside of the enclosure. One opening
shall be within 12 inches of the top and one within 12 inches of the
bottom of the enclosure as shown in Figure 4 below.
The following types of installation (but not limited to the following) will require
outdoor air for combustion due to chemical exposure and may reduce but not
eliminate the presence of corrosive chemicals in the air:
•
Beauty shops
•
Photo processing labs
•
Buildings with indoor pools
•
Water heaters installed in laundry, hobby or craft rooms.
•
Water heaters installed near chemical storage areas
Combustion air must be free of acid-forming chemicals such as sulfur, fluorine,
and chlorine. These elements are found in aerosol sprays, detergents, bleaches,
cleaning solvents, air fresheners, paint and varnish removers, refrigerants, and
many other commercial and household products. When burned, vapors from
these products form highly corrosive acid compounds. These products should
not be stored near the water heater or air inlet.
Combustion and ventilation air requirements are determined by the location of
the water heater. The water heater may be located in either an open
(unconfined) area or in a confined area or small enclosure such as a closet or
small room. Confined spaces are areas with less than 50 cubic feet for
each 1,000 BTUH of the total input for all gas-using appliances.
WATER HEATER LOCATION - UNCONFINED SPACE
A water heater in an unconfined space uses indoor air for combustion and
requires at least 50 cubic feet for each 1,000 BTUH of the total input for
all gas appliances. The table below shows a few examples of the minimum
square feet required for various BTUH inputs.
BTUH
INPUT
30,000
45,000
60,000
75,000
90,000
105,000
120,000
135,000
MIN. SQ. FEET
TYPICAL ROOM SIZE
WITH 8’ CEILING
188
281
375
469
563
657
750
844
WITH 8’ CEILING
9 X 21
14 X 20
15 X 25
15 X 31
20 X 28
20 X 33
25 X 30
28 X 30
Areas which are being used for storage or contain large space consuming items
may not be suitable for water heater installation. The area must be open and be
able to provide the proper air requirements to the water heater.
The size of each opening (free area) is determined by the total Btuh input of all
gas utilization equipment (i.e. water heaters, furnaces, clothes dryers, etc.) and
the method by which the air is provided. The Btuh input can be found on the
water heater data plate. Additional air can be provided by two methods:
1. All air from inside the building.
2. All air from outdoors.
ALL AIR FROM INSIDE THE BUILDING
When additional air is to be provided to the confined area from additional
room(s) within the building, the total volume of the room(s) must be of sufficient
size to properly provide the necessary amount of fresh air to the water heater
and other gas utilization equipment in the area. If you are unsure that the
structure meets this requirement, contact your local gas utility company or
other qualified agency for a safety inspection.
Each of the two openings shall have a minimum free area of 1 square inch per
1,000 Btuh of the total input rating of all gas utilization equipment in the
confined area, but not less than 100 square inches (Figure 5, Page 8).
CAUTION
AIR CANNOT BE TAKEN FROM AREAS THAT CONTAIN NEGATIVE
PRESSURE PRODUCING DEVICES SUCH AS FIREPLACES, EXHAUST
FANS, AND AIR CIRCULATION SYSTEMS.
7
VENTILATION AND COMBUSTION AIR SUPPLY (CONT.)
ALL AIR FROM OUTDOORS
Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and
horizontal ducts. The fresh air can be taken from the outdoors or from crawl or attic spaces that
freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be
properly ventilated to the outside.
Ductwork must be of the same cross-sectional area as the free area of the opening to which they
connect. The minimum dimension of rectangular air ducts cannot be less than 3 inches.
The size of each of the two openings is determined by the method in which the air is to be
provided. Refer to Table 1 to calculate the minimum free area for each opening. Figures 6, 7, and
8 are typical examples of each method.
CAUTION
INLET AIR CANNOT BE TAKEN FROM AN ATTIC EQUIPPED
WITH POWER VENTILATION.
LOUVERS AND GRILLES
In calculating free area for ventilation and combustion air supply openings, consideration must be
given to the blocking affect of protection louvers, grilles, and screens. These devices can reduce
air flow which in turn may require larger openings to achieve the required minimum free area.
Screens must not be smaller than 1/4 inch mesh. If the free area through a particular design of
louver or grille is known, it should be used in calculating the specified free area of the opening. If
the design and free area are not known, it can be assumed that most wood louvers will allow 20 25% of free area while metal louvers and grilles will allow 60 - 75% of free area. Louvers and
grilles must be locked open or interconnected with the equipment so that they are opened
automatically during equipment operation.
Keep louvers and grilles clean and free of debris or other obstructions.
TABLE 1
MINIMUM FREE AREA OF PERMANENT OPENINGS FOR
VENTILATION AND COMBUSTION AIR SUPPLY - ALL AIR FROM
OUTSIDE ONLY.
Based on the total Btuh input rating for all gas utilizing equipment within
the confined space.
OPENING SOURCE
MINIMUM FREE AREA PER
REFERENCE
OPENING (SQ. IN.)
DRAWING
DIRECT TO
1 SQUARE INCH PER 4000 FIGURE 6
OUTDOORS*
BTUH
VERTICAL DUCTS
1 SQUARE INCH PER 4000 FIGURE 7
BTUH
HORIZONTAL DUCTS
1 SQUARE INCH PER 2000 FIGURE 8
BTUH
Example: A water heater with an input rate of 50,000 Btuh using horizontal
ducts would require each opening to have a minimum free area of 25
square inches.
Minimum Free Area = 50,000 Btuh x 1 sq. in. / 2000 Btuh =25 Sq.
Inches.
* These openings may communicate directly with the outdoors through a ventilated attic,
a ventilated crawl space, or through an outside wall.
8
VENT PIPE SYSTEM
GENERAL INFORMATION
WARNING
THE USE OF VENT DAMPERS IS NOT RECOMMENDED BY THE
MANUFACTURERS OF THIS WATER HEATER. ALTHOUGH SOME
VENT DAMPERS ARE CERTIFIED BY THE AMERICAN GAS
ASSOCIATION LABORATORIES, THIS CERTIFICATION APPLIES TO
THE VENT DAMPER DEVICE ONLY AND DOES NOT MEAN THEY ARE
CERTIFIED FOR USE ON THIS WATER HEATER.
WARNING
FAILURE TO PROPERLY VENT THIS WATER HEATER CAN CAUSE AN
EXPLOSION, FIRE, OR CARBON MONOXIDE POISONING WHICH MAY
RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
This water heater uses a non-direct, single-pipe vent system to remove
exhaust gases created by the burning of fossil fuels. Air for combustion is
taken from the immediate water heater location or is ducted in from the
outside (see “Ventilation and Combustion Air Supply”).
This water heater must be properly vented for the removal of exhaust
gases to the outside atmosphere. Correct installation of the vent pipe
system is mandatory for the safe and efficient operation of this
water heater and is an important factor in the life of the unit.
Vent pipe installation must be performed in accordance with the “National
Fuel Gas Code”, NFPA 54, ANSI Z223.1-Latest Edition, or applicable
provisions of the local building codes, and not obstructed so as to prevent
the removal of exhaust gases to the outside atmosphere.
A U.L. APPROVED FUEL GAS AND CO DETECTOR(S) ARE
RECOMMENDED IN ALL APPLICATIONS AND THEIR INSTALLATION
SHOULD BE IN ACCORDANCE WITH THE MANUFACTURER’S
RECOMMENDATIONS
AND/OR
LOCAL
LAWS,
RULES,
REGULATIONS, OR CUSTOMS.
IMPORTANT: If you lack the necessary skills required to properly install
this venting system, you should not proceed but get help from a qualified
installation technician.
WARNING
WATER HEATER VENT CONNECTORS SHALL NOT BE CONNECTED
TO ANY PORTION OF A MECHANICAL DRAFT SYSTEM OPERATING
UNDER POSITIVE STATIC PRESSURE. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL
INJURY, OR DEATH.
VENT PIPE SIZING
The sizing of this vent system must be done in accordance with the “National
Fuel Gas Code”, NFPA 54, ANSI Z223.1-Latest Edition. It is important that
you follow the guidelines in these instructions for sizing a vent pipe system.
If a transition to a larger vent size is required, the vent transition connection
must be made at the draft hood outlet.
VENT CONNECTOR
A vent connector is used to connect the water heater to a certified chimney
or vertical gas vent. Vent connectors for this water heater can be made of the
following materials:
1.
Type B, Double Wall, U.L. Listed Vent Pipe.
2.
Single Wall Vent Pipe.
WHEN USING SINGLE WALL VENT PIPE, MAINTAIN A 6 INCH MINIMUM
CLEARANCE FROM ALL COMBUSTIBLE MATERIALS. WHEN USING TYPE B
DOUBLE WALL VENT PIPE, MAINTAIN THE MANUFACTURER’S SPECIFIED
MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS.
IMPORTANT: Single wall vent pipe cannot be used for water heaters located
in attics and may not pass through attic spaces, crawl spaces or any confined
or inaccessible location. A single wall metal vent connector cannot pass
through any interior wall.
Vent connectors made of Type B, double wall vent pipe material may pass
through walls or partitions constructed of combustible material if the
minimum listed clearance is maintained.
When installing a vent connector please note the following:
•
Maintain a minimum clearance of 6 inches from all combustible
materials when using single wall vent pipe.
•
Install the vent connector so as to avoid unnecessary bends which
create resistance to the flow of vent gases.
Align the legs of the draft hood with the slots on the water heater's top
cover. Insert the legs and secure the drafthood to the water heater's top
with the four screws provided as shown in Figure 9. Do not alter the draft
hood in any way. If you are replacing an existing water heater be sure to
use the new draft hood supplied with this water heater.
•
Install without dips or sags with an upward slope of at least 1/4 inch
per foot (2 cm/m).
•
Joints must be fastened by sheet metal screws or other approved
means. It must be supported to maintain clearances and prevent
separation of joints and damage.
Make sure the flue baffle is engaged in the slots provided in the flue
tube.
•
The length of the vent connector cannot exceed 75% of the vertical
vent height.
•
The vent connector must be accessible for cleaning, inspection and
replacement.
•
Vent connectors cannot pass through any ceiling, floor, fire wall, or fire
partition.
DRAFT HOOD INSTALLATION
CAUTION
MOISTURE IN THE FLUE GASES MAY CONDENSE AND FORM ON
THE EXTERIOR OF THE GAS VENT PIPE. IMPROPER LOCATION OR
INSTALLATION CAN CAUSE STRUCTURAL DAMAGE TO THE
RESIDENCE.
9
VENT PIPE SYSTEM (CONT.)
IMPORTANT: Existing vent systems must be inspected for
obstructions, corrosion and proper installation.
CAUTION
VENT CONNECTORS MAY NOT TERMINATE WITHIN A CHIMNEY
FLUE SERVING A FIREPLACE UNLESS THE FLUE OPENING IS
PERMANENTLY SEALED.
CHIMNEY CONNECTION
IMPORTANT: Before connecting a vent to a chimney, make sure the
chimney passageway is clear and free of obstructions. The chimney must
be cleaned if previously used for venting solid fuel appliances or fireplaces.
•
The connector must be installed above the extreme bottom of the
chimney to prevent potential stoppage of the flue gases.
•
The connector must be firmly attached and sealed to prevent it from
falling out.
•
To aid in removing the connector, a thimble or slip joint may be used.
•
The connector must not extend beyond the inner edge of the chimney
as it may restrict the space between it and the opposite wall of the
chimney (Figure 10).
•
Do not terminate the vent connector in a chimney that has not been
certified for this purpose. Some local codes may prohibit the
termination of vent connectors in a masonry chimney.
VERTICAL GAS VENTS
Vertical gas vents must be installed with UL listed Type B vent pipe
according to the vent manufacturer’s instructions and the terms of its
listing.
It may be connected to the water heater’s draft hood by a certified vent
connector or by directly originating at the draft hood opening.
Vertical gas vents must terminate with a listed cap or other roof assembly
and be installed according to their manufacturer’s instructions.
Gas vents must be supported to prevent damage, joint separation, and
maintain clearances to combustible materials. See Figures 11 and 12.
IMPORTANT: This gas vent must be terminated in a vertical position.
An unused chimney flue or masonry enclosure may be used as a
passageway for the installation of a gas vent. (Figure 12)
COMMON VENTING IS ALLOWABLE WITH VERTICAL TYPE B VENT
SYSTEMS AND LINED MASONRY CHIMNEYS. FOLLOW THE “NATIONAL
FUEL GAS CODE”, NFPA 54 , ANSI Z223.1-LATEST EDITION, FOR
PROPER VENTING PROCEDURES.
FIGURES 10-12 ARE EXAMPLES OF VENT PIPE SYSTEM INSTALLATIONS
AND MAY OR MAY NOT BE TYPICAL FOR YOUR SPECIFIC APPLICATION.
CONSULT THE “NATIONAL FUEL AND GAS CODE”, NFPA 54, ANSI
Z223.1-LATEST EDITION AND THE GUIDELINES SET FORTH BY
PREVAILING LOCAL CODES.
10
WATER SYSTEM PIPING
GENERAL INFORMATION
Water piping, fittings, and valves must be properly installed for the correct
and safe operation of this water heater. Please note the following:
DO NOT install this water heater with iron piping. The system should be
installed only with new piping that is suitable for potable (drinkable)
water such as copper, CPVC, or polybutylene. DO NOT use PVC water
piping.
DO NOT use any pumps, valves, or fittings that are not compatible with
potable water.
DO NOT use valves that may cause excessive restriction to water flow.
Use full flow ball or gate valves only.
DO NOT use 50/50 tin-lead solder (or any lead based solder) in potable
water lines. Use 95/5 tin-antimony or other equivalent material.
DO NOT tamper with the thermostat, gas valve, ignitor control or
temperature and pressure relief valve. Tampering with any of the
components is DANGEROUS and can result in property damage, severe
injury or death. Tampering voids all warranties. Only qualified
technicians should service these components.
DO NOT use with piping that has been treated with chromate's, boiler
seal, or other chemicals.
THE TEMPERATURE & PRESSURE RELIEF VALVE:
DO NOT add any chemicals to the system piping which will contaminate
the potable water supply.
•
DO NOT install check valves in the cold water supply line to the water
heater.
•
CAUTION
NEVER OPERATE AN EMPTY OR PARTIALLY FILLED WATER
HEATER. THIS CAN RESULT IN SERIOUS DAMAGE TO THE TANK.
TEMPERATURE & PRESSURE RELIEF VALVE
WARNING
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITHOUT A
PROPERLY INSTALLED TEMPERATURE AND PRESSURE RELIEF
VALVE. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
For protection against excessive pressures and temperatures, a
temperature and pressure relief valve must be installed in the opening
marked “T & P RELIEF VALVE” (see Figure 13). This valve must be design
certified by a nationally recognized testing laboratory that maintains
periodic inspection of the production of listed equipment or materials as
meeting the requirements for Relief Valves and Automatic Shut-off Devices
for Hot Water Supply Systems., ANSI Z21.22. The function of the
temperature and pressure relief valve is to discharge water in large
quantities in the event of excessive temperature or pressure developing in
the water heater. The valve must not exceed the working pressure of the
water heater as stated on the data plate.
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH,
THE RELIEF VALVE MUST BE ALLOWED TO OPERATE PROPERLY.
Only a new temperature and pressure relief valve should be used with your
water heater. Do not use an old or existing valve as it may be damaged or
not adequate for the working pressure of the new water heater. Do not
place any valve between the relief valve and the tank.
•
Must not be in contact with any electrical part.
Must be connected to an adequate discharge line.
Must not exceed the working pressure shown on the data plate of
the water heater.
THE DISCHARGE LINE:
•
•
•
•
•
Must not be smaller than the pipe size of the relief valve.
Must not be capped, blocked, plugged or contain any valve between
the relief valve and the end of the discharge line.
Must terminate a maximum of 6 inches above a floor drain or external
to the building.
Must be capable of withstanding 250°F (121°C) without distortion.
Must be installed to allow complete drainage of both the temperature
and pressure relief valve and discharge line.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW PROPERLY LISTED
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIMS WHICH MIGHT RESULT FROM
EXCESSIVE TEMPERATURE OR WATER PRESSURE.
Manually operate the temperature and pressure relief valve at least once a
year to make sure it is
working
properly.
To
prevent water damage, the
valve must be properly
connected to a discharge
line which terminates at an
adequate drain. Standing
clear of the outlet
(discharged water may be
hot), slowly lift and release
the lever handle on the
temperature and pressure relief valve to allow the valve to operate freely
and return to its closed position. If the valve fails to completely reset and
continues to release water, immediately shut off the manual gas valve and
the cold water inlet valve and call a qualified service technician.
11
WATER SYSTEM PIPING (CONT.)
DANGER
DISCHARGING WATER MAY BE HOT AND CAN CAUSE SCALD INJURIES
AND PROPERTY DAMAGE. DISCHARGE LINES MUST BE PROPERLY
INSTALLED AND PIPED TO AN ADEQUATE DRAIN.
CLOSED SYSTEM/THERMAL EXPANSION
Periodic discharge of the temperature and pressure relief valve may be due to
thermal expansion in a closed water supply system. The water utility supply
meter may contain a check valve, backflow preventer or water pressure
reducing valve. This will create a closed water system. During the heating cycle
of the water heater, the water expands causing pressure inside the water
heater to increase. The temperature and pressure relief valve may discharge hot
water under these conditions which results in a loss of energy and a build-up of
lime on the relief valve seat. To prevent this from happening, there are two
recommendations:
1.
Install a 125 PSI pressure relief valve in the cold water supply line. Make
sure the discharge of this valve is directed to an open drain and
protected from freezing.
2.
Install a diaphragm-type expansion tank that is suitable for potable water
on the cold water supply line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons of stored water.
Contact the local water supplier or plumbing inspector for information on how
to control this situation. Do not plug the temperature and pressure relief valve.
PIPING INSTALLATION
Piping, fittings, and valves should be installed according to the installation
drawing (Figure 14). If the indoor installation area is subject to freezing
temperatures, the water piping must be protected by insulation.
Water supply pressure should not exceed 80% of the working pressure of the
water heater. The working pressure is stated on the water heater’s data plate.
If this occurs a pressure limiting valve with a by-pass may need to 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.
IMPORTANT: Heat cannot 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 the Figure 14. Connect
the cold water supply (3/4 NPT) to the fitting marked “C”. Connect the
hot water supply (3/4 NPT) to the fitting marked “H”. Make sure the dip
tube is in the cold water fitting before connecting the hot and cold water
lines. (Note: 75T75 has 1" NPT)
IMPORTANT: Some models may contain energy saving heat traps to prevent
the circulation of hot water within the pipes. Do not remove the pink and blue
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.
The manufacturer of this water heater recommends installing a tempering
valve or an anti-scald device in the domestic hot water line as shown in
Figure 15. These valves reduce the point of use temperature of the water
by mixing cold and hot water and are readily available for use. Contact a
licensed plumber or the local plumbing authority.
12
4.
If installing the water heater in a closed water system, install a relief
valve or expansion tank in the cold water line as specified under “Closed
System/Thermal Expansion”.
5.
Install a shutoff 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.
6.
Install a temperature and pressure relief valve and discharge line in the
opening marked “T & P RELIEF VALVE”. Install as specified under
“Temperature and Pressure Relief Valve, pg. 11 “.
7.
After piping has been properly connected to the water heater, open the
nearest hot water faucet and allow the tank to completely fill with water.
To purge the lines of any excess air and sediment, keep the hot water
faucet open for 3 minutes after a constant flow of water is obtained.
Close the faucet and check all connections for leaks.
IMPORTANT: Do not fail to install a suitable drain pan under the
water heater and pipe the drain line to an adequate drain. See
Site Location, page 6, for details.
WARNING
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITH THE COLD
WATER SHUTOFF VALVE CLOSED. THIS CAN RESULT IN SERIOUS
DAMAGE TO THE WATER HEATER TANK.
WATER SYSTEM PIPING (CONT.)
DANGER
DISCHARGING WATER MAY BE HOT AND CAN CAUSE SCALD INJURIES
AND PROPERTY DAMAGE. DISCHARGE LINES MUST BE PROPERLY
INSTALLED AND PIPED TO AN ADEQUATE DRAIN.
CLOSED SYSTEM/THERMAL EXPANSION
Periodic discharge of the temperature and pressure relief valve may be due to
thermal expansion in a closed water supply system. The water utility supply
meter may contain a check valve, backflow preventer or water pressure
reducing valve. This will create a closed water system. During the heating cycle
of the water heater, the water expands causing pressure inside the water
heater to increase. The temperature and pressure relief valve may discharge hot
water under these conditions which results in a loss of energy and a build-up of
lime on the relief valve seat. To prevent this from happening, there are two
recommendations:
1.
Install a 125 PSI pressure relief valve in the cold water supply line. Make
sure the discharge of this valve is directed to an open drain and
protected from freezing.
2.
Install a diaphragm-type expansion tank that is suitable for potable water
on the cold water supply line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons of stored water.
Contact the local water supplier or plumbing inspector for information on how
to control this situation. Do not plug the temperature and pressure relief valve.
PIPING INSTALLATION
Piping, fittings, and valves should be installed according to the installation
drawing (Figure 14). If the indoor installation area is subject to freezing
temperatures, the water piping must be protected by insulation.
Water supply pressure should not exceed 80% of the working pressure of the
water heater. The working pressure is stated on the water heater’s data plate.
If this occurs a pressure limiting valve with a by-pass may need to 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.
IMPORTANT: Heat cannot 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 the Figure 14. Connect
the cold water supply (3/4 NPT) to the fitting marked “C”. Connect the
hot water supply (3/4 NPT) to the fitting marked “H”. Make sure the dip
tube is in the cold water fitting before connecting the hot and cold water
lines. (Note: 75T75 has 1" NPT)
IMPORTANT: Some models may contain energy saving heat traps to prevent
the circulation of hot water within the pipes. Do not remove the pink and blue
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.
The manufacturer of this water heater recommends installing a tempering
valve or an anti-scald device in the domestic hot water line as shown in
Figure 15. These valves reduce the point of use temperature of the water
by mixing cold and hot water and are readily available for use. Contact a
licensed plumber or the local plumbing authority.
12
4.
If installing the water heater in a closed water system, install a relief
valve or expansion tank in the cold water line as specified under “Closed
System/Thermal Expansion”.
5.
Install a shutoff 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.
6.
Install a temperature and pressure relief valve and discharge line in the
opening marked “T & P RELIEF VALVE”. Install as specified under
“Temperature and Pressure Relief Valve, pg. 11 “.
7.
After piping has been properly connected to the water heater, open the
nearest hot water faucet and allow the tank to completely fill with water.
To purge the lines of any excess air and sediment, keep the hot water
faucet open for 3 minutes after a constant flow of water is obtained.
Close the faucet and check all connections for leaks.
IMPORTANT: Do not fail to install a suitable drain pan under the
water heater and pipe the drain line to an adequate drain. See
Site Location, page 6, for details.
WARNING
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITH THE COLD
WATER SHUTOFF VALVE CLOSED. THIS CAN RESULT IN SERIOUS
DAMAGE TO THE WATER HEATER TANK.
SPECIAL APPLICATIONS
COMBINATION SPACE HEATING/POTABLE WATER
HEATING SYSTEM
Some water heater models are equipped with inlet/outlet tappings
for use with space heating applications. If this water heater is to be
used to supply both space heating and domestic potable (drinking)
water, the instructions listed below must be followed.
•
Be sure to follow the manual(s) shipped with the air handler
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.
•
This water piping contains potable (drinkable) water. Do
not add boiler treatment or any chemicals to any water
heater piping.
•
If the space heating system requires water temperatures in
excess of 120°F, a tempering valve or an anti-scald device
should be installed per its manufacturer’s instructions in the
domestic (potable) hot water supply to limit the risk of scald
injury.
•
Pumps, valves, piping, and fittings must be compatible with
potable water.
WARNING
FAILURE OF THE FLOW CONTROL VALVE MAY RESULT IN
EXCESSIVELY HIGH WATER TEMPERATURE FROM
THERMOSIPHONING.
•
•
A properly installed flow control valve is required for proper
operation. (See Figure above)
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 and Pressure Relief Valve ( T & P) or higher than normal
water temperatures are the first signs of thermosiphoning.
SOLAR INSTALLATION
If this water heater is used as a SOLAR STORAGE HEATER OR AS A
BACKUP FOR THE SOLAR SYSTEM, the water supply temperatures to
the water heater tank may be in excess of 120°F. A tempering valve or
other temperature limiting valve must be installed in the water supply line to
limit the supply temperature to 120°F. An anti-scald device must be installed
in the domestic hot water supply line to limit the risk of scald injury.
Solar Water Heating Systems can often supply water with temperatures
exceeding 180°F and may result in water heater malfunction. Please read
the following warning.
•
Domestic hot water line from the water heater should be vertical
past any tempering valve or supply line to the air handler to remove
air bubbles from the system. These bubbles will be trapped in the Air
Handler heat exchanger coil, reducing the efficiency.
Some jurisdictions may require a backflow preventer in the incoming cold
water line. This may cause the temperature and pressure relief valve on the
water heater to discharge or weep due to expansion of the heated water. A
diaphragm-type expansion tank suitable for potable water will normally
eliminate this weeping condition. Please read and follow the
manufacturer’s instructions for the installation of such tanks.
Also see “General Information, Water System Piping”, pg. 11 for additional
instructions on the safe and correct installation and operation of this water
heater.
WARNING
WATER SUPPLY TO THIS HEATER MUST NOT EXCEED 180°F.
WATER TEMPERATURE IN EXCESS OF 180°F WILL CAUSE THE
HIGH LIMIT CONTROL TO OPEN AND SHUT OFF THE GAS SUPPLY
TO THE UNIT. THE HIGH LIMIT CONTROL IS A SINGLE USE TYPE
THAT WILL REQUIRE THE REPLACEMENT OF THE THERMOSTAT
BEFORE THE BURNER CAN OPERATE.
13
GAS SUPPLY AND PIPING
GENERAL INFORMATION
DANGER
THIS WATER HEATER IS EQUIPPED FOR ONE TYPE OF GAS ONLY.
DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN
THE ONE LISTED ON THE DATA PLATE LOCATED NEAR THE GAS
CONTROL. FAILURE TO USE THE CORRECT GAS CAN RESULT IN
PROPERTY DAMAGE, BODILY INJURY, OR DEATH.
This water heater must only be connected to gas supplied by a
commercial utility.
GAS PIPING
Install the gas piping according to all local and state codes or with the
”National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)-Latest Edition.
Do not use copper and brass piping and fittings (except tin-lined copper
tubing) if the gas contains more than 0.3 grains of hydrogen sulfide per
100 standard cubit feet of gas. Contact your local gas utility company if
you are unsure about this.
Table 2 and Table 3 are provided as a sizing reference for commonly used
gas pipe materials. Consult the “National Fuel and Gas Code” for the
recommended gas pipe size of other materials.
DANGER
THE GAS LINE MUST BE OF ADEQUATE SIZE SO AS TO PREVENT
UNDUE PRESSURE DROP AND NEVER SMALLER THAN THE PIPE
SIZE TO THE GAS VALVE ON THE WATER HEATER. FAILURE TO
PROPERLY SIZE THE GAS LINE CAN CAUSE A FIRE OR EXPLOSION
RESULTING IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
When installing gas piping, use a pipe joint compound that is resistant to
the action of propane (LPG) gases. Apply the compound to male threads
only. Do not apply the compound to the first 2 threads. Do not use TEFLON
tape.
Do not use pipe joint compound or TEFLON tape on the union connection.
CAUTION
CONTAMINANTS IN THE GAS PIPING MAY FOUL THE THERMOSTAT
CAUSING A MALFUNCTION, FIRE, OR EXPLOSION. BE SURE ALL
GAS PIPING IS CLEAN AND CLEAR ON THE INSIDE BEFORE
ATTACHING THE GAS LINE.
When making pipe connections, use a back-up wrench to prevent any
twisting of the control valve/ thermostat assembly. Do not use excessive
force when tightening the pipe joint at the thermostat inlet.
Refer to Figure 16 page 15 and install as follows:
1. Install a readily accessible manual shutoff valve in the gas supply line
as recommended by the local utility. Know the location of this valve
and how to turn off the gas to this unit.
2. Install a drip leg (if not already incorporated as part of the water
heater) as shown. The drip leg must be no less than 3 inches long for
the accumulation of dirt, foreign material and water droplets.
3. Install a ground joint union between the gas valve/thermostat and the
manual shutoff valve. This is to allow easy removal of the gas valve/
thermostat.
IMPORTANT: Refer to the "Gas Pressure Testing" section on the next
page before pressure testing the gas lines.
TABLE 2
NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas).
Nominal
Length of Pipe, Feet
Iron Pipe
Size, Inches
10
20
30
40
50
60
70
80
90
100
125
150
175
200
1/2
132
92
73
63
56
50
46
43
40
38
34
31
28
26
3/4
278
190
152
130
115
105
96
90
84
79
72
64
59
55
1
520
350
285
245
215
195
180
170
160
150
130
120
110
100
1-1/4
1050
730
590
500
440
400
370
350
320
305
275
250
225
210
1-1/2
1600
1100
890
760
670
610
560
530
490
460
410
380
350
320
After the length of pipe has been determined, select the pipe size which will provide the minimum cubit feet per hour required for the gas input rating of the
water heater. By formula:
Gas Input of Water Heater (BTU/HR)
Cu. Ft. Per Hr. Required =
Heating Value of Gas (BTU/FT³)
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT3) may be determined by consulting the local
natural gas utility.
TABLE 3
LP GAS PIPE CAPACITY TABLE
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column pressure). Based on a Pressure Drop
of 0.5 Inch Water Column.
Nominal iron
Length of Pipe, Feet
pipe size, in.
10
20
30
40
50
60
70
80
90
100
125
150
1/2
275
189
152
129
114
103
96
89
83
78
69
63
3/4
567
393
315
267
237
217
196
185
173
162
146
132
1
1071
732
590
504
448
409
378
346
322
307
275
252
1-1/4
2205
1496
1212
1039
913
834
771
724
677
630
567
511
Example: Input BTU requirement of the water heater, 100,000 BTUH
Total pipe length, 80 feet = 3/4" IPS required.
14
14
GAS SUPPLY AND PIPING (CONT.)
4.
Turn the gas supply on and check for leaks. Use a chloride-free soap
and water solution (bubbles forming indicate a leak) or other
approved method. Do not use an open flame. ALL LEAKS MUST
BE FIXED IMMEDIATELY.
DANGER
DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK
GAS PIPING FOR LEAKS. IF LEAKING GAS IS PRESENT, AN
EXPLOSION OR FIRE MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
IMPORTANT: This water heater and its gas connection must be leak
tested before placing the appliance in operation.
IMPORTANT: Air may be present in the gas lines and could prevent the
pilot from lighting on initial start-up. The gas lines should be purged of air
by a qualified service technician after installation of the gas piping system.
The gas supply pressure must not exceed the maximum supply pressure as
stated on the water heater’s data plate. The minimum supply pressure is
for the purpose of input adjustment.
GAS PRESSURE TESTING
IMPORTANT: Subjecting the gas valve/thermostat to pressures
exceeding 14” W.C. (1/2 psi, 3.7 kPa) may cause damage resulting in
an extremely hazardous condition.
•
If the code requires the gas lines to be tested at a pressure exceeding
14” W.C., the water heater and its manual shutoff valve must be
disconnected from the gas supply piping system and the line
capped.
•
If the gas lines are to be tested at a pressure less than 14” W.C. the
water heater must be isolated from the gas supply piping system by
closing its manual shutoff valve.
A U.L. RECOGNIZED FUEL GAS AND CO DETECTOR(S) ARE
RECOMMENDED IN ALL APPLICATIONS AND THEIR INSTALLATION
SHOULD BE IN ACCORDANCE WITH THE MANUFACTURER’S
RECOMMENDATIONS AND/OR LOCAL LAWS, RULES, REGULATIONS,
OR CUSTOMS.
INSTALLATION CHECKLIST
WATER HEATER LOCATION
◊
Centrally located with the water piping system. Located close to the
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. Drain pan
installed and piped to an adequate drain
◊
Installation area free of corrosive elements and flammable materials.
◊
Sufficient room to service the water heater.
◊
Vent connectors securely fastened with screws and supported
properly to maintain 6 inch clearance.
◊
Vent connector made of approved material and sized correctly.
◊
Vent pipe system in accordance with “National Fuel Gas Code”, NFPA
54, ANSI Z223.1-Latest Edition or prevailing provisions of local codes.
◊
Flue baffle engaged in slots provided in the flue tube.
◊ Flue way, draft hood or vent pipe system not obstructed in any way.
WATER SYSTEM PIPING
◊
◊ Water heater not located near an air moving device.
Temperature and 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.
VENTILATION AND COMBUSTION AIR SUPPLY
◊
Heater completely filled with water.
◊
Sufficient fresh air supply for proper water heater operation.
◊
Closed system pressure build-up precautions installed.
◊
Fresh air not taken from areas that contain negative pressure
producing devices.
◊ Tempering valve installed per manufacturer’s instructions
◊
Fresh air supply free of corrosive elements and flammable vapors.
◊
Fresh air openings sized correctly with consideration given to the
blocking effect of louvers and grilles.
◊ Ductwork is the same cross-sectional area as the openings.
VENT PIPE SYSTEM
◊ Draft hood properly installed.
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 drip leg.
◊
Approved pipe joint compound used.
◊
Adequate pipe size and of approved material.
◊
Chloride-free soap and water solution or other approved means used
to check all connections and fittings for possible gas leaks.
15
START-UP/OPERATION
WARNING
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE
OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
Read these directions thoroughly before attempting to light or relight the pilot.
Make sure the tank is completely filled with water before lighting the
pilot. Check the data plate near the gas valve control/thermostat for the correct
gas. Do not use this water heater with any gas other than the one listed on the
data plate. If you have any questions or doubts consult your gas supplier or gas
utility company.
DO NOT:
•
•
•
•
•
•
•
Operate the water heater if it has been subjected to physical damage,
flooding, or fire.
Operate the water heater unless the tank is filled with water.
Operate the water heater if the cold water supply inlet valve is closed.
Allow flammable liquids such as gasoline or paint thinner to be stored or
used near this water heater.
Allow combustible materials such as newspapers, rags or mops to
accumulate near this water heater.
Light this water heater until all lighting instructions are understood and
followed. Lighting instructions are clearly given in this manual and on the
water heater label.
Light this water heater if you smell gas around the appliance area.
IF YOU SMELL GAS:
1.
2.
3.
4.
5.
6.
7.
8.
Open the windows.
Get all people out of the building.
Do not light matches or any other appliance. Do not smoke.
Do not touch any electrical switches (on or off) or use any phones in your
residence.
Extinguish any open flames immediately.
Shut off the gas at the manual shut-off valve. (If using liquid propane gas,
shut off the gas at the L.P. tank outside of your residence.)
Use an outside phone and immediately call the gas company and the fire
department. Give your name and address and ask for instructions.
Do not go back into the building. Wait for help to arrive outside of the
building.
L.P.G. (BOTTLED PROPANE) MODELS
Liquefied Petroleum Gas is over 50% heavier than air and in the occurrence of a
leak in the system the gas will settle at FLOOR LEVEL. Basements, crawl
spaces, skirted areas under mobile homes (even when ventilated), closets and
areas below ground level will serve as pockets for the accumulation of gas.
Before lighting an L.P. gas water heater, smell all around the appliance
at floor level. If you smell gas, follow the directions as given on this page.
When your L.P. tank runs out of fuel, turn off the gas at all gas appliances
including pilot lights. After the tank is refilled, all appliances must be re-lit
according to their manufacturer’s instructions.
WATER EXPOSURE
Do not try to light this water heater if the gas controls, main burner, or
pilot have been exposed to water in any way. Immediately call a qualified
service technician to inspect the water heater and replace any part of the gas
control system that has been exposed to water. DO NOT attempt to repair
these parts. Water heaters subjected to flood conditions or any time the main
burner, gas controls or pilot have been submerged in water require replacement
of the entire water heater.
16
LIGHTING THE WATER HEATER
Check the Gas Control Valve/Thermostat and determine which model is being
used for your water heater. Refer to either Figure 17A, 17B, 17C, or 17D and
light the water heater according to its directions.
WARNING
DO NOT ATTEMPT TO LIGHT THIS WATER HEATER UNTIL IT IS
PROPERLY INSTALLED AND YOU UNDERSTAND ALL OF THE
SAFETY WARNINGS AND PRECAUTIONS.
CHECKING THE DRAFT
After successfully lighting the water heater,
allow the unit to operate for 15 minutes and
check the draft hood relief opening for proper
draft. Pass a match flame around the relief
opening of the draft hood . A steady flame drawn
into the opening indicates proper draft. If the flame flutters or is blown out,
combustion products are escaping from the relief opening. If this occurs, do not
operate the water heater until proper adjustments or repairs are made to the
vent pipe system.
BURNER FLAMES
Inspect the burner flames and compare
them to the drawings in Figure 18. 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. A main burner adjustment
is provided for L.P. gas water heaters
only. This is a primary air controlling
device and is located at the end of the
burner venturi. (See Figure 19). Loosen
the screw and open the device to sharpen
the flame. Close the device to soften the
flame. Retighten the screw after
adjusting the flame. Natural gas models
do not have a field adjustment. Contact a
qualified service technician if the flame is not satisfactory.
WATER TEMPERATURE REGULATION
The thermostat is adjusted to its lowest temperature 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. Align
the index bar on the thermostat with the desired water temperature as shown
in Figures 20 and 21, page 19. There is a hot water scald potential if the
thermostat is set too high.
DANGER
ADJUSTING THE THERMOSTAT PAST THE 120°F BAR ON THE
TEMPERATURE DIAL WILL INCREASE THE RISK OF SCALD INJURY.
During low demand periods when hot water is not being used, 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 (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.
FIGURE 17A : LIGHTING INSTRUCTIONS (ROBERTSHAW THERMOSTAT)
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
If you do not follow these directions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
•
A. This appliance has a pilot which must be lighted by hand.
When lighting the pilot, follow these instructions exactly.
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 electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire
department.
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 move 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 call a qualified service technician to inspect the
appliance. Water heaters subjected to flood conditions or
anytime the gas controls, main burner or pilot have been
submerged in water require replacement of the entire water
heater.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety warnings
before lighting the pilot.
6.
Find pilot - follow the
smaller metal tube from the
thermostat to the pilot.
7.
Turn the gas control knob
2. Remove outer and inner doors.
3. Turn the temperature dial counterclockwise
lowest setting.
to its
counterclockwise
“PILOT”.
8.
4.
Light match and hold to pilot. Depress the reset button all
the way in; hold until pilot lights. Repeat immediately if pilot
does not light on the first try. Continue to hold the button
for about (1) minute after the pilot is lit. Release the reset
button and it will pop back up. Pilot should remain lit. If the
pilot light goes out, repeat steps 3 - 8.
IMPORTANT: If the pilot will not stay lit after several tries, turn
gas control knob to “OFF” and call your service technician or
gas supplier.
IMPORTANT: If the reset button does not pop up when released,
stop and immediately shut off the
gas at the line valve or tank. Call
your service technician or gas
supplier.
9. Replace the inner door.
10. Turn the gas control knob
Turn gas control knob
clockwise
position.
to
to the “OFF”
5. To clear any gas that may
have accumulated wait ten
(10) minutes. If you then
smell gas, STOP! Follow “B”
in the safety warning above.
If you do not smell gas go to
the next step.
counterclockwise
to “ON”.
11. Set the temperature dial to the desired setting.
12. Replace the outer door.
TO TURN OFF GAS TO APPLIANCE
1. Turn the temperature dial counterclockwise
lowest setting.
to its
2. Turn the gas control knob clockwise
position.
to the “OFF”
FIGURE 17B : LIGHTING INSTRUCTIONS (WHITE-RODGERS THERMOSTAT)
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
If you do not follow these directions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by a hand.
• If you cannot reach your gas supplier, call the fire
When lighting the pilot, follow these instructions exactly.
department.
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 electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
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 move 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 call a qualified service technician to inspect the
appliance. Water heaters subjected to flood conditions or
any time the gas controls, main burner or pilot have been
submerged in water require replacement of the entire water
heater.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety
warnings before lighting the pilot.
2. Remove outer and inner doors.
6.
Find the pilot - Follow the
smaller metal tube from
thermostat to the pilot.
3. Set the thermostat to its lowest setting. (Rotate
clockwise
).
7.
Turn the gas control knob
4.
Depress the gas control knob slightly and turn clockwise
to “OFF”. If the knob is “ON”, turn it clockwise
to “PILOT” then depress the knob slightly and turn
counterclockwise
8.
to “PILOT”.
Light the match and hold to the pilot. Depress the control
knob all the way; hold until pilot lights. Continue to hold
the control knob down for about (1) minute after the pilot
is lit. Release knob and it will pop back up. Pilot should
remain lit. If the pilot light goes out, repeat steps 3 -8.
IMPORTANT: If the pilot will not stay lit after several tries,
turn gas control knob to “OFF” and call your service
technician or gas supplier.
IMPORTANT: If the knob does not pop up when released, turn
the knob to “OFF”, stop and immediately call your service
technician or gas supplier.
to “OFF”.
clockwise
NOTE: Knob cannot be turned from “PILOT” to “OFF” unless
knob is depressed slightly. Do not use tools or excessive
force.
5. To clear any gas that may have accumulated wait ten (10)
minutes. If you then smell gas, STOP! Follow “B” in the
safety warning above. If you do not smell gas go to the
next step.
9. Replace the inner door.
10. Turn the gas control knob counterclockwise
to “ON”.
11. Set the temperature dial to the desired setting.
12. Replace the outer door.
TO TURN OFF THE GAS TO APPLIANCE
1. Set the thermostat to its lowest setting.
2. Turn gas control knob clockwise
to “PILOT”.
3. Depress the gas control knob slightly and turn clockwise
to “OFF”. Do not use tools or force.
FIGURE 17C : LIGHTING INSTRUCTIONS-PIEZOELECTRIC IGNITER (ROBERTSHAW THERMOSTAT)
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.
A. This appliance has a pilot which is lighted by a piezoelectric
igniter. When lighting the pilot, follow these instructions
exactly.
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 electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire
department.
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 move 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 call a qualified service technician to inspect the
appliance. Water heaters subjected to flood conditions or
anytime the gas controls, main burner or pilot have been
submerged in water require replacement of the entire water
heater.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety warnings
before lighting the pilot.
7.
2. Remove outer and inner doors.
Depress the reset button all the way in and
IMMEDIATELY depress the igniter until you
hear a loud click. Repeat immediately if pilot
does not light on the first try. If the pilot does
not light by the fourth attempt with the igniter,
repeat steps 4 - 7. Continue to hold the button
for about (1) minute after the pilot is lit.
Release the reset button and it will pop back up. Pilot should
remain lit. If the pilot light goes out, repeat steps 3 - 7.
IMPORTANT: If the pilot will not stay lit after several tries, turn
gas control knob to “OFF” and call your service technician or
gas supplier.
3. Turn the temperature dial counterclockwise
lowest setting.
4. Turn gas control knob
clockwise
to the “OFF”
position.
to its
IMPORTANT: If the reset button does not pop up when released,
stop and immediately shut off the gas at the line valve or tank.
Call your service technician or gas supplier.
8. Replace the inner door.
9. Turn the gas control knob
5. To clear any gas that may have
accumulated wait ten (10)
minutes. If you then smell gas,
STOP! Follow “B” in the
safety warning above. If you
do not smell gas go to the next
step.
counterclockwise
“ON”.
to
10. Set the temperature dial to
the desired setting.
11. Replace the outer door.
6. Turn the gas control knob counterclockwise
“PILOT”.
to
TO TURN OFF GAS TO APPLIANCE
1.
Turn the temperature dial counterclockwise
lowest setting.
to its
2.
Turn the gas control knob clockwise
position.
to the “OFF”
FIGURE 17D : LIGHTING INSTRUCTIONS WITH PIEZOELECTRIC IGNITER (WHITE-RODGERS THERMOSTAT)
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
If you do not follow these directions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which is lighted by a piezoelectric
• If you cannot reach your gas supplier, call the fire
igniter. When lighting the pilot, follow these instructions
department.
exactly.
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 move by
B. BEFORE LIGHTING smell all around the appliance area for
hand, don’t try to repair it, call a qualified service
gas. Be sure to smell next to the floor because some gas is
technician. Force or attempted repair may result in a fire or
heavier than air and will settle on the floor.
explosion.
WHAT TO DO IF YOU SMELL GAS:
D. Do not use this appliance if any part has been under water.
• Do not try to light any appliance.
Immediately call a qualified service technician to inspect the
• Do not touch any electrical switch; do not use any
appliance. Water heaters subjected to flood conditions or
phone in your building.
any time the gas controls, main burner or pilot have been
submerged in water require replacement of the entire water
• Immediately call your gas supplier from a neighbor’s
heater.
phone. Follow the gas supplier’s instructions.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety
warnings before lighting the pilot.
2. Remove outer and inner doors.
3. Set the thermostat to its lowest setting. (Rotate
).
clockwise
6. Turn the gas control knob counterclockwise
“PILOT”.
7.
4. Depress the gas control knob slightly and turn clockwise
to “OFF”. If the knob is “ON”, turn it clockwise
to “PILOT” then depress the knob slightly and turn
clockwise
to “OFF”.
to
Depress the control knob all the way in and
IMMEDIATELY depress the igniter until you
hear a loud click. Repeat immediately if the
pilot does not light on the first try. If the pilot
does not light by the fourth attempt with the
igniter repeat steps 4-7. Continue to hold the
control knob down for about (1) minute after
the pilot is lit. Release knob and it will pop
back up. Pilot should remain lit. If the pilot
light goes out, repeat steps 3 -7.
IMPORTANT: If the pilot will not stay lit after several tries,
turn gas control knob to “OFF” and call your service
technician or gas supplier.
NOTE: Knob cannot be turned from “PILOT” to “OFF” unless
knob is depressed slightly. Do not use tools or excessive
force.
5. To clear any gas that may have accumulated wait ten (10)
minutes. If you then smell gas, STOP! Follow “B” in the
safety warning above. If you do not smell gas go to the
next step.
IMPORTANT: If the knob does not pop up when released, turn
the knob to “OFF”, stop and immediately call your service
technician or gas supplier.
8.
Replace the inner door.
9.
Turn the gas control knob counterclockwise
“ON”.
to
10. Set the temperature dial to the desired setting.
11. Replace the outer door.
TO TURN OFF THE GAS TO APPLIANCE
1. Set the thermostat to its lowest setting.
2. Turn gas control knob clockwise
to “PILOT”.
3. Depress the gas control knob slightly and turn clockwise
to “OFF”. Do not use tools or force.
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
If you do not follow these directions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instructions
exactly.
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 electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
•
If you cannot reach your gas supplier, call the fire
department.
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
move 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 call a qualified service technician
to inspect the appliance. Water heaters subjected to
flood conditions or anytime the gas controls, main
burner or pilot have been submerged in water require
replacement of the entire water heater.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety
warnings before lighting the pilot.
7. Turn the gas control
knob counterclockwise
2. Remove outer and inner doors.
to “PILOT”.
3. Turn the temperature dial counterclockwise
lowest setting.
to its
IMPORTANT: If the pilot will not stay lit after several
tries, turn gas control knob to “OFF” and call your
service technician or gas supplier.
IMPORTANT: If the reset button does not pop up when
released, stop and immediately shut off the gas at the
line valve or tank. Call your service technician or gas
supplier.
9. Replace the inner
door.
10. Turn the gas control
knob counterclockwise
4. Turn gas control knob
clockwise
position.
8. Light match and hold to
pilot. Depress the reset
button all the way in;
hold until pilot lights. Repeat immediately if pilot does
not light on the first try. Continue to hold the button
for about (1) minute after the pilot is lit. Release the
reset button and it will pop back up. Pilot should
remain lit. If the pilot light goes out, repeat steps 3 - 8.
to the “OFF”
5. To clear any gas that may
have accumulated wait ten
(10) minutes. If you then
smell gas, STOP! Follow
“B” in the safety warning
above. If you do not smell
gas go to the next step.
6. Find pilot - follow the
smaller metal tube from the thermostat to the pilot.
to “ON”.
11. Set the temperature
dial to the desired setting.
12. Replace the outer door.
TO TURN OFF GAS TO APPLIANCE
1. Turn the temperature dial counterclockwise
its lowest setting.
to
2. Turn the gas control knob clockwise
position.
to the “OFF”
START-UP/OPERATION (CONT.)
DANGER
HOT WATER CAN PRODUCE FIRST DEGREE BURNS WITHIN:
3 SECONDS AT 140°F (60°C)
20 SECONDS AT 130°F (54°C)
8 MINUTES AT 120°F (49°C)
WARNING
HOUSEHOLDS WITH SMALL CHILDREN, ELDERLY, IMPAIRED OR DISABLED MEMBERS AND
ANYONE WITH TEMPERATURE SENSITIVE SKIN MAY REQUIRE A LOWER TEMPERATURE
SETTING TO REDUCE THE RISK OF SCALD INJURY.
STACKING
Stacking occurs when consecutive short draws of hot water (3 gallons or less) are taken from the water
heater tank. This causes increased cycling of the burner and can result in increased water temperatures at
the hot water outlet. Always install an anti-scald device in the hot water supply line to reduce the risk of
scald injury.
EMERGENCY SHUT DOWN
IMPORTANT: Should overheating occur or the gas supply fail to shut off, turn off the water heater’s
manual gas control valve and call a qualified service technician.
OPERATIONAL CONDITIONS
CONDENSATION
Moisture from the products of combustion condenses on the tank surface and the
outside jacket of the water heater and forms drops of water which may fall onto the
burner or other hot surfaces. This will produce a “sizzling” or “frying” noise. This
condensation is normal and should not be confused with a leaking tank.
Condensation may increase or decrease at different times of the year.
High efficient Energy Saver water heaters will produce larger amounts of condensation
on initial light up or when a large amount of hot water is being used. Do not confuse
this with a “tank leak”. Once the water reaches a temperature of 120°F and the
tank warms up (usually 1-2 hours), the condensation will stop.
Operating the water heater at the lowest thermostat setting may increase the amount
of condensation. Adjusting the thermostat slightly higher may eliminate this problem.
IMPORTANT: It is always recommended that a suitable drain pan be installed under
the water heater to protect the area from water damage resulting from normal
condensation production or a leaking tank or piping connections (See page 6, “Location
Requirements and Considerations” ). Under no circumstances is the manufacturer to
be held responsible for any water damage in connection with this water heater.
WATER HEATER SOUNDS
During the normal operation of the water heater, sounds or noises may be heard. These
noises are common and may result from the following:
1.
Normal expansion and contraction of metal parts during periods of heat-up and
cool-down .
2.
Condensation causes sizzling and popping within the burner area and should be
considered normal.
3.
Sediment build-up in the tank bottom will create varying amounts of noise and
may cause premature tank failure. Drain and flush the tank as directed under
“Draining and Flushing”.
SMOKE/ODOR
The water heater may give off a small amount of smoke and odor during the initial
start-up of the unit. This is due to the burning off of oil from the metal parts of a new
unit and will disappear after a few minutes of operation.
SAFETY SHUT-OFF
This water heater is designed to automatically shut-off in the event of the following:
1.
2.
The pilot flame is extinguished for any reason.
The water temperature exceeds 180°F (83°C).
A flame-sensing thermocouple is used to determine if a pilot flame is present and will
immediately shut off the gas supply to the main burner and the pilot burner if the flame
is absent.
A high temperature limit switch or ECO (Energy Cut Off) is used to shut off the unit if
the water temperature exceeds 180°F (83°C). The ECO is a single use switch and
requires complete replacement of the entire thermostat. If the ECO should function, the
water heater cannot be used until the thermostat is replaced by a qualified service
agency. Contact your local dealer for service information.
DANGER
DO NOT ATTEMPT TO BY-PASS OR JUMPER THE ECO AS THIS CAN
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH. THIS WILL
VOID THE WARRANTY AND RELEASE THE MANUFACTURER FROM ANY
LIABILITY FOR ANY INCIDENT RESULTING FROM ELIMINATING THE ECO
FROM THE WATER HEATER CIRCUIT.
WATER ODOR
Each water heater contains at least one anode rod which will slowly dissipate while
protecting the tank from corrosion. Certain water conditions will cause a reaction
between this rod and the water. The most common complaint associated with the anode
rod is one of a “rotten egg smell” produced from the presence of hydrogen sulfide gas
dissolved in the water. Do not remove this rod as it will void any warranties,
stated or implied. The parts list includes a special anode that can be ordered if water
odor or discoloration occurs. 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.
HYDROGEN GAS BUILD-UP
DANGER
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM THAT HAS
NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY TWO WEEKS
OR MORE). HYDROGEN GAS IS EXTREMELY FLAMMABLE AND CAN IGNITE
WHEN EXPOSED TO A SPARK OR FLAME. TO PREVENT THE POSSIBILITY
OF INJURY UNDER THESE CONDITIONS, WE RECOMMEND THE HOT
WATER FAUCET BE OPENED FOR SEVERAL MINUTES AT THE KITCHEN
SINK BEFORE USING ANY ELECTRICAL APPLIANCE WHICH IS CONNECTED
TO THE HOT WATER SYSTEM. IF HYDROGEN IS PRESENT, THERE WILL
PROBABLY BE AN UNUSUAL SOUND SUCH AS AIR ESCAPING THROUGH
19
THE FAUCET AS WATER BEGINS TO FLOW. DO NOT SMOKE OR HAVE ANY
8
OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
MAINTENANCE
DRAINING AND FLUSHING
The water heater should be drained if being shut down during freezing
temperatures. It is recommended that the tank be drained, flushed and cleaned
every 6 months to remove sediment which may build-up during operation.
To drain the tank perform the following steps:
1. Turn off the gas to the water heater at the Manual Gas Shutoff Valve.
2. Close the cold water inlet valve.
3. Open a nearby hot water faucet.
4. Connect a hose to the drain valve and terminate it to an adequate drain.
Open the water heater drain valve and allow all the water to drain from
the tank.
5. Flush the tank with water as needed to remove sediment.
6. Close the drain valve, refill the tank, and restart the heater as directed
under “Start-Up/Operation”.
If the water heater is going to be shut down for an extended period, the drain
valve should be left open.
IMPORTANT: Condensation may occur when refilling the tank and should not
be confused with a tank leak.
TROUBLESHOOTING
WATER HEATER SERVICE MUST ONLY BE PERFORMED BY A QUALIFIED
SERVICE TECHNICIAN. Refer to the Troubleshooting Chart on pages 22 and
23 for determining the cause of water heater problems.
SELF-CLEANING (SOME MODELS)
Some water heaters may include a self-cleaning device that inhibits the build-up
of lime and other sediment on the metal surfaces of the water heater. As cold
water passes through the dip tube, lime-causing particles and minerals are
suspended automatically. This controls sediment and lime build-up within the
tank and results in higher efficiencies and lower operation costs.
REMOVING THE BURNER ASSEMBLY
WARNING
REMOVAL AND REPLACEMENT OF THE BURNER ASSEMBLY INVOLVES
THE DISCONNECTION OF THE MANIFOLD TUBE, PILOT TUBE, AND
THERMOCOUPLE FROM THE THERMOSTAT AND LEAK TESTING. THE
FOLLOWING PROCEDURES MUST ONLY BE PERFORMED BY A
QUALIFIED SERVICE TECHNICIAN.
DANGER
WATER DRAINING FROM THIS HEATER MAY BE HOT AND CAN RESULT
IN A SCALD INJURY. DO NOT ALLOW ANYONE TO COME IN CONTACT
WITH THE DRAINING WATER AND TERMINATE THE DRAIN HOSE TO AN
ADEQUATE DRAIN.
3 MONTH INSPECTION
At least every 3 months a visual inspection should be made of the venting and
air supply system, piping systems, main burner and pilot burner. Check the
water heater for the following:
• Obstructions, damage, or deterioration in the venting system. Make sure
the ventilation and combustion air supplies are not obstructed.
• Build-up of soot and carbon on the main burner and pilot burner. Check for
a soft blue flame.
• Leaking or damaged water and gas piping.
• Presence of flammable or corrosive materials in the installation area.
1.
Turn the gas control knob on the combination gas control
valve/thermostat clockwise to the “OFF” position.
2.
Remove the outer and inner doors.
3.
Disconnect the thermocouple, pilot
tube, and manifold tube at the
thermostat (Figure 22). Note that
L.P. gas systems use reverse (lefthanded) threads on the manifold
tube.
4.
Grasp the manifold tube and push
down slightly to free the manifold,
pilot tube and thermocouple. Tilt
the burner to one side and remove it
from the burner compartment
(Figure 23).
5.
Check the burner to see if it is dirty
or clogged. The burner may be
cleaned with soap and hot water. If
a sooty condition exists, refer to the
Troubleshooting Chart , “Smoking
and Carbon Formation”.
WARNING
OBSTRUCTIONS OR HOLES IN THE VENT PIPE CAN CAUSE TOXIC
FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE
POISONING OR DEATH. THE VENT PIPE MUST BE REPLACED IF IT IS
LEAKING.
A U.L. RECOGNIZED FUEL GAS AND CO DETECTOR(S) ARE
RECOMMENDED IN ALL APPLICATIONS AND THEIR INSTALLATION
SHOULD BE IN ACCORDANCE WITH THE MANUFACTURER’S
RECOMMENDATIONS AND/OR LOCAL LAWS, RULES, REGULATIONS, OR
CUSTOMS.
IMPORTANT: VERIFY PROPER OPERATION AFTER SERVICING THIS WATER
HEATER.
REPLACEMENT PARTS
Replacement parts may be ordered through your plumber or the local distributor.
Parts will be shipped at prevailing prices and billed accordingly. 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.
See page 24 for a list of available repair parts.
20
BURNER ASSEMBLY REMOVAL, CLEANING, AND REPLACEMENT
REPLACING THE BURNER ASSEMBLY
1.
2.
3.
Insert the burner into the burner compartment making sure that the
manifold tab engages with the bracket inside the burner compartment
(Figure 24). The tab is located at the bottom of the burner for L.P.
models. The manifold tube will now line up with the thermostat
connection.
Reconnect the manifold tube and
pilot tube. Do not cross thread
these fittings. L.P. gas systems use
reverse (left-handed) threads on the
manifold tube. Do not apply any
thread sealant (pipe dope, Teflon
tape, etc.) to these connections.
Reconnect the thermocouple. The
thermocouple nut should be started
and turned all the way in by hand.
An additional quarter turn with a 3/8” open end wrench will then be
sufficient to seat the lockwasher.
IMPORTANT: Overtightening may damage the thermocouple or the
thermostat.
4.
Relight the water heater according to the lighting instructions.
5.
Check for gas leaks with a chloride-free soap and water solution or
other approved method. FIX ALL LEAKS IMMEDIATELY.
DANGER
DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK
GAS PIPING FOR LEAKS. IF LEAKING GAS IS PRESENT, AN
EXPLOSION OR FIRE MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
NOTE: The burner assembly shown in Figures 23, 24, and 25 is typical for
Natural Gas models. LPG models and models equipped with Low Nox
burners will vary in appearance.
THERMOCOUPLE AND / OR PILOT ASSEMBLY
REPLACEMENT
Reference Figures 25 and 26 for the following procedures.
1. Remove the burner assembly as directed in “Removing the Burner
Assembly”, page 20.
2.
3.
4.
Grasp the thermocouple line and gently pull the thermocouple from the
pilot assembly.
Push the replacement thermocouple through the hole in the pilot bracket
until it snaps in place. The end of the thermocouple should extend
approximately 1/4 inch past the tip of the pilot assembly.
Replace the burner assembly as directed above.
If the thermocouple will not disengage from the pilot assembly, the
entire pilot assembly must be replaced:
1. Remove the No. 8-32 screw which holds the pilot assembly and pilot
shield (if provided) to the main burner.
2. Install the replacement pilot assembly to the main burner making sure
the pilot shield (if provided) is in the correct location.
3. Replace the burner assembly as directed above.
PIEZOELECTRIC IGNITER SYSTEM (SOME MODELS)
The piezoelectric igniter system consists of the igniter button, electrode and
wire. Gas accumulating in the area surrounding the pilot is ignited by an
electric spark generated when the igniter button is pressed. The spark gap of
.125 inch is set at the factory. (See Figures below)
TESTING THE IGNITER SYSTEM
WARNING
IGNITER TESTING SHOULD ONLY BE PERFORMED BY A QUALIFIED
SERVICE TECHNICIAN.
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
them 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
grain sandpaper.
21
REMOVAL AND REPLACEMENT OF THE GAS CONTROL VALVE/ THERMOSTAT
WARNING
CAUTION
REMOVAL AND REPLACEMENT OF THE GAS CONTROL VALVE /
THERMOSTAT INVOLVES THE DISCONNECTION OF GAS PIPING,
MANIFOLD TUBE, PILOT TUBE, AND THERMOCOUPLE. IT IS
RECOMMENDED THAT THIS PROCEDURE BE PERFORMED BY A
QUALIFIED SERVICE TECHNICIAN.
WHEN REMOVING THE GAS CONTROL VALVE / THERMOSTAT DO NOT
USE PIPE WRENCH OR VISE TO GRIP BODY OR ANY TYPE OF BLUNT
INSTRUMENT INTO THE INLET OR OUTLET CONNECTIONS. USING
THESE TYPE TOOLS MAY RESULT IN DAMAGE TO THE GAS CONTROL
VALVE / THERMOSTAT.
1. On the gas control valve/thermostat turn the temperature dial
To replace the gas control valve/ thermostat repeat the
previous procedure in reverse order.
counterclockwise to its lowest setting. Turn the gas control knob
clockwise to the "OFF" position. See Figures 20 and 21 page 19.
• Be sure to use Approved Teflon Tape or Pipe Joint Compound on the gas
2. Turn off the gas at the manual shutoff valve on the gas supply pipe.
See Figure on page 15.
• Be sure to remove the pilot ferrule nut from the new gas control valve/
3. Drain the water heater. Refer to section "Draining and Flushing" on
page 20 and follow procedure.
• Turn gas supply on and check for leaks. Use a chloride-free soap and water
4. Disconnect the thermocouple, pilot tube, and manifold tube at the
thermostat. See Figure 22 page 20. Note that L.P. gas systems use
reverse (left-handed) threads on the manifold tube.
5. Refer to Gas Piping Figure 16 on page 15 and disconnect the ground
joint union in the gas piping. Disconnect the remaining pipe from the gas
valve/thermostat.
6. Turn the gas control valve/thermostat counterclockwise. Remove the
gas control valve/thermostat.
piping connections and fitting on the back of gas valve that screws into tank.
thermostat.
solution (bubbles forming indicate a leak) or other approved method. Do not
use an open flame. ALL LEAKS MUST BE FIXED IMMEDIATELY.
• Be sure tank is completely filled with water before lighting and activating the
water heater. Check the gas control valve/thermostat and determine which
model is used for your water heater. Refer to corresponding Figure 17A - 17D
and follow lighting procedure.
• If additional information is required, contact the Service Department at the
800 number shown on the front of this manual.
TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
BURNER WILL NOT IGNITE
1.
2.
3.
4.
5.
6.
7.
8.
BURNER FLAME YELLOW-LAZY
1.
2.
3.
4.
5.
6.
7.
PILOT WILL NOT LIGHT OR REMAIN
LIT.
1.
2.
3.
4.
5.
6.
7.
8.
9.
HIGH OPERATION COSTS
PILOT FLAME TOO LARGE
22
No gas
Dirt in the gas lines
Pilot line clogged
Main burner line clogged
Defective thermocouple
Defective thermostat
Thermostat set too low
Heater installed in a confined area
CORRECTIVE ACTION
1.
2.
3.
4.
5.
6.
7.
8.
Check with gas utility company
Notify utility-install trap in gas line
Clean, locate source and correct
Clean, locate source and correct
Replace thermocouple
Replace thermostat
Turn temp. dial to desired temperature.
Provide fresh air ventilation
1.
2.
3.
4.
5.
6.
7.
Provide ventilation to water heater
Check with gas utility company
Clean, locate source and correct
Clean, locate source and correct
Provide fresh air ventilation
Clean or replace orifice
See page 16, “Burner Flames” for flame adjustment.
Low gas pressure
Air in gas line
No gas
Dirt in gas lines
Pilot line or orifice clogged
Thermocouple connection loose
Defective thermocouple
Cold drafts
Thermostat ECO switch open
1.
2.
3.
4.
5.
6.
7.
8.
9.
Check with gas utility company
Bleed the air from the gas line
Check with gas utility company
Notify utility-install dirt trap in gas line
Clean, locate source and correct
Finger tighten-then 1/4 turn with wrench
Replace thermocouple
Locate source and correct
Replace thermostat
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Improper Calibration
Thermostat set too high
Sediment or lime in tank
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
No flue baffle
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Replace thermostat
Set temperature dial to lower setting.
Drain/Flush-Provide water treatment if needed
Install adequate heater
Correct piping-dip tube must be in cold inlet
Repair faucets
Check with utility-repair at once
Advise customer
Insulate piping
Insulate piping
Install flue baffle
1.
Wrong pilot burner
1.
Replace with correct burner
Insufficient secondary air
Low gas pressure
Flue clogged
Main burner line clogged
Heater installed in a confined area
Obstruction in main burner orifice
Main burner needs adjusting (L.P. only)
22
TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
INSUFFICIENT HOT WATER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Low gas pressure
Orifice too small
Improper calibration
Thermostat set too low
Sediment or lime in tank
Water heater too small
Wrong piping connections
Leaking faucets
Wasted hot water
Long runs of exposed piping
Hot water piping in outside wall
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Check with gas utility company
Replace with correct orifice
Replace thermostat
Turn temperature dial to lower setting
Drain/flush-provide water treatment if needed
Install adequate heater
Correct piping-dip tube must be in cold inlet
Repair faucets
Advise customer
Insulate piping
Insulate piping
SLOW HOT WATER RECOVERY
1.
Insufficient secondary air
1.
2.
3.
4.
5.
6.
7.
8.
9.
Flue clogged
Low gas pressure
Orifice too small
Improper calibration
Thermostat set too low
Heater too small
Wrong piping connections
Wasted hot water
2.
3.
4.
5.
6.
7.
8.
9.
Provide ventilation to water heater. Check flue way , flue baffle
and burner.
Clean flue, locate source and correct
Check with gas utility company
Replace with correct orifice
Replace thermostat
Turn temperature dial to lower setting
Install adequate heater
Correct piping-dip tube must be in cold inlet
Advise customer
DRIP FROM RELIEF VALVE
1.
2.
3.
Excessive water pressure
Heater stacking
Closed water system
1.
2.
3.
Use a pressure reducing valve and relief valve.
Lower the thermostat setting
See page 12, “Closed System/Thermal Expansion”.
DISCOLORATION OF JACKET
ABOVE COMBUSTION AREA
1.
2.
3.
Burner orifice too large
Flue clogged
High gas pressure
1.
2.
SMOKING AND CARBON
FORMATION (SOOTING)
1.
Insufficient secondary air
2.
3.
4.
5.
6.
7.
Low gas pressure
Orifice too large
Flue clogged
Defective thermostat
Heater installed in a confined area
Burner flame yellow-lazy
Replace with correct orifice
Clean, locate source and correct
3. Adjust pressure to proper setting by qualified service personnel
only.
1. Provide ventilation to water heater. Check flue way, flue baffle,
and burner.
2. Check with gas utility company
3. Replace with correct orifice
4. Clean, locate source and correct
5. Replace thermostat
6. Provide fresh air ventilation.
7. See “Burner Flame Yellow-Lazy” above.
COMBUSTION ODORS
1.
2.
3.
Insufficient secondary air
Flue clogged
Heater installed in a confined area
1.
2.
3.
CONDENSATION
1.
Temperature setting too low
1.
SMELLY WATER
1.
THERMOSTAT FAILS TO SHUT
OFF
1.
2.
Defective thermostat
Improper calibration
1.
2.
BURNER FLAME TOO HIGH
1.
2.
Insufficient secondary air
Orifice too large
1.
2.
Provide ventilation to water heater
Replace with correct orifice
FLAME BURNS AT ORIFICE
1.
2.
Low gas pressure
Defective thermostat
1.
2.
Check with gas utility company
Replace thermostat
PILOT FLAME TOO SMALL
1.
2.
3.
Low gas pressure
Pilot line or orifice clogged
Wrong pilot burner
1.
2.
3.
Check with utility
Clean, locate source and correct
Replace with correct burner
BURNER FLAME FLOATS AND
LIFTS OFF PORTS
1.
2.
3.
4.
5.
High gas pressure
Orifice too large
Flue clogged
Heater installed in a confined area
Cold drafts
1.
2.
3.
4.
5.
Check with utility
Replace with correct orifice
Clean flue and burner-locate source & correct
Provide fresh air ventilation
Locate source and correct
Sulfides in the water
1.
Provide ventilation to the water heater
Clean, locate source and correct.
Provide fresh air ventilation.
Increase the temperature setting. See page 16.
Replace the anode with a special anode.
Replace thermostat
Replace thermostat
23
32
REPAIR PARTS ILLUSTRATION
REPAIR PARTS
When ordering repair parts always give the following information:
1. Model, serial, and product number
2. Type of gas
3. Item number
4. Parts description
REPAIR PARTS LIST
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
13A
14
15
16
17
18
19
20
21
22
23
24
25
PARTS DESCRIPTION
DRAFTHOOD
REDUCER RING - SOME MODELS
BAFFLE ASSEMBLY
HEAT TRAP (COLD) - SOME MODELS
HEAT TRAP (HOT) - SOME MODELS
COLD WATER DIP TUBE
ANODE ROD
V
TEMPERATURE & PRESSURE RELIEF VALVE (LOCATED TOP OR
SIDE)
Q
DRAIN VALVE
THERMOSTAT
+
MANIFOLD
+
ORIFICE
+
MAIN BURNER
+
BURNER NATURAL LOW NOx
PILOT ASSEMBLY
+
PILOT TUBE
THERMOCOUPLE
SCREW 8-32 X .312 PH RD MACH
SCREW 8-32 X .25 SELF TAPPING
INNER DOOR
OUTER DOOR
ALTERNATE OUTER DOOR - SOME MODELS
PILOT SHIELD -SOME MODELS
AIR SHUTTER - L.P. MODEL ONLY
PIEZOELECTRIC IGNITER ASSEMBLY - SOME MODELS
IGNITER BUTTON AND BRACKET- SOME MODELS
LEGEND
V Special anode rod (see page 19).
Q Temperature and Pressure Relief Valve is required, but may not be
factory installed.
+ It is imperative the replacement main burner, orifice, manifold, pilot
burner, and the thermostat be ordered for the proper gas type. Natural
gas thermostat will be marked "Natural Gas Only". Propane gas
thermostats will be marked “For L.P. Gas Only”.
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