Whirlpool BFG2J5040T3NOV E Use & care guide

Gas Water Heater
with the Flame Guard®
Safety System
Installation
Instructions and
Use & Care Guide
R
Made under license from Flame Guard Water Heaters, Inc.
NATURAL GAS MODELS ONLY
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.
WHAT TO DO IF YOU SMELL GAS
•
Do not try to light any appliance.
•
Do not touch any electrical switch;
do not use any phone in your
building.
•
Immediately call your gas supplier
from a neighbor’s phone. Follow
the gas supplier’s instructions.
•
If you cannot reach your gas
supplier, call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
INSTALLER:
• AFFIX THESE INSTRUCTIONS TO OR ADJACENT
TO THE WATER HEATER.
OWNER:
• RETAIN THESE INSTRUCTIONS AND WARRANTY
FOR FUTURE REFERENCE. RETAIN THE ORIGINAL
RECEIPT AS PROOF OF PURCHASE.
To obtain technical, warranty, or service assistance during or after
the installation of this water heater, visit our website at:
http://www.americanwaterheater.com
or call toll free
1-800-999-9515
When calling for assistance, please have the following
information ready:
1.
2.
3.
4.
5.
Model number
7 digit product number
Serial number
Date of installation
Place of purchase
Table of Contents ......................................................
2
6510366
December 2005
1
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or
“WARNING.” These words mean:
You can be killed or seriously injured if you don’t
immediately follow instructions.
You can be killed or seriously injured if you don’t
follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.
•
•
Important Instructions
Do not use this appliance if any part has been under water. Immediately call a qualified service technician. 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.
Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde, carbon
monoxide, and soot.
Table Of Contents
PAGE
Water Heater Safety .............................................................................. 1-2
Installing Your Gas Water Heater ........................................................ 3-16
Unpacking the Water Heater........................................................... 3
Location Requirements................................................................... 4
Gas Supply ..................................................................................... 6
Combustion Air Supply and Ventilation........................................... 7
Water System Piping .................................................................... 12
Installation Checklist ..................................................................... 16
Operating Your Water Heater ............................................................ 17-19
Lighting Instructions...................................................................... 17
Operational Conditions ................................................................. 19
Maintenance of Your Water Heater ................................................... 20-24
Troubleshooting Chart ....................................................................... 24-26
Repair Parts Illustration ..................................................................... 27-28
2
INSTALLING YOUR GAS WATER HEATER
Consumer Information
Unpacking the Water Heater
This water heater is design-certified by CSA International
as a Category I, non-direct 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 must be installed according to all local
and state codes or, in the absence of local and state codes,
the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest edition. This is available from the following:
CSA America, Inc.
8501 East Pleasant Valley Road
Cleveland, OH 44131
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269
Check your phone listings for the local authorities having
jurisdiction over your installation.
Consumer Responsibilities
This manual has been prepared to acquaint you with the
installation, operation, and maintenance of your gas water
heater and provide important safety information in these
areas.
IMPORTANT: Do not remove any permanent instructions,
labels, or the data label from either the outside of the water
heater or on the inside of water heater panels.
•
Remove exterior packaging and place installation components aside.
•
Inspect all parts for damage prior to installation and
start-up.
•
Completely read all instructions before attempting to
assemble and install this product.
•
After installation, dispose of/recycle all packaging
materials.
Read all of the instructions thoroughly before attempting
the installation or operation of this water heater.
Do not discard this manual. You or future users of this
water heater will need it for future reference.
Service to the Flame Guard® Safety System should only
be performed by a qualified service technician.
Examples of qualified service technicians include:
those trained in the plumbing and heating industry,
local gas utility personnel, or an authorized service
person.
The manufacturer and seller of this water heater will
not be liable for any damages, injuries, or deaths
caused by failure to comply with the installation and
operating instructions outlined in this manual.
If you lack the necessary skills required to properly install
this water heater, or you have difficulty following the
instructions, you should not proceed but have a qualified
service technician perform the installation of this water
heater. Massachusetts code requires this water heater to
be installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR Section 2.00 and 5.00.
A data plate identifying your water heater can be found next
to the gas control valve/thermostat. When referring to your
water heater, always have the information listed on the data
plate readily available.
Retain your original receipt as proof of purchase.
3
Location Requirements
FLAMMABLES
Flammable Vapors
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Storage of or use of gasoline or other
flammable vapors or liquids in the
vicinity of this or any other appliance can
result in serious injury or death.
Read and follow water heater warnings
and instructions.
The Flame Guard® Safety System is designed to reduce
the risk of flammable vapor-related fires. The patented
system protects your family by trapping the burning vapors
within the water heater combustion chamber through
the special flame-trap. The burning vapors literally “burn
themselves out” without escaping back into the room.
In the event of a flammable vapor incident, the Flame
Guard® Safety System shuts off the gas supply to the
water heater’s burner and pilot, preventing re-ignition of
any remaining flammable vapors in the area. This will
disable the water heater until the system is reset. Note: Not
following these instructions and/or an inadequate air supply
can cause the Flame Guard® Safety System to disable
the water heater. Please make required installation and
venting/air supply changes prior to resetting the system.
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas
burning appliances in the vicinity must be shut off and their
pilot lights extinguished. Open the doors and windows for
ventilation while flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in the
area of the water heater, leave the area immediately and
call the fire department from a neighbor’s home. Do not
attempt to clean the spill until all ignition sources have been
extinguished.
Do not store combustible materials (boxes, magazines,
clothes, etc.) on or in close proximity to the water heater.
Site Location
•
Select a location near the center of the water piping
system. The water heater must be installed indoors
and in a vertical position on a level surface. DO NOT
install in bathrooms, bedrooms, or any occupied room
normally kept closed.
•
Locate the water heater as close to the chimney or gas
vent as 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 termination with minimal
length and elbows.
•
Locate the water heater near the existing gas piping.
If installing a new gas line, locate the water heater to
minimize the pipe length and elbows.
NOTE: This water heater must be installed according to all
local and state codes or, in the absence of local and state
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA
54)-latest edition.
4
Important: The water heater should be located in
an area where leakage of the tank or connections will
not result in damage to the area adjacent to the water
heater or to lower floors of the structure. Due to the
normal corrosive action of the water, the tank will
eventually leak after an extended period of time.
Also any external plumbing leak, including those
from improper installation, may cause early failure
of the tank due to corrosion if not repaired. If the
homeowner is uncomfortable with making the repair
a qualified service technician should be contacted.
A suitable metal drain pan should be installed under
the water heater as shown below, to help protect
the property from damage which may occur from
condensate formation or leaks in the piping connections
or tank. The pan must limit the water level to a maximum
depth of 1-3/4” and be two inches wider than the heater
and piped to an adequate drain. The pan must not
restrict combustion air flow. Locate the water heater
near a suitable indoor 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. Under no circumstances will the
manufacturer or seller of this water heater be held liable
for any water damage which is caused by your failure to
follow these instructions.
1 3/4” maximum
Pipe to
adequate
drain
At least 2” greater than the
diameter of the water heater.
•
The water heater should be located in an area not
subject to freezing temperatures. Water heaters located
in unconditioned spaces (i.e., attics, basements,
etc.) may require insulation of the water piping and
drain piping to protect against freezing. The drain and
controls must be easily accessible for operation and
service. Maintain proper clearances as specified on the
data plate.
•
Do not locate the water heater near an air-moving
device. The operation of air-moving devices such as
exhaust fans, ventilation systems, clothes dryers,
fire-places, etc., can affect the proper operation of
the water heater. Special attention must be given to
conditions these devices may create. Flow reversal of
flue gases may cause an increase of carbon monoxide
inside of the dwelling.
•
If the water heater is located in an area that is
subjected to lint, dirt, and oil, it may be necessary
to periodically clean the flame-trap (see “External
Inspection & Cleaning of the Flame-trap,” Page 22).
Figure 1
Air-moving
Devices
Exhaust
Fan
Reverse flow
of gases
Clearances and Accessibility
Notice: Minimum clearances from combustible materials
are stated on the data plate adjacent to the gas control
valve/thermostat of the water heater.
The water heater is certified for installation on a
combustible floor.
• Important: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath
the water heater. The protective panel must extend
beyond the full width and depth of the water heater by
at least three inches (76.2mm) in any direction; or if in
an alcove or closet installation, the entire floor must be
covered by the panel.
• Figure 2 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches of front clearance should be provided for
inspection and service.
Figure 2
Minimum Clearance
Locations
Back
Vent
Top
to
ceiling
Sides
Front
24” minimum
for service
Sides
Top
View
State of California
Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake.
Contact local utilities for code requirements in your area
or call 1-800-999-9515 and request instructions.
5
Gas Supply
3. Install a ground joint union between the gas valve/
thermostat and the manual shut-off valve. This is to
allow easy removal of the gas valve/ thermostat.
4. Turn the gas supply on and check for leaks. Test the
water heater by brushing on an approved noncorrosive
leak detection solution. Bubbles forming indicate a
leak. Correct any leak found.
Figure 3
Gas Piping
Manual Gas
Shut-off Valve
Explosion Hazard
Use a new CSA approved gas supply line.
Install a shut-off valve.
Do not connect a natural gas water
heater to an L.P. gas supply.
Do not connect an L.P. gas water heater
to a natural gas supply.
Failure to follow these instructions can
result in death, explosion, or carbon
monoxide poisoning.
Gas Requirements
Read the data plate to be sure the water heater is made
for the type of gas you will be using in your home. This
information will be found on the data plate located near the
gas control valve/thermostat. If the information does not
agree with the type of gas available, do not install or light.
Call your dealer.
Note: An odorant is added by the gas supplier to the gas
used by this water heater. This odorant may fade over an
extended period of time. Do not depend upon this odorant
as an indication of leaking gas.
Gas Piping
The gas piping must be installed according to all local and
state codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest
edition.
Table 1 on page 7 provides a sizing reference for commonly
used gas pipe materials. Consult the “National Fuel Gas
Code” for the recommended gas pipe size of other materials.
Refer to Figure 3
Note: When installing gas piping, apply approved pipe joint
compound.
1. Install a readily accessible manual shut-off valve in the
gas supply line as recommended by the local utility.
Know the location of this valve and how to turn off the
gas to this unit.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no
less than three inches long for the accumulation of dirt,
foreign material, and water droplets.
6
Ground
Joint
Union
Check with
local utility
for minimum height
3” minimum
Drip leg
Gas Pressure
Important: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heater’s
data plate. The minimum supply pressure is for the purpose
of input adjustment.
Gas Pressure Testing
Important: This water heater and its gas connection must
be leak tested before placing the appliance in operation.
•
If the code requires the gas lines to be tested at a
pressure exceeding 14” W.C., the water heater and its
manual shut-off valve must be disconnected from the
gas supply piping system and the line capped.
• If the gas lines are to be tested at a pressure less than
14” W.C., the water heater must be isolated from the
gas supply piping system by closing its manual shut-off
valve.
U.L. recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and should
be installed using the manufacturer’s instructions and local
codes, rules, or regulations.
Note: Air may be present in the gas lines and could prevent
the pilot from lighting on initial start-up. The gas lines
should be purged of air by a qualified service technician
after installation of the gas piping system.
Table 1
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 Iron Pipe
Size, in. 10
20
1/2 132
92
3/4 278 190
1
520 350
1-1/4 1050 730
1-1/2 1600 1100
30
73
152
285
590
890
40
63
130
245
500
760
50
56
115
215
440
670
Length of Pipe, Feet
60
70
80
90
50
46
43
40
105
96
90
84
195 180 170 160
400 370 350 320
610 560 530 490
100
38
79
150
305
460
125
34
72
130
275
410
150
31
64
120
250
380
175
28
59
110
225
350
200
26
55
100
210
320
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour
required for the gas input rating of the water heater. By formula:
Cu. Ft. Per Hr. Required=
Gas Input of Water Heater (BTU/HR)
Heating Value of Gas (BTU/FT³)
3
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT )
may be determined by consulting the local natural gas utility.
Additional tables are available in the latest edition of the "National Fuel Gas Code", ANSI Z223.1.
Combustion Air Supply and
Ventilation
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 or used 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.
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.
The following types of installation (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
7
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
footage (area) required for various BTUH inputs.
Table 2
BTUH
Input
Minimum Square
Feet with
8' Ceiling
Typical Room
with 8' Ceiling
30,000
188
9 x 21
45,000
281
14 x 20
60,000
375
15 x 25
75,000
469
15 x 31
90,000
563
20 x 28
105,000
657
20 x 33
120,000
750
25 x 30
135,000
844
28 x 30
Important:
•
The area must be open and be able to provide the
proper air requirements to the water heater. Areas that
are being used for storage or contain large objects may
not be suitable for water heater installation.
•
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.
•
Figure 4
Opening LocationsConfined Spaces
12” maximum
Permanent
openings to
the outside or
additional
rooms within
the building
12” maximum
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).
Confined
Space
Modern home construction usually requires supplying
outside air into the water heater area.
Permanent
Openings
Confined Space
For the correct and proper 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.
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.
8
Closet
or
other
confined
space
1 square
inch/1000
BTUH
(minimum
100 sq. In.)
Figure 5
All Air from Inside Building
Confined Space Installation
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 three 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
3 to calculate the minimum free area for each opening.
Figures 6, 7, and 8 are typical examples of each method.
Louvers and Grilles
In calculating free area for ventilation and combustion
air supply openings, consideration must be given to the
blocking effect of protection louvers, grilles, and screens.
These devices can reduce airflow, which in turn may
require larger openings to achieve the required minimum
free area. Screens must not be smaller than 1/4” 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.
Gable vent
to outdoors
Install above
insulation
Confined
Space
Outlet
air to attic
1 Sq. inch per
4000 BTUH
Inlet air
from the
crawl
space
Alternate
Air Inlet
1 sq. inch per
4000 BTUH
Open
Foundation
Vent
Figure 6
All Air from Outdoors; Inlet Air from Ventilated
Crawl Space/Outlet Air to Ventilated Attic
Gable vent
to outdoors
Install above
insulation
Outlet air
to attic
1 Sq. inch per
4000 BTUH
Confined
Space
Louvers and grilles must be locked open or interconnected
with the equipment so that they are opened automatically
during equipment operation.
Inlet air duct
1 sq. inch per
4000 BTUH
Keep louvers and grilles clean and free of debris or other
obstructions.
Table 3
Minimum Free Area of Permanent Openings for Ventilation and
Combustion Air Supply - All Air from Outdoors Only.
Based on the total BTUH input rating for all gas utilizing equipment
within the confined space.
Opening
Source
Minimum Free Area
Per Opening
(sq. in.)
Reference
Drawing
Direct to
outdoors
1 Square inch per 4000
BTUH
Figure 6
Vertical ducts
1 Square inch per 4000
BTUH
Figure 7
Horizontal ducts
1 Square inch per 2000
BTUH
Figure 8
1 sq. inch
per
2000 BTUH
Confined
Space
These openings connect directly with the outdoors
through a ventilated attic, a ventilated crawl space, or
through an outside wall.
Consult the local codes of your area for specific ventilation
and combustion air requirements.
Outlet
Outdoor
Air Ducts
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.
*
12” maximum
Figure 7
All Air from Outdoors
Through Ventilated Attic
Inlet
Figure 8
All Air from Outdoors
Using Horizontal Ducts
1 sq. Inch
per
2000 BTUH
9
Vent Pipe System
Vent Pipe Size
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
“Combustion Air Supply and Ventilation”).
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 drafthood outlet.
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
proper and efficient operation of this water heater and is an
important factor in the life of the unit.
The vent pipe must be installed according to all local and
state codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest
edition. The vent pipe installation must not be obstructed so
as to prevent the removal of exhaust gases to the outside
atmosphere.
Important: The use of vent dampers is not recommended
by the manufacturer of this water heater. Although some
vent dampers are certified by CSA America, Inc., this
certification applies to the vent damper device only and
does not mean they are certified for use on this water
heater.
U.L. recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and should
be installed using the manufacturer’s instructions and local
codes, rules, or regulations.
Important: If you lack the necessary skills required
to properly install this venting system, you should not
proceed, but get help from a qualified service technician.
Vent Connectors
1. Type B, Doublewall, U.L. Listed Vent Pipe.
2. Singlewall Vent Pipe.
Maintain the manufacturer’s specified minimum clearance
from combustible materials when using type B doublewall
vent pipe.
Vent connectors made of type B, doublewall vent pipe
material may pass through walls or partitions constructed
of combustible material, if the minimum listed clearance is
maintained.
Maintain a six inch minimum clearance from all combustible
materials when using singlewall vent pipe.
Important: Singlewall 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 singlewall metal vent connector cannot pass
through any interior wall.
When installing a vent connector, please note the following:
•
Install the vent connector avoiding unnecessary bends,
which create resistance to the flow of vent gases.
•
Install without dips or sags with an upward slope of at
least 1/4-inch per foot.
•
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.
•
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,
firewall, or fire partition.
Drafthood Installation
Align the legs of the drafthood with the slots provided.
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 drafthood in any way. If you are
replacing an existing water heater, be sure to use the new
drafthood supplied with the water heater.
Figure 9
Drafthood Installation
Sheet Metal Screws (four provided)
Drafthood
Legs
Legs
Slots
Slots
Jacket top
Install the drafthood with
the four screws provided.
10
Important: Existing vent systems must be inspected for
obstructions, corrosion, and proper installation.
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. Also
consult local and state codes for proper chimney sizing and
application or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-latest
edition.
•
The connector must be installed above the extreme
bottom of the chimney to prevent potentially blocking
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.
3 ft. minimum
2 ft. minimum above any
object within10 ft.
horizontally
*
Slope up
1/4 in.
per ft.
minimum
3 ft. minimum
2 ft. minimum above any
object within10 ft.
horizontally
*
Vertical Exhaust Gas Vent
Vertical exhaust gas vents must be installed with U.L. listed
type B vent pipe according to the vent manufacturer’s
instructions and the terms of its listing.
Vent
connector
slope up
1/4 in. per ft.
minimum
It must be connected to the water heater’s drafthood by
a certified vent connector or by directly originating at the
drafthood opening.
Vertical gas vents must terminate with a listed cap or
other roof assembly and be installed according to their
manufacturer’s instructions.
5 in. minimum
Gas vents must be supported to prevent damage, joint
separation, and maintain clearances to combustible
materials (Figures 11 and 12).
Important: This gas vent must be terminated in a vertical
position to facilitate the removal of the burnt gases.
An unused chimney flue or masonry enclosure may be
used as a passageway for the installation of a gas vent
(Figure 12).
Common (combined) venting is allowable with vertical type
B vent systems and lined masonry chimneys.
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 Gas Code”, NFPA
54, ANSI Z223.1-latest edition and the guidelines set forth
by prevailing local codes.
*
Slope up
1/4 in.
per ft.
minimum
* Maintain vent pipe clearance requirements to local, state
and/or the “National Fuel Gas Code”, ANSI Z223.1(NFPA
54)-latest edition.
11
Water System Piping
Piping Installation
Piping, fittings, and valves should be installed according to
the installation drawing (Figure 13). 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 bypass 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.
7. After piping has been properly connected to the water
heater, remove the aerator at the nearest hot water
faucet. Open the hot water faucet and allow the tank to
completely fill with water. To purge the lines of any excess air, keep the hot water faucet open for 3 minutes
after a constant flow of water is obtained. Close the
faucet and check all connections for leaks.
Figure 13
Water Piping Installation
Hot Water
Outlet
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 14.
These valves reduce the point-of-use temperature of
the water by mixing cold and hot water and are readily
available for use.
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” (Page 13).
5. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve and
how to shut off the water to the heater.
6. Install a temperature and pressure relief valve in the
opening marked “Temperature and Pressure (T & P)
Relief Valve” on the water heater. Add a discharge
line to the opening of the T & P relief valve. Follow the
instructions under “Temperature and Pressure Relief
Valve” (Page 14).
12
Main
Water
Supply
Pressure reducing
valve with bypass
Cold Water
Inlet Valve
Union
Temperature and
Pressure Relief Valve
Important: Always use a good grade of joint compound
and be certain that all fittings are drawn up tight.
1. Install the water piping and fittings as shown in Figure
13. 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”.
Important: Some models may contain energy saving heat
traps to prevent the circulation of hot water within the pipes.
Do not remove the inserts within the heat traps.
In a closed system use a
thermal expansion tank
Cold Water
Supply to Fixtures
Discharge line
6” maximum
above drain
Drain line
3/4” ID
minimum
Drain
1”minimum
Metal
Drain Pan
1 3/4” depth maximum
Figure 14
Typical Tempering
Valve Installation
Massachusetts:
Install a vacuum relief
in cold water line per
section 19 MGL 142.
Cold
Water
Inlet
Follow the tempering
valve manufacturer’s
instructions.
Hot
Water
Outlet
Tempered water
to fixtures
Tempering valve
(Set to 120°F)
Please note the following:
DO NOT install this water heater with iron piping. The
system should be installed only with piping that is
suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. DO NOT use PVC water piping.
Closed System/Thermal Expansion
DO NOT tamper with the gas valve/thermostat, igniter,
thermocouple, or temperature and pressure relief valve.
Tampering voids all warranties. Only qualified service
technicians should service these components.
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. This
may cause the temperature and pressure relief valve to
discharge small quantities of hot water. To prevent this, it
is recommended that a diaphragm-type expansion tank
(suitable for potable water) be installed 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 other methods to control this
situation.
DO NOT use with piping that has been treated with
chromates, boiler seal, or other chemicals.
Important: Do not plug or remove the temperature and
pressure relief valve.
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 add any chemicals to the system piping which
will contaminate the potable water supply.
13
Temperature and Pressure
Relief Valve
The Temperature & Pressure Relief Valve:
•
•
•
Must not be in contact with any electrical part.
Must be connected to an adequate discharge line.
Must not be rated higher than the working pressure
shown on the data plate of the water heater.
The Discharge Line:
•
•
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
qualified service technician replace it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
Figure 15A
Temperature and Pressure
Relief Valve Installation
Discharge line 3/4" minimum
Do not cap or plug.
6" maximum
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 15A). 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’s relief pressure must not
exceed the working pressure of the water heater as stated
on the data plate.
Important: 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.
14
•
•
•
Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in the
discharge line.
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 six 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 valve and discharge line
T&P Valve and Pipe Insulation (Some Models)
1. Locate the T&P Valve on the water heater.
2. Locate the slit running the length of the insulation.
3 Spread this slit open and slip it over the T&P Valve. See
Figure 15B. Apply gentle pressure to the insulation to
ensure it is fully seated on the T&P Valve. Once sealed
secure the insulation with a section of tape.
IMPORTANT: The insulation or tape should not block
or cover the T&P drain opening. Also the insulation or
tape should not block or hinder access to the T&P valve
manual relief lever.
4. Next locate the hot water (outlet) & cold water (inlet)
pipes to the water heater.
5. Select one of the sections of pipe insulation and locate the
slit that runs the length of the insulation.
6. Spread the slit open at the base of the insulation and slip
it over the cold water (inlet) pipe. Apply gentle
pressure along the length of the insulation to ensure it is
fully seated around the cold water pipe. Also ensure that
the base of insulation is flush with the water heater. Once
seated secure the insulation with a section of tape.
7. Repeat steps 5 through 6 for the hot water (outlet) pipe.
Figure 15B
T&P Valve and Pipe Insulation
T&P Insulation
Manual Relief Lever
T&P Valve
T&P Valve
Drain Line
Special Applications
Combination Space Heating/Potable
Water 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 and do not
add any chemicals to the water heater piping.
•
If the space heating system requires water temperatures in excess of 120°F, a tempering valve or an antiscald 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.
•
A properly installed flow control valve is required to prevent thermosiphoning. Thermosiphoning is the result
of a continuous flow of water through the air handler
circuit during the off cycle. Weeping (blow off) of the
temperature and pressure relief valve (T & P) or higher
than normal water temperatures are the first signs of
thermosiphoning.
•
•
The 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. Otherwise, these bubbles will be trapped in the
air handler heat exchanger coil, reducing the efficiency.
Do not connect the water heater to any system or
components previously used with non-potable water
heating appliances when used to supply potable water.
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 “Water System Piping” (Page 12) for additional
instructions on the safe and correct installation and
operation of this water heater.
Figure 16
Typical Tempering Valve Installation
Combination Space Heating/Potable
Water Heating System
Domestic
Hot Water
Out
Tempering
Valve
Must be vertical to
remove air bubbles
Cold
Water
Inlet
Hot
Water
Out
Unions
Flow Control
Pump Valve
Out
To
Air
Handler
Shut-off
Valve
In
Coil
Air
Handler
Massachusetts code
does not allow this
type of installation.
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.
Note: Solar water heating systems can often supply water
with temperatures exceeding 180°F and may result in water
heater malfunction.
15
Installation Checklist
Water Heater Location
□
□
□
□
□
□
□
Centrally located with the water piping system. Located
as 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.
Water heater not located near an air moving device.
Combustion Air Supply and Ventilation
□
□
□
□
□
Sufficient fresh air supply for proper water heater
operation.
Fresh air not taken from areas that contain negative
pressure producing devices such as exhaust fans,
fireplaces, etc.
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
□
□
□
□
□
□
Drafthood properly installed.
Vent connectors securely fastened with screws and
supported properly to maintain six inch clearance.
Vent connector made of approved material and sized
correctly.
Vent pipe system must be installed according to all
local and state codes or, in the absence of local and
state codes, the “National Fuel Gas Code”, ANSI
Z223.1(NFPA 54)-latest edition.
Flue baffle engaged in slots provided in the flue tube.
Flue way, drafthood, or vent pipe system not obstructed
in any way.
Water System Piping
□
□
□
□
□
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.
Heater completely filled with water.
Closed system pressure build-up precautions installed.
Tempering valve installed per manufacturer’s
instructions, when applicable (See Water Temperature
Regulation section.)
Gas Supply and Piping
□
□
□
□
□
16
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.
An approved noncorrosive leak detection solution to
check all connections and fittings for possible gas leaks.
Correct any leak found.
Important Information About
Your Water Heater
This gas water heater was manufactured to voluntary
safety standards to reduce the likelihood of a flammable
vapor ignition incident. New technology used in meeting
these standards makes this product less tolerant of
installation errors or improper installation environments.
Please review the following information and make any
necessary installation upgrades or changes:
1. Check for insufficient combustion air. Insufficient
air for the combustion of gas will result in the flame
becoming “lazy,” thereby allowing heat to build up in
the combustion chamber. This excessive heat will
cause a thermal switch on the door assembly to trip.
Is the water heater installed in a closet or other small,
enclosed space? If so:
• Is there an opening for make-up air to enter the
room/area?
• Is the opening of sufficient size? Remember,
if there are other gas-fired or air-consuming
appliances in the same room, you need more
make-up air. Refer to the Location Requirements
section of this water heater manual for specific
requirements.
• Is there a furnace/air handler in the same room/
space as the water heater? If so, has a return air
duct system been attached that exits the room?
If so, check for leaks on the air duct system. If no
air duct system is present, correct immediately
by contacting a local Heating, Ventilation, AirConditioning & Refrigeration (HVAC-R) authorized
service provider.
2. Check for proper drafting at the water heater draft
hood. Make sure all other appliances in the area are
operating and all doors are closed when performing
the draft test. To perform the draft test, open a hot
water faucet for 3-5 minutes or until the burner ignites,
and then check for a draft at the inlet to the draft hood
(top of the heater) using a match or small amount of
smoke. The smoke should be pulled into the draft
hood. If there is no draft:
• Recheck #1
• Check the vent system for restrictions/obstructions
and check the vent termination height. Refer to
the Air Supply and Ventilation section of this water
heater manual for specific requirements.
3. Is the installed environment dirty (excessive amounts
of lint, dirt, dust, etc.)? If so, make sure the flame
arrestor located on the bottom of the water heater
has been cleaned. Refer to the Maintenance of your
Water Heater section of this manual for information on
cleaning the flame-trap.
4. Is it possible that flammable vapors entered the
water heater and were ignited in the burner area (a
flammable vapor incident)? If a flammable vapor
incident has occurred or if you are unsure whether it
has, call the number below immediately.
Proper installation will ensure the safe, effective and
efficient operation of the water heater. Make sure that
you review and follow the instructions in this manual.
Questions? Call 1-800-999-9515.
OPERATING YOUR WATER HEATER
Lighting Instructions
WARNING
Read and understand these directions thoroughly before
Explosion Hazard
attempting to light or re-light the pilot. Make sure the
viewport is not missing or damaged. (See Figure 23)
Make sure the tank is completely filled with water before
lighting the pilot. Check the data plate near the gas control
valve/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.
Replace viewport if glass is missing
or damaged.
Failure to do so can result in death,
explosion or fire.
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.
E. DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN
IGNITION OF VAPORS. Immediately call a qualified service
technician to inspect the appliance. Water heaters
subjected to a flammable vapors ignition will show a
discoloration on the air intake grid and require
replacement of the entire water heater.
LIGHTING INSTRUCTIONS
7. Depress the reset button all the way PUSHBUTTON
in and IMMEDIATELY depress the
igniter button until you hear a loud
click. Observe the pilot through the
view port. Do not release the reset
button. 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.
IGNITER
1. STOP! It is imperative that you read all the safety warnings
before lighting the pilot.
2. Remove the outer door.
3. Turn the temperature dial counterclockwise
lowest setting.
120° F
BAR
ES
UR
Y
H
H
TE OTTER S
RI R INCREA J
SK
IN
OF SCALD
VAC
A
HOT
RM
A
W
N
VACA
TIO
130° F
BAR
A
W
E
TH
INDEX
BARS
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.
O N
L
CAU
TI
O
WA
R
UTION
CA
ON
TI
IT
RO
REA
BE D WA
FO AL R
RE L IN NIN
ST G
RU
LIC
GTI
ON
HTI
NS
G
T
O
DIAL
STOP
M
UN
P IL OT
N
4. Turn gas control knob clockwise
to the “OFF” position.
CAUTION
DO NOT PRY
ON DIAL
DAMAGE
WILL
RESULT
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.
IMPORTANT: If the reset button (see graphic at step 3) 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. Turn the gas control knob
counterclockwise
to “ON”.
CAUTION
DO NOT PR Y
OFF
O N
6. Turn the gas control knob
counterclockwise
to “PILOT”.
ON DIAL
DAMAGE
WILL
RESUL T
P IL O T
9. Set the temperature dial to
the desired setting.
CAUTION
DO NOT PRY
PILOT
130° F
BAR
GAS
CONTROL
KNOB
O FF
RESET
BUTTON
to its
ON DIAL
DAMAGE
WILL
RESULT
O N
10. 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”
17
Checking the Draft
Water Temperature Regulation
Burn Hazard
Do not touch vent.
Doing so can result in
burns.
RO
L
Index
Bars
H
TE OTTER S
RI R INCREA J
SK
IN
OF SCALD
130°F
Bar
VAC
A
CAU
TI
O
Dial
Stop
M
IT
WA
R
UTION
CA
A
W
E
TH
18
UN
RE
BE AD WA
FO AL R
RE L IN NIN
ST G
RU
CT
LIG
IO
HT N
INS
G
T
O
VACA
TIO
Important: Should overheating occur or the gas supply fails
to shut off, turn off the water heater’s manual gas control
valve and call a qualified service technician.
120°F
Bar
130°F
Bar
Control
Knob
N
Emergency Shut Down
Figure 19
Robertshaw Gas Valve/Thermostat
Settings
Reset
Button
Gas
M
AR
W
Stacking occurs when a series of 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. An
anti-scald device is recommended in the hot water supply
line to reduce the risk of scald injury.
120°F (49°C) more than 5 minutes
130°F (54°C) at 20 seconds
140°F (60°C) at 3 seconds
150°F (66°C) at 1-1/2 seconds
160°F (71°C) at less than 1 second
ES
U
RY
Stacking
Important: Adjusting the thermostat past the 120°F bar
on the temperature dial will increase the risk of scald injury.
Hot water can produce first degree burns within:
HOT
Inspect the burner
flames through the
Correct flame
viewport and compare
soft blue
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. Contact a qualified
service technician if the flame is not satisfactory.
H
Yellow inner
cones are
satisfactory
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 Figure 19. There is a hot water
scald potential if the thermostat is set too high.
N
Burner Flames
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.
Feel water before bathing or showering.
Temperature limiting valves are
recommended.
ON
TI
After successfully lighting the water heater, allow the unit
to operate for 15 minutes and check the drafthood relief
opening for proper draft. Make sure all other appliances
in the area are operating and
Figure 17
Drafthood
all doors are closed when
Relief
performing the daft test. Pass
Opening
Match
a match flame around the relief
opening of the drafthood. 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
18
until proper adjustments Figure
Flame Characteristics
or repairs are made to
Tips may have
a yellow tint
the vent pipe system.
Note: 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.
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 start-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.
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, a leaking tank or piping connections. Refer to
“Location Requirements” on page 4. 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 buildup 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 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. The pilot flame is extinguished for any reason.
2. The water temperature exceeds 180°F (83°C).
3. Excessive combustion chamber temperatures.
4. The ignition of flammable vapors.
A thermocouple is used to determine if a pilot flame is
present, and will shut off the gas supply to the main
burner and the pilot if the flame is absent. This unit is
also equipped with a thermal switch, designed to shut off
the gas supply in the event the heater has been exposed
to flammable vapors (spilled gasoline or paint fumes for
example), poor combustion caused by a blocked vent
or insufficient combustion air. If the switch opens, check
the flame-trap for signs of high temperature (blue or
black discoloration), and inspect your installation for any
problems with venting or combustion air (See Pilot Light
Troubleshooting Flowchart on page 26). Reset the switch
by depressing the small button in the center of the switch.
Important: Correct any issues prior to resetting the switch.
Contact the Product Service and Support Department for
service information at 1-800-999-9515.
A high temperature limit switch or ECO (Energy Cut Off) in
the tank 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
technician. Contact your local dealer for service information.
Anode Rod/Water Odor
Each water heater contains at least one anode rod, which
will slowly deplete while protecting the glass-lined tank
from corrosion and prolonging the life of the water heater.
Once the anode is depleted, the tank will start to corrode,
eventually developing a leak. Certain water conditions
will cause a reaction between this rod and the water. The
most common complaint associated with the anode rod is a
“rotten egg smell” produced from the presence of hydrogen
sulfide gas dissolved in the water. Do not remove this rod
permanently as it will void any warranties. 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.
Artificially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease the
life of the water heater tank.
The anode rod should be removed from the water heater
tank every 3 years for inspection. The following are typical
(but not all) signs of a depleted anode rod:
• The majority of the rods diameter is less than 3/8”.
• Significant sections of the support wire (approx. 1/3 or
more of the anode rod’s length) are visible.
If the anode rod show signs of either or both it should be
replaced. Note: Whether re-installing or replacing the anode
rod, check for any leaks and immediately correct if found.
In replacing the anode:
1. Turn off gas supply to the water
heater.
2. Shut off the water supply and
open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons
of water from tank (Refer to
“Draining and Flushing” for
proper procedures). Close drain
valve.
4. Remove old anode rod.
5. Use Teflon® tape or approved
pipe sealant on threads and
install new anode rod.
6. Turn on water supply and open
nearby hot water faucet to purge
air from water system. Check
for any leaks and immediately
correct any if found.
7. Restart the water heater as directed under “Operating
Your Water Heater.” See the “Repair Parts Illustration”
for anode rod location on page 27.
19
MAINTENANCE OF YOUR WATER HEATER
Draining and Flushing
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up
during operation. The water heater should be drained if
being shut down during freezing temperatures. To drain the
tank, perform the following steps:
Temperature and Pressure
Relief Valve
1. Turn off the gas to the water heater at the Manual Gas
Shut-off 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.
Note: The drain hose should be rated for at least 200°F.
If the drain hose does not have this rating, open the cold
water inlet valve and a nearby hot faucet until the water is
no longer hot.
5. Open the water heater drain valve and allow all the
water to drain from the tank. 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 “Operating Your Water
Heater”.
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.
Routine Preventative
Maintenance
At least annually, a visual inspection should be made of
the venting and air supply system, piping systems, main
burner, pilot burner, and Flame-trap. 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.
•
Presence of combustible materials near the water
heater.
•
Verify proper operation after servicing this water heater.
Important: If you lack the necessary skills required to
properly perform this visual inspection, you should not
proceed, but get help from a qualified service technician.
20
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
qualified service technician replace it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
Manually operate the temperature and pressure relief valve
at least once a year to make sure it is working properly.
To prevent water damage,
Figure 21
Temperature and Pressure
the valve must be properly
Relief Valve
connected to a discharge
Manual Relief
Valve
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
Discharge line to drain
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.
Replacement Parts
The following maintenance procedures are for the
Flame Guard® Safety System components and should
be performed by a qualified service technician.
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
Removing the Burner from the
Manifold Assembly
Natural Gas Burner (Low Nox)
1. Take off the burner by removing the two (2) screws
located underneath the burner.
2. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water (Figure
24).
Manifold Door
Assembly
Figure 24
Natural Gas (Low Nox)
Burner Assembly
2. type of gas
3. item number
4. parts description
Burner
Two Piece Wire
Connector
Thermal Switch
Igniter Wire
See pages 27-28 for a list of available repair parts.
Pilot
Tube
Removing the Manifold Assembly
1. Turn off the gas to the water heater at the manual
shut-off valve (Figure 3).
Manifold
Door
Gasket
2. Turn the gas control knob on the combination gas
control valve/thermostat
Figure 22
clockwise to the “OFF”
Igniter
Button
position (Figure 19).
Pilot Bracket
Thermocouple
Retainer Clip
Pilot Assembly
3. Remove the outer door.
Manifold
Tube
Thermocouple
Viewport
Pilot
Tube
Thermocouple
4. Remove the two screws
securing the manifold
door assembly to the
combustion chamber
(Figure 22).
UNITROL
WARNING
READ ALL INSTRUCTIONS
BEFORE
LIGHTING
Manifold Door
Assembly
W
A
R
T
OF
A
S
SCA L
D
I
W
Burner
CA
T
HO
T T ER
A
I N C RE
ER
VA
NJ E S
UR
Y
N
SH
SK
IO
HO
O
RT
T
WA I
R
T HE
R OB E
C A
M
U T I
Pilot Assembly
N
Right-Hand
Thread
5. Disconnect the
thermocouple (right-hand
thread), pilot tube, the
igniter wire from the igniter
Thermocouple
button, the two connectors
Manifold Tube
attached to the thermal
switch, and manifold tube
at the thermostat. (Figures 22 & 23.)
Igniter
Wire
Pilot
Tube
Thermal
Switch Wires
Manifold
Tube
Screws
6. Grasp the manifold tube and push down slightly to free
the manifold, pilot tube, and thermocouple.
7. Carefully remove the manifold assembly from the
burner compartment. Be sure not to damage internal
parts.
Figure 23
Burner Assembly
Removal
Piezo
Igniter
Button
Gas Valve /
Thermostat
Manifold
Tube
Pilot Tube
UNITROL
WARNING
READ ALL INSTRUCTIONS
BEFORE
LIGHTING
W
A
RM
C A
W
HA
NJ E S
UR
Y
S
N
TS
VA
CA
T
AT
W
RI
T HE
R OBER
N
HO
T T ER
EA
ER
I N CR
SK
I
OF
D
SCA L
IO
HO
T
U T I
O
Thermocouple
Thermal Switch
Viewport
Manifold
Screw (2)
Two Piece Wire
Connector
Manifold
Door
21
Replacing the Thermocouple
1. Remove the manifold assembly as directed previously.
2. Remove the retainer clip from the back of the two piece
wire connector and remove the two piece wire connector from the manifold door (Figure 25).
3. Pull the thermocouple from the pilot assembly (Figure
28).
Be careful not to bend or alter the position of the pilot
assembly components.
External Inspection & Cleaning of the
Flame-trap
Although not likely to occur, if debris collects on the flametrap, use a vacuum, compressed air, or a soft bristle brush
to remove it. Note: If unable to inspect or clean the flame
trap from underneath, follow the “Cleaning the Combustion
Chamber and Flame-trap” instructions.
Figure 27
Flame-trap visual inspection
4. Push the new thermocouple through the holes in the pilot bracket. Insert the thermocouple tube into the holes
provided in the pilot assembly until it clicks into place.
5. Position the new thermocouple through the larger
opening of the two piece wire connector (Figure 25). Be
sure igniter wire is positioned through the small opening of the two piece wire connector.
6. See “Replacing Manifold Assembly” Page 23.
Flashlight
Figure 25
Two Piece Wire
Connector
Assembly
Thermocouple
Igniter Wire
Other fittings
not shown
for clarity
Mirror
Retainer Clip
Two Piece
Wire Connector
Pilot T ube
Manifold
Door
Figure 26
Thermocouple
Assembly
Mirror
Cleaning the Combustion Chamber and
Flame-trap
1. Follow procedure outlined in “Removing the Manifold
Assembly”.
2. Use a vacuum cleaner/shop vac to remove all loose
debris in the combustion chamber (Figure 28A). Use
compressed air to clear any dust or debris that may
have accumulated in the flame-trap.
3. Reassemble following the procedure under “Replacing
the Manifold Assembly”.
22
Figure 28A
Combustion Chamber
Door Gasket
Explosion Hazard
Tighten both manifold door screws
securely.
Remove any fiberglass between the door
gasket and combustion chamber.
Replace viewport if glass is missing or
damaged.
Replace two piece wire connector if
missing or removed.
Replace door gasket if damaged.
Failure to do so can result in death,
explosion, or fire.
2. Inspect the viewport for damage and replace as
required.
3. Insert the manifold assembly into the burner
compartment making sure that the tab of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figure 28B).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
Figure 28B
Manifold Assembly
Close-up
Close-up inside view of
the combustion chamber.
Slot
Manifold tube
The thermocouple nut should be started and turned
all the way in by hand. An additional quarter turn
with a 7/16” open-end wrench will then be sufficient
to seat the lockwasher.
7. Reconnect the igniter wire.
8. Turn gas supply on and refer to the “Lighting
Instructions” on page 17.
9. Check for leaks. Use an approved noncorrosive leak
detection solution. Bubbles forming indicate a leak. All
leaks must be fixed immediately.
10. Replace the outer door.
Tab
Bracket
Piezoelectric Igniter System
The piezoelectric igniter system consists of the igniter
button, electrode, and wire. The pilot is ignited by an
electric spark generated when the igniter button is pressed.
The spark gap of 0.125 inch is set when the electrode is
installed at the factory. (See Figure 29). Use only factory
authorized piezoelectric igniter parts for replacement.
Figure 29
Natural Gas Igniter Assembly
Thermocouple
Igniter
Button
Pilot
5. Replace the two screws which secure the manifold
assembly door to the combustion chamber. Tighten
securely. There should be no space between the
gasket part of the manifold door and combustion
chamber. Do not operate the water heater if the door
gasket is not sealed.
6. Reconnect the two wire leads to the thermal switch, the
manifold tubing, pilot tubing, and thermocouple to the
thermostat. Do not cross-thread or apply any thread
sealant to these fittings.
Bracket
Tab
Replacing the Manifold Assembly
1. Check the door gasket for damage or imbedded debris
prior to installation.
Flame-trap
.125
Tip
Wire
to
electrode
Pilot
Bracket
Electrode
Snap-on Connector
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shutoff valve. Watch the electrode tip while activating the igniter.
A visible spark should jump from the electrode. To avoid
shock, do not touch the burner or any metal part on the
pilot or pilot assembly. If no spark is visible, check the wire
connections and make sure the electrode is not broken.
Replace the igniter if defective. Dirt and rust on the pilot or
electrode tip can prevent the igniter spark. Wipe clean with
a damp cloth and dry completely. Rust can be removed
from the electrode tip and metal surfaces by lightly sanding
with an emery cloth or fine grit sandpaper.
23
pipe into the inlet and use it to turn the gas valve
(counterclockwise.) Do not use pipe wrench or
equivalent to grip body. Damage may result, causing
leaks. Do not insert any sharp objects into the inlet or
outlet connections. Damage to the gas valve may result.
Removing and Replacing the Gas
Control Valve/Thermostat
IMPORTANT: The gas control valve/thermostat is a standard
valve with wire leads that connect to a thermal switch.
Removing the Gas Valve:
Replacing the Gas Valve:
1. On the gas control valve/thermostat turn the
temperature dial counterclockwise to its lowest setting.
Turn the gas control knob clockwise to the “OFF”
position (Figure 19).
To replace the gas control valve/thermostat, reassemble
in reverse order. When replacing the gas valve, thread a
correctly sized pipe into the inlet and use it to turn the gas
valve (clockwise.) DO NOT OVER TIGHTEN, damage may
result.
2. Turn off the gas at the manual shut-off valve on the gas
supply pipe (Figure 3).
3. Drain the water heater. Refer to the section of “Draining
and Flushing” on page 20 and follow the procedure.
4. Disconnect the igniter wire from the igniter button.
Remove the igniter button by depressing front and rear
holding tabs and lift. Remove igniter bracket. Disconnect
the thermocouple (right-hand threads), pilot tube, two
wire leads at the thermal switch, and manifold tube at
the gas control valve/thermostat (Figure 22).
5. Refer to “Gas Piping” (Figure 3) and disconnect the
ground joint union in the gas piping. Disconnect the
remaining pipe from the gas control valve/thermostat.
•
•
•
•
•
6. To remove the gas valve, thread a correctly sized
Be sure to use approved Teflon tape or pipe joint
compound on the gas piping connections and fitting on
the back of the gas control valve that screws into tank.
Be sure to remove the pilot ferrule nut from the new gas
control valve/thermostat.
Turn the gas supply on and check for leaks. Test the
water heater by brushing on an approved noncorrosive
leak detection solution. Bubbles forming indicate a leak.
Correct any leak found.
Be sure tank is completely filled with water before
lighting and activating the water heater. Follow the
“Lighting Instructions” on page 17.
If additional information is required, contact the Service
Department at: 1-800-999-9515.
Flame Guard® Safety System Operational Checklist
1.
2.
3.
4.
Manifold gasket properly sealed.
Viewport not damaged or cracked.
Flame-trap free of debris and undamaged.
Two piece wire connector properly installed.
5. No leaks at pilot and manifold connection.
6. Manifold door screws securely tightened.
7. Depress the thermal switch button to verify it is operational.
TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
BURNER WILL NOT IGNITE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Pilot not lit
Thermostat set too low
No gas
Dirt in the gas lines
Pilot line clogged
Main burner line clogged
Defective thermocouple
Defective thermostat
Heater installed in a confined area
1.
2.
3.
4.
5.
6.
7.
8.
9.
Light pilot
Turn temp. dial to desired temperature
Check with gas utility company
Notify utility-install trap in gas line
Clean, locate source and correct
Clean, locate source and correct
Replace thermocouple
Replace thermostat
Provide fresh air ventilation
SMELLY WATER
1.
Sulfides in the water
1.
Replace the anode with a special anode
BURNER FLAME YELLOWLAZY
1.
2.
3.
4.
5.
6.
Insufficient secondary air
Low gas pressure
Flue clogged
Main burner line clogged
Heater installed in a confined area
Obstruction in main burner orifice
1.
2.
3.
4.
5.
6.
Provide ventilation to water heater
Check with gas utility company
Clean, locate source and correct
Clean, locate source and correct
Proper fresh air ventilation
Clean or replace orifice
PILOT WILL NOT LIGHT OR
REMAIN LIT
1.
2.
Defective igniter
The thermal switch tripped
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Thermocouple connection loose
Air in gas line
Low gas pressure
No gas
Dirt in gas lines
Cold drafts
Thermostat ECO switch open
Pilot line or orifice clogged
Defective thermocouple
Air for combustion obstructed
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Replace igniter pilot assembly
See Pilot Light Troubleshooting Flowchart
section
Finger tighten; then 1/4 turn with wrench
Bleed the air from the gas line
Check with gas utility company
Check with gas utility company
Notify utility-install dirt trap in gas line
Locate source and correct
Replace thermostat
Clean, locate source and correct
Replace thermocouple
See maintenance section for inspection and
cleaning of flame trap
Replace water heater, eliminate flammable
vapors source. Call 1-800-999-9515
13. Flammable vapors incident, Flame Guard®
function utilized
24
13.
PROBLEM
HIGH OPERATION COSTS
POSSIBLE CAUSE(S)
1.
2.
3.
4.
5.
6.
7.
8.
9.
CORRECTIVE ACTION
Thermostat set too high
Sediment or lime in tank
Water heater too small for job
Wrong piping connections
Leaking faucets
Gas leaks
Wasted hot water
Long runs of exposed piping
Hot water piping in exposed wall
1.
2.
3.
4.
5.
6.
7.
8.
9.
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
INSUFFICIENT HOT WATER 1.
2.
3.
4.
5.
6.
7.
8.
9.
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
Low gas pressure
1.
2.
3.
4.
5
6.
7.
8.
9.
Turn temperature dial to desired 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
Check with gas utility company
SLOW HOT WATER
RECOVERY
1.
Insufficient secondary air
1.
2.
3.
4.
5.
6.
7.
8.
Flue clogged
Low gas pressure
Improper calibration
Thermostat set too low
Water heater too small
Wrong piping connections
Wasted hot water
2.
3.
4.
5.
6.
7.
8.
Provide ventilation to water heater. Check flue
way, flue baffle, and burner
Clean flue, locate source and correct
Check with gas utility company
Replace thermostat
Turn temperature dial to desired 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 “Closed System/Thermal Expansion”
THERMOSTAT FAILS TO
SHUT-OFF
1.
2.
Defective thermostat
Improper calibration
1.
2.
Replace thermostat
Replace thermostat
COMBUSTION ODORS
1.
Insufficient secondary air
1.
2.
3.
Flue clogged
Heater installed in a confined area
2.
3.
Provide ventilation to water heater. Check flue
way, flue baffle, and burner
Clean, locate source and correct
Provide fresh air ventilation
SMOKING AND CARBON
FORMATION (SOOTING)
1.
Insufficient secondary air
1.
2.
3.
4.
5.
6.
Low gas pressure
Flue clogged
Defective thermostat
Heater installed in a confined area
Burner flame yellow-lazy
2.
3.
4.
5.
6.
Provide ventilation to water heater. Check flue
way, flue baffle, burner
Check with gas utility company
Clean, locate source and correct
Replace thermostat
Provide fresh air ventilation
See “Burner Flame Yellow-Lazy”
CONDENSATION
1.
Temperature setting too low
1.
Increase the temperature setting
BURNER FLAME FLOATS
AND LIFTS OFF PORTS
1.
2.
3.
4.
Orifice too large
High gas pressure
Flue clogged
Cold drafts
1.
2.
3.
4.
Replace with correct orifice
Check with gas utility company
Clean flue and burner-locate source and correct
Locate source and correct
BURNER FLAME TOO HIGH 1.
Orifice too large
1.
Replace with correct orifice
FLAME BURNS AT ORIFICE
1.
2.
Defective thermostat
Low gas pressure
1.
2.
Replace thermostat
Check with gas utility company
PILOT FLAME
TOO SMALL
1.
2.
Pilot line or orifice clogged
Low gas pressure
1.
2.
Clean, locate source and correct
Check with gas utility company
25
PILOT LIGHT TROUBLESHOOTING CHART
Does pilot light go out
NO
when button is released?
YES
Has the thermal switch
tripped?
NO
YES
Check Draft. (See Checking the
Draft section of this manual.)
Are the wires from the gas
control valve/thermostat firmly
connected to the switch?
Secure connections
and attempt a relight.
NO
YES
Are the wires damaged
and/or frayed?
Is the thermocouple
NO
connection loose?
YES
NO
YES
Tighten the connection
Replace the gas control
valve/thermostat.
Check for insufficient
combustion air.
Are there openings
for make-up air to
NO
enter the room?
YES
Test the thermocouple using the following
procedure: Disconnect the thermocouple
from the gas control valve/thermostat. Using
a multimeter with alligator clip leads, attach
the red lead to the body (copper part) of
the thermocouple. Attach the black lead to
the end (silver part) of the thermocouple
that connects to the gas control valve/
thermostat. Follow the instruction to light
the pilot and watch the voltage readings on
the multimeter. After 45 seconds the meter
should read 12 millivolts DC or more.
YES Does the thermocouple pass the test? NO
Replace the thermocouple.
Install correct size make-up air openings
per the Combustion Air Supply and
Ventilation section in this manual.
Are the openings of sufficient size?
See Combustion Air Supply and Ventilation NO
section in this manual for requirements.
Correct size of openings
to allow sufficient air.
YES
Is there a furnace/air
NO handler in the same room
as the water heater?
YES
Does the return air duct for the furnace/air handler
draw its air from a separate location than the water
NO
heater? See the Location Requirements section
and the Combustion Air Supply section.
Contact a local Heating, Ventilation, AirConditioning & Refrigeration authorized
service provider.
YES
Is there proper drafting at the
drafthood? See Checking the
Draft section in this manual.
NO
Check the vent system for restrictions/obstructions and check
the vent termination height. Refer to the Installation Instructions
section of this manual for specific requirements.
UNITROL
WARNING
READ ALL INSTRUCTIONS
BEFORE
LIGHTING
YES
W
A
S
N
T
HO
C A
W
HA
IO
TS
NJ E S
UR
Y
HO
T T ER
EA
VA
CA
T
AT
W
RI
T HE
R OBER
N
NO
O
Is the flame-trap free from
debris due to excessive lint,
dirt, dust or oil?
RM
U T I
ER
I N CR
SK
I
OF
D
SCA L
Refer to the Use & Care Guide section of this manual for
information on cleaning the flame-trap.
YES
Check the water heater for a Flammable Vapor (FV) event. Note: it may
be necessary to remove the manifold door assembly to visually inspect
the water heater. Reference the Maintenance of your Water Heater
section of this manual for removal instructions.
N
Is the igniter wire insulation burnt or
show signs of discoloration?
YES
NO
Is the pilot tube
NO
damaged?
YES
Does the flametrap show signs
of discoloration
and/or debris?
YES
Shut-off the gas supply to the water
heater at the manual gas shut-off
valve, then contact Customer Service
at: 1-800-999-9515.
26
Thermal
Switch
REPAIR PARTS ILLUSTRATION
Alternate anode
location for top
T&P
5
1
4
2
Anode location
for side T & P
8
3
When ordering repair parts always give the following
information:
1.
2.
3.
4.
Model, serial, and product number
Type of gas
Item number
Parts description
Repair Parts List
Item
No.
6
10
7
Parts Description
1
DRAFTHOOD
2
REDUCER RING - SOME MODELS
3
FLUE BAFFLE
4
HEAT TRAP (COLD) - SOME MODELS
5
HEAT TRAP (HOT) - SOME MODELS
6
COLD WATER DIP TUBE
7
ANODE ROD
8
TEMPERATURE & PRESSURE RELIEF VALVE
(LOCATED TOP OR SIDE)
9
DRAIN VALVE
10
GAS CONTROL VALVE/THERMOSTAT (with wire leads)
11
OUTER DOOR
12*
PILOT ASSEMBLY KIT
(Natural Gas)
13
BURNER (Natural Gas/Low Nox)
14*
MANIFOLD DOOR ASSEMBLY
(Natural Gas/Low Nox)
15*
TWO PIECE WIRE CONNECTOR
WITH RETAINER CLIP
16*
MANIFOLD DOOR GASKET
17*
VIEWPORT ASSEMBLY
18*
THERMOCOUPLE
Special anode rod (see page 19)
19*
PIEZOELECTRIC IGNITER
Temperature and Pressure Relief Valve is required,
but may not be factory installed
*Pictured on next page.
9
11
LEGEND
Unique: Flame Guard® Safety System parts
27
Listed Parts Kits and Illustrations
Item 12: Pilot assembly kit, which contains the pilot assembly and retainer clip (Natural Gas)
Item 13: Burner (Natural Gas/Low Nox)
Item 14: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two piece wire
connector with retainer clip, thermal switch, and pilot assembly. (Natural Gas/Low Nox)
Item 15: Contains two piece wire connector and retainer clip
Item 16: Contains manifold door gasket
Item 17: Contains viewport
Item 18: Contains thermocouple
Item 19: Contains piezoelectric igniter
© 2005 American Water Heater Company. All Rights Reserved.
28
Listed Parts Kits and Illustrations
Item 11:
Item 12:
Item 14:
Item 15:
Item 16:
Item 17:
Item 18:
Item 19:
Item 20:
Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter,
thermocouple, and retainer clip. (Natural Gas)
Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter,
thermocouple, and retainer clip. (L.P. Gas)
Burner (Natural Gas/Low Nox)
Burner (L.P. Gas)
Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (Natural Gas/Low Nox)
Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (L.P. Gas)
Contains two piece wire connector with retainer clip, and pilot assembly
Contains manifold door gasket
Contains viewport
Item #11
Item # 14
Item #12
Item #16
Item #17
Item # 15
Item #18
Item #19
Item #20
© 2004 American Water Heater Company. All Rights Reserved.
29