American Water Heater Ultra Low Nox Instruction manual

Instruction Manual
ULTRA LOW NOX RESIDENTIAL GAS WATER HEATERS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
LOW LEAD
CONTENT
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 1112
1
324257-000
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use or service this water heater.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.
CAUTION
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
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 included in the Act.
IMPORTANT DEFINITIONS
•
Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must have a thorough
understanding of this instruction manual.
•
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines
provided by the manufacturer.
•
Gas Supplier: The Natural Gas or Propane Utility or service which supplies gas for utilization by the gas burning
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of
gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also
offer service and inspection of appliances within the building.
2
GENERAL SAFETY
3
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE............................2
GENERAL SAFETY..................................................................3
TABLE OF CONTENTS............................................................4
INTRODUCTION ......................................................................4
Preparing for the New Installation .....................................4
TYPICAL INSTALLATION......................................................5,6
LOCATING THE NEW WATER HEATER ............................. 7-9
Facts to Consider About Location ..................................7,8
Insulation Blankets ............................................................8
Combustion Air and Ventilation for Appliances
Located in Unconfined Spaces .........................................8
Combustion Air and Ventilation for Appliances
Located in Confined Spaces ..........................................8,9
INSTALLING THE NEW WATER HEATER ...................... 10-14
Water Piping ..............................................................10,11
Temperature-Pressure Relief Valve ................................11
Filling the Water Heater ..................................................12
Venting ............................................................................12
Draft Hood Installation ...............................................12,13
Gas Piping .................................................................13,14
Sediment Traps ...............................................................14
LIGHTING & OPERATING INSTRUCTIONS .........................15
TEMPERATURE REGULATION ............................................16
FOR YOUR INFORMATION ..............................................16,17
Start Up Conditions ....................................................16,17
Draft Hood Operation ......................................................16
Condensation .............................................................16,17
Smoke/Odor ....................................................................17
Thermal Expansion .........................................................17
Strange Sounds ..............................................................17
Operational Conditions ...................................................17
Smelly Water ...................................................................17
“Air” in Hot Water Faucets ..............................................17
High Temperature Shut Off System ................................17
PERIODIC MAINTENANCE ............................................. 18-20
Venting System Inspection..............................................18
Burner Inspection ............................................................18
Burner Flames ................................................................18
Burner Cleaning ..............................................................18
Housekeeping .................................................................19
Anode Rod Inspection.....................................................19
Temperature-Pressure Relief Valve Operation ...............20
Draining and Flushing .....................................................20
Service ............................................................................20
REPLACEMENT PARTS .................................................. 21-23
Removing the Burner Door Assembly .............................21
Natural Gas Burner .........................................................21
Replacing the Pilot Assembly..........................................21
Replacing the Burner Door Assembly .............................22
Piezoelectric Igniter System............................................22
Testing the Igniter System...............................................22
Removing and Replacing the Gas Control
Valve/Thermostat ...........................................................23
Operational Checklist ......................................................23
Flue Baffle Installation.....................................................23
LEAKAGE CHECKPOINTS ....................................................24
REPAIR PARTS ......................................................................25
TROUBLESHOOTING GUIDELINES............................... 26-27
WARRANTY ......................................................................Insert
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
2. The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54 current addition. This publication is available from
the CSA International, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
INTRODUCTION
Abbreviations Found In This Instruction Manual:
•
ANSI - American National Standards Institute
•
NFPA - National Fire Protection Association
•
ASME - American Society of Mechanical Engineers
•
AHRI - Air Conditioning, Heating and Refrigeration Institute
•
CAN - Canada
•
EPACT - Energy Policy Act
•
CSA - Canadian Standards Association
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility
or the manufacturer whose name appears on the rating plate.
4. Carefully plan the place where you are going to put the water
heater. Correct combustion, vent action, and vent pipe installation
are very important in preventing death from possible carbon
monoxide poisoning and fires, see Figures 3 through 8A.
This gas-fired water heater is design certified
by American National Standard/CSA Standard
for Gas Water Heaters ANSI Z21.10.3 • CSA 4.3 (current edition).
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
PREPARING FOR THE INSTALLATION
5. For California installation this water heater must be braced, anchored,
or strapped to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may be
obtained from California Office of the State Architect, 400 P Street,
Sacramento, CA 95814.
1. Read the “General Safety” section, page 3 of this manual first and
then the entire manual carefully. If you don’t follow the safety rules,
the water heater will not operate properly. It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired water heater. It also contains warnings
throughout the manual that you must read and be aware of. All
warnings and all instructions are essential to the proper operation
of the water heater and your safety. Since we cannot put everything
on the first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
7. Complies with SCAQMD rule #1146.2 and districts having
equivalent NOx requirements.
4
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
G
H
Vent Pipe
Drafthood
Anode
Hot Water Outlet
Outlet
Insulation
Gas Supply
Manual Gas Shut-off Valve
I
J
K
L
M
N
O
P
Ground Joint Union
Sediment Trap
Inner Door
Outer door
Union
Inlet Water Shut-off Valve
Cold Water Inlet
Inlet Dip Tube
Q
R
S
T
U
V
W
X
Temperature-Pressure Relief Valve
Rating Plate
Flue Baffle(s)
Gas Control Valve/Thermostat
Drain Valve
Pilot and Main Burner
Flue
Metal Drain Pan
(T) GAS CONTROL VALVE/THERMOSTAT
GAS CONTROL KNOB
* INSTALL IN ACCORDANCE WITH
LOCAL CODES.
* SEDIMENT TRAP AS REQUIRED
BY LOCAL CODES.
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
A
**INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER
HEATER IS INSTALLED IN A
CLOSED WATER SYSTEM
B
S
D E
M
N
O
C
WATER TEMPERATURE
(ADJUSTING DIAL)
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
Q
P
F
G
H
R
I
T
U
J
6” MAXIMUM
AIR GAP
K
X
W
V
(V) PILOT & MAIN BURNER - NATURAL GAS
L
MAIN BURNER
**CLOSED WATER SYSTEMS ARE THOSE
WITH BACK FLOW PREVENTION DEVICES
INSTALLED IN THE WATER SERVICE LINE.
FIGURE 1.
5
PILOT
TYPICAL INSTALLATION
MIXING VALVE USAGE
FIGURE 2.
This water heater has been design certified as complying with ANSI
Z21.10.3 current edition for water heaters and is considered suitable
for:
Water (Potable) Heating and Space Heating: All models are
considered suitable for combination water (potable) heating and
space heating. Not suitable for space heating applications only.
Water
Temperature
°F (°C)
Time for 1st
Degree Burn
(Less Severe Burns)
110 (43.3)
(normal shower temp.)
116 ( 46.6)
(pain threshold)
116 ( 46.6)
35 minutes
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
instantaneous
1 second
154 (67.7)
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to
a temperature which will satisfy space heating, clothes washing, dish
washing, and other sanitizing needs can scald and permanently injure
you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly, children,
the infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is a local
code requiring a certain temperature water at the hot water tap, then
6
LOCATING THE NEW WATER HEATER
you must take special precautions. In addition to using the lowest
possible temperature setting that satisfies your hot water needs,
a means such as a *Mixing Valve should be used at the hot water
taps used by these people or at the water heater. Mixing valves are
available at plumbing supply or hardware stores. Consult a qualified
installer or service agency. Follow mixing valve manufacturer’s
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the “Temperature Regulation” section
in this manual, see Figures 15 and 16.
FACTS TO CONSIDER ABOUT THE LOCATION
The water supply pressure should not exceed 80 psi (551.58 kPa).
If this occours, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed on the
supply to the entire house in order to maintain equal hot and cold
water pressures.
Carefully choose an indoor location for the new water heater, because
the placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
appliance. This water heater is not for use in manufactured
(mobile) homes or outdoor installation.
Whether replacing an old water heater or putting the water heater
in a new location, the following critical points must be observed:
1. Select a location indoors as close as practical to the gas vent or
chimney to which the water heater vent is going to be connected,
and as centralized with the water piping system as possible.
2. Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES,
STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as
gasoline, solvents, propane [LP or butane, etc.] and other substances
such as adhesives, etc.) emit flammable vapors which can be ignited
by a gas water heater’s pilot light or main burner. The resulting
flashback and fire can cause death or serious burns to anyone in
the area, as well as property damage. If installation in such areas
is your only option, then the installation must be accomplished in a
way that the pilot flame and main burner flame are elevated from
the floor at least 18 inches. While this may reduce the chances of
flammable vapors, from a floor spill being ignited, gasoline and other
flammable substances should never be stored or used in the same
room or area containing a gas water heater or other open flame or
spark producing appliance. NOTE: Flammable vapors may be drawn
by air currents from other areas of the structure to the appliance.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install
the water heater in an attic or upper floor. When such locations cannot
be avoided, a suitable metal drain pan should be installed under the
water heater. Metal drain pans are available at your local hardware
store. Such a metal drain pan must have a minimum length and
width of at least 2” (51 mm) greater than the water heater dimensions
and must be piped to an adequate drain. The pan must not restrict
combustion air flow.
Water heater life depends upon water quality, water pressure and
the environment in which the water heater is installed. Water heaters
are sometimes installed in locations where leakage may result in
property damage, even with the use of a drain pan piped to a drain.
However, unanticipated damage can be reduced or prevented by
a leak detector or water shut-off device used in conjunction with a
piped drain pan. These devices are available from some plumbing
supply wholesalers and retailers, and detect and react to leakage
in various ways:
•
•
•
•
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
Sensors mounted in the drain pan that trigger an alarm or turn off
the incoming water to the water heater when leakage is detected.
Sensors mounted in the drain pan that turn off the water supply
to the entire home when water is detected in the drain pan.
Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
Devices that will turn off the gas supply to a gas water heater
while at the same time shutting off its water supply.
7
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
appliance extending beyond the full width and depth of the appliance
by at least 3” (76.2 mm) in any direction, or if the appliance is installed
in an alcove or closet, the entire floor must be covered by the panel.
Failure to heed this warning may result in a fire hazard.
FIGURE 4.
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry cleaning
equipment, it is imperative that the water heater or water heaters
be installed so that combustion and ventilation air be taken from
outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly flammable in many cases, will also change to corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
Minimum clearances between the water heater and combustible
materials are 0 inch at the sides and rear, 4” (102 mm) at the front,
and 6” (153 mm) from the vent pipe. Clearance from the top of the
jacket is 12” (305 mm) on most models. Note that a lesser dimension
may be allowed on some models, refer to the label attached adjacent
to the gas control valve on the water heater, see Figure 3.
INSULATION BLANKETS
FIGURE 3.
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with these products. The
purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your water heater meets or
exceeds the EPACT standards with respect to insulation and standby
loss requirements, making an insulation blanket unnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the draft hood.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Do not install in a confined area such as a closet,
unless you provide air as shown in the “Locating The New Water Heater”
section. Never obstruct the flow of ventilation air. If you have any doubts
or questions at all, call your gas supplier. Failure to provide the proper
amount of combustion air can result in a fire or explosion and cause
death, serious bodily injury, or property damage.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
• Do not allow insulation to come within 2” (50.8 mm) of the floor to
prevent blockage of combustion air flow to the burner.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air flow.
8
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 m3 per kW) of the aggregate
input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to provide
air for combustion, ventilation and dilution of flue gases. However, in
buildings of tight construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), additional air may need to
be provided using the methods described in “Combustion Air and
Ventilation for Appliances Located in Confined Spaces.”
FIGURE 6.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SPACES
2. When communicating with the outdoors through vertical ducts,
each opening must have a minimum free area of 1 square inch
per 4,000 Btu per hour (5.5 cm2/kW) of total input rating of all
equipment in the enclosure, see Figure 7.
CONFINED SPACE is a space whose volume is less than 50 cubic
feet per 1,000 Btu per hour (4.8 m3 per kW) of the aggregate input
rating of all appliances installed in that space.
3. When communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 square inch
per 2,000 Btu per hour (11 cm2/kW)) of total input rating of all
equipment in the enclosure, see Figure 8.
A. ALL AIR FROM INSIDE BUILDINGS: (See Figures 4 and 5)
The confined space shall be provided with two permanent openings
communicating directly with an additional room(s) of sufficient
volume so that the combined volume of all spaces meets the
criteria for an unconfined space. The total input of all gas utilization
equipment installed in the combined space shall be considered in
making this determination. Each opening shall have a minimum
free area of one square inch per 1,000 Btu per hour (22 cm2/kW) of
the total input rating of all gas utilization equipment in the confined
space, but not less than 100 square inches (645 cm2). One opening
shall commence within 12” (30 cm) of the top and one commencing
within 12” (30 cm) of the bottom of the enclosures.
FIGURE 7.
4. When ducts are used, they shall be of the same cross-sectional
area as the free area of the openings to which they connect. The
minimum short side dimension of rectangular air ducts shall not
be less than 3” (76.2 mm), see Figure 8.
5. Alternatively a single permanent opening may be used when
communicating directly with the outdoors, or with spaces that
freely communicate with the outdoors. The opening shall have a
minimum free area of 1 square inch per 3,000 BTU per hour (8.3
cm2/kW) of total input rating of all equipment in enclosure. See
Figure 8A.
FIGURE 5.
B. ALL AIR FROM OUTDOORS: (See Figures 6, 7 and 8)
The confined space shall be provided with two permanent
openings, one commencing within 12” (30 cm) of the top and one
commencing within 12” (30 cm) from the bottom of the enclosure. The
openings shall communicate directly, or by ducts, with the outdoors
or spaces (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall
have a minimum free area of 1 square inch per 4,000 Btu per hour
(5.5 cm2/kW) of total input rating of all equipment in the enclosure,
see Figure 6.
FIGURE 8.
9
INSTALLING THE NEW WATER HEATER
6. Louvers and Grilles: In calculating free area, consideration shall be given
to the blocking effect of louvers, grilles or screens protecting openings.
Screens used shall not be smaller than 1/4 inch (6.4 mm) mesh. If the
free area through a design of louver or grille is known, it should be used
in calculating the size opening required to provide the free area specified.
If the design and free area is not known, it may be assumed that wood
louvers will be 20-25 percent free area and metal louvers and grilles will
have 60-75 percent free area. Louvers and grilles shall be fixed in the
open position or interlocked with the equipment so that they are opened
automatically during equipment operation.
7. Special Conditions Created by Mechanical Exhausting or Fireplaces:
operation of exhaust fans, ventilation systems, clothes dryers or
fireplaces may create conditions requiring special attention to avoid
unsatisfactory operation of installed gas utilization equipment.
This water heater shall not be connected to any heating systems or
component(s) used with a non-potable
These water heaters cannot be used in space heating applications only..
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall not be
introduced into this system.
When the system requires water for space heating at temperatures
higher than required for domestic water purposes, a mixing valve must
be installed. Please refer to Figure 2 for suggested piping arrangement.
FIGURE 8A.
WATER PIPING
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among others,
have installed devices such as pressure reducing valves, check valves,
back flow preventers, etc. to control these types of problems. When
these devices are not equipped with an internal by-pass, and no other
measures are taken, the devices cause the water system to be closed.
As water is heated, it expands (thermal expansion) and closed systems
do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of the
water heater’s temperature-pressure relief valve is reached, the valve
will relieve the excess pressure. The temperature-pressure relief
valve is not intended for the constant relief of thermal expansion.
This is an unacceptable condition and must be corrected.
It is recommended that any devices installed which could create a
closed system have a by-pass and/or the system have an expansion
tank to relieve the pressure built by thermal expansion in the water
system. Expansion tanks are available for ordering through a local
plumbing contractor. Refer to the “Thermal Expansion” section in this
manual and/or contact the local water supplier and/or a service agency
for assistance in controlling these situations.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated
to a temperature which will satisfy space heating, clothes washing,
dish washing, cleaning and other sanitizing needs can scald and
permanently injure you upon contact. Some people are more likely
to be permanently injured by hot water than others. These include
the elderly, children, the infirm, or physically/mentally handicapped.
If anyone using hot water in your home fits into one of these groups
or if there is a local code or state law requiring a certain temperature
water at the hot water tap, then you must take special precautions. In
addition to using the lowest possible temperature setting that satisfies
your hot water needs, a means such as a *mixing valve should be used
at the hot water taps used by these people or at the water heater, see
Figure 2. Valves for reducing point of use temperature by mixing cold
and hot water are also available. Consult a qualified installer or
service agency. Follow manufacturer’s instructions for installation
of the valves. Before changing the factory setting on the thermostat,
read the “Temperature Regulation” section in this manual.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe.
10
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
The valve is certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment of
materials as meeting the requirements for Relief Valves for Hot Water
Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements
of ASME.
If replaced, the valve must meet the requirements of local codes, but
not less than a combination temperature and pressure relief valve
certified as indicated in the above paragraph.
The valve must be marked with a maximum set pressure not to
exceed the marked maximum working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity not less than the water
heater input rate as shown on the model rating plate.
For safe operation of the water heater, the relief valve must not be
removed from its designated opening nor plugged.
The temperature-pressure relief valve must be installed directly into
the fitting of the water heater designed for the relief valve. Position
the valve downward and provide tubing so that any discharge will exit
only within 6” (153 mm) above, or at any distance below the structural
floor. Be certain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in size under
any circumstances. Excessive length, over 30’ (9.14 m), or use of
more than four elbows can cause restriction and reduce the discharge
capacity of the valve, see Figure 10.
No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect tubing directly to discharge drain unless
a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge water
in quantities should circumstances demand. If the discharge pipe is
not connected to a drain or other suitable means, the water flow may
cause property damage.
FIGURE 9.
Figure 9 shows the typical attachment of the water piping to the water
heater. The water heater is equipped with 1” NPT threaded nipple
(75 gallon models) or 1.25” NPT threaded nipple (100 gallon models)
water connections.
The Discharge Pipe:
• Should not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
• Should not be plugged or blocked.
• Should be of material listed for hot water distribution.
• Should be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain or
external to the building. In cold climates, it is recommended that
the discharge pipe be terminated at an adequate drain inside the
building.
• Should not have any valve between the relief valve and tank.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the cold water inlet connection. Do not
solder the cold water supply line directly to the cold water inlet.
It will harm the dip tube and damage the tank.
TEMPERATURE-PRESSURE RELIEF VALVE
11
FILLING THE WATER HEATER
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
To fill the water heater with water:
The temperature-pressure relief valve must be manually operated at
least once a year. Caution should be taken to ensure that (1) no one
is in front of or around the outlet of the temperature-pressure relief
valve discharge line, and (2) the water manually discharged will not
cause any bodily injury or property damage because the water may
be extremely hot.
1. Close the water heater drain valve by turning the handle to the
right (clockwise). The drain valve is on the lower front of the water
heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when
the water heater is in use.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.
3. To insure complete filling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow is
obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as
needed.
VENTING
FIGURE 10.
VENT DAMPERS - Any vent damper, whether it is operated thermally
or otherwise must be removed if its use inhibits proper drafting of
the water heater.
Thermally Operated Vent Dampers: this gas-fired water heater
has a thermal efficiency at or above 80% which may produce a
relatively low flue gas temperature. Such temperatures may not
be high enough to properly open thermally operated vent dampers.
This would cause spillage of the flue gases and may cause carbon
monoxide poisoning.
Vent dampers must bear evidence of certification as complying with
the current edition of the American National Standard ANSI Z21.66
12
CGA 6.14 (covering electrically and mechanically actuated vent
dampers). Before installation of any vent damper, consult the local
gas utility for further information.
To ensure proper venting of this gas-fired water heater, the correct
vent pipe diameter must be utilized. Any additions or deletions of
other gas appliances on a common vent with this water heater may
adversely affect the operation of the water heater. Consult your gas
supplier if any such changes are planned.
For proper venting in certain installations, a larger diameter vent pipe
may be necessary. Consult your gas supplier to aid you in determining
the proper venting for your water heater from the vent tables in the
current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54.
FIGURE 12.
There must be a minimum of 6” (153 mm) clearance between single
wall vent pipe and any combustible material. Fill and seal any
clearance between single wall vent pipe and combustible surfaces
with mortar mix, cement, or other noncombustible substance. For
other than single wall, follow vent pipe manufacturer’s clearance
specifications. To insure a tight fit of the vent pipe in a brick chimney,
seal around the vent pipe with mortar mix cement.
Periodically check the venting system for signs of obstruction or
deterioration and replace if needed.
The combustion and ventilation air flow must not be obstructed.
The water heater with draft hood installed must be connected to a
chimney or listed vent pipe system, which terminates to the outdoors.
Never operate the water heater unless it is vented to the outdoors
and has adequate air supply to avoid risks of improper operation,
explosion or asphyxiation.
•
Place the draft hood legs in the receiving holes on the top of the
water heater. The legs will snap in the holes to give a tight fit.
Secure draft hood with the supplied screws.
•
Place the vent pipe over the draft hood. With the vent pipe in position,
drill a small hole through both the vent pipe and draft hood. Secure
them together with a sheet metal screw.
Failure to have required clearances between vent piping and
combustible material will result in a fire hazard.
Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
DRAFT HOOD INSTALLATION
Align the legs of the draft hood with the slots provided. Insert the
legs and secure the draft hood to the water heater’s top with the
four screws provided as shown in Figure 11. 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 the water heater.
SHEET METAL SCREWS (FOUR PROVIDED)
DRAFT HOOD
LEGS
LEGS
SLOT
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
SLOT
JACKET TOP
INSTALL THE DRAFT HOOD WITH
THE FOUR SCREWS PROVIDED.
FIGURE 11.
The vent pipe from the water heater must be no less than the diameter
of the draft hood outlet on the water heater and must slope upward
at least 1/4 inch per linear foot (21 mm per meter), see Figure 12.
All vent gases must be completely vented to the outdoors of the
structure (dwelling). Install only the draft hood provided with the
new water heater and no other draft hood.
Vent pipes must be secured at each joint with sheet metal screws.
13
GAS PIPING
Water heaters covered in this manual have been tested and approved
for installation at elevations up to 7,700 feet (2,347 m) above sea
level. For installation above 7,700 feet (2,347 m), the water heater’s
Btu input should be reduced at the rate of 4 percent for each 1,000
feet (305 m) above sea level which requires replacement of the
burner orifice in accordance with the National Fuel Gas Code
ANSI Z223.1/NFPA 54. Contact your local gas supplier for further
information.
Make sure the gas supplied is the same type listed on the model
rating plate. The inlet gas pressure must not exceed 14 inch water
column (2.6 kPa) for natural gas. The minimum inlet gas pressure
shown on the rating plate is that which will permit firing at rated input.
If the gas control valve is subjected to pressures exceeding 1/2 pound
per square inch (3.5 kPa), the damage to the gas control valve could
result in a fire or explosion from leaking gas.
Failure to replace the standard orifice with the proper high altitude
orifice when installed at elevations above 7,700 feet (2,347 m)
could result in improper and inefficient operation of the appliance,
producing carbon monoxide gas in excess of the safe limits. This
could result in serious injury or death. Contact your local gas supplier
for any specific changes that may be required in your area.
If the main gas line shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code ANSI Z223.1/NFPA
54 and your gas supplier concerning pipe size.
There must be:
•
A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
•
A sediment trap ahead of the gas control valve to help prevent
dirt and foreign materials from entering the gas control valve.
•
A flexible gas connector or a ground joint union between the shut
off valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the water
heater. Use a soapy water solution, not a match or open flame.
Rinse off soapy solution and wipe dry.
The minimum inlet gas pressure shown on the rating plate is that
which will permit firing at the rated input.
14
SEDIMENT TRAP
FIGURE 13. GAS PIPING WITH FLEXIBLE CONNECTOR.
Use pipe joint compound or teflon tape marked as being resistant
to the action of petroleum gases.
The water heater and its gas connection must be leak tested before
placing the appliance in operation.
The water heater and its individual shut-off valve shall be
disconnected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of 1/2 pound per
square inch (3.5 kPa). It shall be isolated from the gas supply piping
system by closing its individual manual shut-off valve during any
pressure testing of the gas supply piping system at test pressures
equal to or less than 1/2 pound per square inch (3.5 kPa).
SEDIMENT TRAP
FIGURE 14. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
Connecting the gas piping to the gas control valve of the water
heater can be accomplished by either of the two methods shown in
Figures 13 and 14.
SEDIMENT TRAPS
A sediment trap shall be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The
sediment trap shall be either a tee fitting with a capped nipple in the
bottom outlet or other device recognized as an effective sediment
trap. If a tee fitting is used, it shall be installed in conformance
with one of the methods of installation shown in Figures 13 and 14.
Contaminants in the gas lines may cause improper operation of the
gas control valve that may result in fire or explosion. Before attaching
the gas line be sure that all gas pipe is clean on the inside. To trap
any dirt or foreign material in the gas supply line, a sediment trap must
be incorporated in the piping. The sediment trap must be readily
accessible. Install in accordance with the “Gas Piping” section. Refer
to the current edition of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54.
15
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.
FLAMMABLE
BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES
A. This appliance has a pilot which is lit by a piezo-
If you cannot reach your gas supplier, call the fire
department.
electric spark gas ignition system. 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.
C. Use only your hand to push down or turn the gas
control knob. Never use tools. If the knob will
not push down or turn by hand, don't try to repair
it, call a qualified service technician. Force or
attempted repair may result in fire or explosion.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not use any
phone in your building.
D. Do not use this appliance if any part has been
under water. Immediately contact a qualified
installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit!
It must be replaced!
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
LIGHTING INSTRUCTIONS
GAS CONTROL
KNOB
FIGURE 'A'
FIGURE 'B'
THERMOCOUPLE &
BURNER TUBE PILOT
FIGURE 'C'
PIL0T
OFF
OFF
OFF
PILOT
MAIN BURNER
ON
PILOT
ON
ON
PIEZO
IGNITOR
GENERATOR
PILOT
CAUTION:
RISK OF SCALDING
INCREASES WITH
HOTTER WATER
GAS CONTROL
THERMOSTAT
DIAL
"OFF" POSITION
"PILOT" POSITION
TOP KNOB
STOP! Read the safety information
above on this label.
Set
the
thermostat
to the lowest setting by turning
2.
thermostat dial fully clockwise
until it stops.
3. Push the gas control knob down slightly and turn
clockwise
to "OFF". SEE FIGURE 'A'.
NOTE: Knob cannot be turned from "PILOT" to "OFF"
unless knob is pushed down slightly. Do not force.
4. Remove the outer door located below
the gas control unit.
5. Wait five (5) minutes to clear out any gas. If you
then smell gas,
STOP! Follow "B" in the
safety information
above on this label. If
you do not smell gas,
go to next step.
6. This unit is equipped with a push button pilot ignitor,
which is used to light the pilot. Locate the ignitor
on the gas control.
7. Turn gas control knob counterclockwise
to "PILOT". SEE FIGURE 'B'.
8. The pilot is located on the left front corner of the burner.
It can be located by looking through the sight glass to
the left while pressing the piezo ignitor button
several times. Look for a spark at the pilot location .
1.
"ON" POSITION
FIGURE "D"
9. Once the pilot has been found, push the gas knob
all the way down. Immediately press the pilot ignitor
button rapidly (4) to (5) times. If the pilot does not
light, repeat step (3) through (9).
10. Continue to hold the gas control knob down for about
one (1) minute after the pilot is lit. Release the gas
control knob and it will pop back up. Pilot should
remain lit. If it goes out , repeat step (3) through (9).
It may take several minutes for air to clear the lines
before the pilot will light.
If knob does not pop up when released, stop and
immediately call your service technician or gas
supplier.
If the pilot will not stay lit after several tries,
turn the gas control knob clockwise to 'OFF' and
call your service technician or gas supplier.
SEE FIGURE 'A'
11. Replace the outer door.
12. At arm's length away, turn gas control knob
counterclockwise
to 'ON'. SEE FIGURE 'C'.
13. Set thermostat to desired setting.
DANGER: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
TO TURN OFF GAS TO APPLIANCE
1. S e t t h e t h e r m o s t a t t o l o w e s t s e t t i n g .
2. Push gas control knob down slightly and turn clockwise to 'OFF'. Do not force. SEE FIGURE 'A'.
16
TEMPERATURE REGULATION
Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended
in a bathtub or shower.
Short repeated heating cycles caused by small hot water uses can
cause temperatures at the point of use to exceed the thermostat setting
by up to 30°F (16.7°C). If you experience this type of use you should
consider using lower temperature settings to reduce scald hazards.
NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is
recommended by most dishwasher manufacturers.
Any water heater’s intended purpose is to heat water. Hot water is
needed for cleansing, cleaning, and sanitizing (bodies, dishes, clothing).
Untempered hot water can present a scald hazard. Depending on the
time element, and the people involved (adults, children, elderly, infirm,
etc.) scalding may occur at different temperatures.
The thermostat of this water heater has been factory set at its lowest
position (PILOT LIGHTING). It is adjustable and must be reset to
the desired temperature setting to reduce the risk of scald injury.
The mark ( ) indicative of approximately 120°F (49°C) is preferred
starting point. Some States have a requirement for a lower setting.
) to decrease the
Turn the water temperature dial clockwise (
temperature, or counterclockwise (
) to increase the temperature.
Should overheating occur or the gas supply fail to shut off, turn off
the manual gas control valve to the appliance.
HOTTER WATER CAN SCALD: Water heaters are intended to
produce hot water. Water heated to a temperature which will satisfy
space heating, clothes washing, dish washing, and other sanitizing
needs can scald and permanently injure you upon contact. Some
people are more likely to be permanently injured by hot water than
others. These include the elderly, children, the infirm, or physically/
mentally handicapped. If anyone using hot water in your home
fits into one of these groups or if there is a local code or state law
requiring a certain temperature water at the hot water tap, then you
must take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means such
as a mixing valve should be used at the hot water taps used by these
people or at the water heater. Mixing valves are available at plumbing
supply or hardware stores, see Figure 2. Follow manufacturer’s
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the “Temperature Regulation” section
in this manual, see Figures 15 and 16.
FIGURE 15.
Temperature
Time to Produce 2nd & 3rd
Settings
Degree Burns on Adult Skin
VERY HOT= approx. 160°F (71°C)
About 1/2 second
C = approx. 150°F (66°C)
About 1-1/2 seconds
B = approx. 140°F (60°C)
Less than 5 seconds
A = approx. 130°F (54°C)
About 30 seconds
= approx. 120°F (49°C)
More than 5 minutes
LOW = approx. 80°F (27°C)
----------------
FIGURE 16.
FOR YOUR INFORMATION
START UP CONDITIONS
form while the burner is on. A water heater may appear to be leaking
when in fact the water is condensation. This usually happens when:
DRAFT HOOD OPERATION
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters, particularly
high efficiency models where flue temperatures are lower.
c. Large amounts of hot water are used in a short time and the refill
water in the tank is very cold.
Check draft hood operation by performing a worst case
depressurization of the building. With all doors and windows closed,
and with all air handling equipment and exhaust fans operating such
as furnaces, clothes dryers, range hoods and bathroom fans, a match
flame should still be drawn into the draft hood of the water heater with
its burner firing. If the flame is not drawn toward the draft hood, shut
off water heater and make necessary air supply changes to correct.
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the burner
or other hot surfaces to produce a “sizzling” or “frying” noise.
CONDENSATION
Excessive condensation can cause pilot outage due to water running
down the flue tube onto the main burner and putting out the pilot.
Whenever the water heater is filled with cold water, some condensate will
17
Because of the suddenness and amount of water, condensation
water may be diagnosed as a “tank leak”. After the water in the
tank warms up (about 1-2 hours), the condition should disappear.
OPERATIONAL CONDITIONS
SMELLY WATER
In each water heater there is installed at least one anode rod (see
parts section) for corrosion protection of the tank. 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” in the hot water. This odor is derived from
hydrogen sulfide gas dissolved in the water. The smell is the result
of four factors which must all be present for the odor to develop:
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation. The water
heater must be sized properly to meet the family’s demands for hot
water including dishwashers, washing machines and shower heads.
Excessive condensation may be noticed during the winter and early
spring months when incoming water temperatures are at their lowest.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated within the
water heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosion protective action of the anode.
Good venting is essential for a gas fired water heater to operate properly
as well as to carry away products of combustion and water vapor.
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material, and
then chlorinating the water heater tank and all hot water lines. Contact
the local water heater supplier or service agency for further information
concerning an Anode Replacement Kit and this chlorination treatment.
THERMAL EXPANSION
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that chlorination or
aeration of the water supply be considered to eliminate the water
problem.
Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
As water is heated, it expands (thermal expansion). In a closed
system, the volume of water will increase. As the volume of water
increases, there will be a corresponding increase in water pressure
due to thermal expansion. Thermal expansion can cause premature
tank failure (leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause intermittent
temperature-pressure relief valve operation: water discharged from
the valve due to excessive pressure build up. The temperaturepressure relief valve is not intended for the constant relief of thermal
expansion. This condition is not covered under the limited warranty.
A properly-sized thermal expansion tank should be installed on all
closed systems to control the harmful effects of thermal expansion.
Contact a plumbing service agency or your retail supplier reguarding
the installation of a thermal expansion tank.
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances which are
connected to the hot water system are used (such as a dishwasher
or washing machine). If hydrogen gas is present, there will probably
be an unusual sound similar to air escaping through the pipe as the
hot water faucet is opened. There must be no smoking or open flame
near the faucet at the time it is open.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered normal.
See “Condensation” in this section.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
This water heater is equipped with an automatic gas Shut-off system.
This system works when high water temperatures are present. The
high temperature Shut-off is built into the gas control valve. It is
non-resettable. If the high temperature Shut-off activates, the gas
control valve must be replaced. Contact your gas supplier or service
agency. Turn “OFF” the entire gas supply to the water heater.
18
PERIODIC MAINTENANCE
You should check for sooting. Soot is not normal and will impair
proper combustion.
VENTING SYSTEM INSPECTION
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until repairs
are made, because failure to correct the cause of the sooting can
result in a fire causing death, serious injury, or property damage.
Flame Characteristics
Correct Flame
Red/Orange
FIGURE 17
BURNER FLAMES
At least once a year a visual inspection should be made of the venting
system. You should look for:
Inspect burner flames through viewport. Flames should be very
small with a blue haze and small amounts of yellow or orange at
the edges. After several minutes of operation the burner screen
may glow red. If large flames are observed at anytime, shut off
unit and call a qualified person.
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
BURNER CLEANING
2. Damage or deterioration which could cause improper venting or
leakage of combustion products.
3. Rusted flakes around top of water heater.
If inspection of the burner shows that cleaning is required, turn the
gas control knob clockwise (
) to the “OFF” position, depressing
slightly.
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gases which could cause deadly asphyxiation.
NOTE: The knob cannot be turned from “PILOT” to “OFF” unless
knob is depressed slightly. DO NOT FORCE.
NATURAL GAS BURNER (ULTRA LOW NOX)
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Check the burner to see if it’s dirty or clogged. The burner may be
cleaned with a soft paint brush, see Figure 18. Do not use a wire
brush or any tool that may damage the burner screen. Important: Do
not use the burner if the burner screen is damaged. NOTE: Damage
may be rips or holes in the burner screen. Discoloration is normal.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
Natural Gas (Low Nox)
Burner Door Assembly
Use brush on this surface
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to
correct the problem and clean or replace the flue and venting before
resuming operation of the water heater.
Burner
Pilot Assembly
BURNER INSPECTION
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a qualified installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit! It must be replaced!
At least once a year a visual inspection should be made of the main
burner and pilot burner, see Figure 17.
FIGURE 18
19
The anode rod should be removed from the water heater tank every
3 years for inspection. NOTE: artificially softened water requires
the anode rod to be inspected annually.
HOUSEKEEPING
The following are typical (but not all) signs of a depleted anode rod:
• The majority of the rods diameter is less than 3/8”.
• Signifi cant sections of the support wire (approx. 1/3 or more of
the anode rod’s length) are visible.
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
FIGURE 19
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.
INSTALLED IN SUITABLE AREA: To insure sufficient ventilation
and combustion air supply, proper clearances from the water heater
must be maintained. See “Locating the New Water Heater” section.
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent to
the water heater which can cause a fire.
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.
ANODE ROD INSPECTION
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 Tefl on® tape or approved pipe sealant on threads and
install new anode rod.
6. Turn on water supply and open a 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 in this manual. See the
Repair Parts Illustration for anode rod location.
Each water heater contains at least one anode rod, which will
slowly deplete (due to electrolysis) prolonging the life of the water
heater by protecting the glass-lined tank from corrosion. Adverse
water quality, hotter water temperatures, high hot water usage,
and water softening methods can increase the rate of anode rod
depletion. Once the anode rod is depleted, the tank will start to
corrode, eventually developing a leak.
Certain water conditions will cause a reaction between the anode
rod and the water. The most common complaint associated with
the anode rod is a “rotten egg smell” produced from the presence
of hydrogen sulfi de gas dissolved in the water. IMPORTANT: Do
not remove this rod permanently as it will void any warranties. A
special anode rod may be available if water odor or discoloration
occurs. NOTE: This rod may reduce but not eliminate water odor
problems. The water supply system may require special fi ltration
equipment from a water conditioning company to successfully
eliminate all water odor problems.
Artifi cially 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.
20
4. Connect a hose to the drain valve and terminate it to an adequate
drain or external to the building.
TEMPERATURE-PRESSURE
RELIEF VALVE OPERATION
5. Open the water heater drain valve and allow all of 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 in this manual.
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 refi lling the tank and
should not be confused with a tank leak.
The temperature-pressure relief valve must be manually operated
at least once a year.
SERVICE
When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of the
temperature-pressure relief valve discharge line, and (2) that the
water discharge will not cause any property damage, as the water
may be extremely hot, see Figure 20
Before calling for repair service, read the “Start Up Conditions” and
“Operational Conditions” found in the “For Your Information” section
of this manual.
If a condition persists or you are uncertain about the operation of the
water heater contact a service agency. If you are not thoroughly familiar
with gas codes, your water heater, and safety practices, contact your
gas supplier or qualified installer to check the water heater.
Use the ”Leakage Checkpoints” guide to check a “Leaking”
water heater. Many suspected “Leakers” are not leaking tanks. Often
the source of the water can be found and corrected.
Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
Never use this water heater unless it is completely filled with water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
FIGURE 20
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater, follow the draining instructions, and replace
the temperature-pressure relief valve with a new one.
If the temperature-pressure relief valve on the appliance weeps
or discharges periodically, this may be due to thermal expansion.
You may have a check valve installed in the water line or a water
meter with a check valve. Consult your local water supplier or
service agency for further information. Do not plug the temperaturepressure relief valve.
DRAINING AND FLUSHING
It is recommended that the tank be drained and fl ushed 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:
1. Turn off the gas to the water heater at the manual gas shut-off
valve.
2. Open a nearby hot water faucet until the water is no longer hot.
3. Close the cold water inlet valve.
21
REPLACING PARTS
REPLACEMENT PARTS
Natural Gas Burner (Ultra Low Nox)
IMPORTANT: The following maintenance procedures should be
performed by a qualified person.
Check the burner screen to see if it is dirty or clogged. The burner
screen may be cleaned with a soft paint brush. Do not use a wire
brush or any tool that might damage the burner screen.
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.
2.
3.
!MPORTANT: Do not use the burner if the burner screen is damaged.
NOTE: Damage would be rips or holes in the burner screen.
Discoloration is normal.
model, serial and product number
item number
parts description
Natural Gas (Low Nox)
Burner Door Assembly
Use brush on this surface
See “Repair Parts” section for a list of available repair parts.
Removing the Burner Door Assembly
1.
Turn off the gas to the water heater at the manual gas shut-off
valve (Figure 1).
2.
Turn the gas control knob on the combination gas control valve/
thermostat clockwise to the off position.
3.
Remove the outer door.
4.
Remove the four screws securing the burner door assembly
to the combustion chamber (Figure 21).
5.
Disconnect the thermocouple (right-hand thread), pilot tube,
the ignitor wire from the ignitor button, and manifold tube at
the thermostat (Figure 21).
6.
Grasp the manifold tube and push down slightly to free the
manifold tube, pilot tube and thermocouple.
7.
Carefully remove the burner door assembly from the
combustion chamber. Be careful not to damage the burner
screen or pilot assembly.
Ignitor Wire
Pilot Tube
Burner
Pilot Assembly
FIGURE 22
Replacing the Pilot Assembly:
1.
Follow the instructions in “Removing the Burner Door Assembly”
section to remove the assembly.
2.
Remove the retainer clip securing the two piece wire connector
to the burner door assembly. (Note the orientation of the retainer
clip). Insert the tip of a large flathead screwdriver between the
clip and the top of the two piece wire connector. Carefully rotate
the screwdriver to raise the clip. It may be necessary to remove
the connector one side at a time.
3.
Remove the screw securing the pilot assembly to the burner and
keep it for reuse later.
4.
Remove the old pilot assembly (including the ignitor wire) from
the burner door assembly.
5.
Use the screw removed previously step to secure the new pilot
assembly to the burner.
6.
Insert the ignitor wire, pilot tube and thermocouple through the
hole in the burner door.
7.
R e i n s t a l l t h e t w o p i e c e w i r e c o n n e c t o r.
NOTE: The pilot tube must be at the top followed by the ignitor
wire then the thermocouple.
8.
Follow the instructions in “Replacing the Burner Door Assembly”
section to reinstall the assembly.
Manifold Tube
Thermocouple
Screws (4)
FIGURE 21
22
Replacing the Burner Door Assembly
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 electrode should be centered
between the pilot and thermocouple (Figure 23). Use only factory
authorized piozoelectric igniter parts for replacement.
WARNING
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shut-off valve.
Watch the electrode tip while activating the igniter. A visible spark
should jump from the electrode. To avoid shock, do not touch the
burner or any metal part on the pilot or pilot assembly. If no spark is
visible, check the wire connections and make sure the electrode is
not broken. Replace the electrode if defective. Note: The electrode is
part of the pilot assembly and cannot be replaced seperately. Dirt and
rust on the pilot or electrode tip can prevent the ignitor 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
emory cloth or fine grit sandpaper.
Explosion Hazard
Tighten burner door screws
securely.
Remove any fiberglass between gasket
and combustion chamber.
Replace viewport if glass is missing or
damaged.
Thermocouple
Replace manifold component block if missing
or removed.
Electrode
Replace door gasket if damaged.
Pilot
Failure to follow these instructions can
result in death, explosion, or fire.
1.
Check the door gasket for damage or imbedded debris prior
to installation.
2.
Inspect the viewport for damage and replace as required.
3.
Insert the burner door assembly into the combustion
chamber and slide it completely forward.
Note: When inserting the burner door assembly, tip the burner
end up slightly to ensure it engages with the burner bracket.
4.
Inspect the door gasket and make sure there is no fiberglass
insulation between the door gasket and the combustion
chamber.
5.
Replace the four screws securing the burner door assembly
to the combustion chamber and tighten securely. Once the
burner door assembly is tightened, visually inspect the door
gasket between the burner door assembly and the combustion
chamber for spaces or gaps that would prevent a seal.
IMPORTANT: Do not operate the water heater if the door gasket
does not create a seal between the burner door assembly and
the combustion chamber.
6.
Reconnect the manifold tubing, pilot tubing and thermocouple
to the thermostat. Do not cross-thread or apply any thread
sealant to these fittings. The thermocouple nut should be
started and turned all the way by hand. An additional 1/2 - 3/4
turn with a 7/16” open end wrench will then be sufficient to seat
the lockwasher.
7.
Reconnect the ignitor wire.
8.
Turn the gas on and refer to the “Lighting Instructions”
9.
Check for leaks by brushing on an approved leak detection
solution. Bubbles will show a leak. Correct any leak found.
FIGURE 23
10. Replace the outer door.
23
Removing and Replacing the Gas Control Valve/
Thermostat:
6.
IMPORTANT: The gas control valve/thermostat is a standard valve
with a right hand thread thermocouple. Use only factory authorized
replacement parts.
To remove the gas control valve/thermostat, thread a corerctly
sized pipe into the the inlet and use it to turn the gas valve
(counterclockwise). Do not use a pipe wrench or equivalent
to grip body. Damage may result causing leaks. Do not insert
any sharp objects into the inlet or outlet connections. Damage
to the gas control valve/thermostat may result.
Removing the Gas Valve:
Replacing the Gas Valve:
1.
Turn the gas control knob on the combination gas control
valve/thermostat clockwise to the “OFF” position. See “Lighting
Instructions” on water heater.
2.
Turn off the gas at the manual shut-off valve on the gas supply
pipe (Figure 1).
To replace the gas control valve/thermostat, reassemble in reverse
order. When replacing the gas control valve/thermostat, thread a
correctly sized pipe into the inlet and use it to turn the gas control
valve/thermostat (clockwise). DO NOT OVERTIGHTEN, damage
may result.
3.
Drain the water heater. Refer to the “Draining and Flushing”
section and follow the procedure.
4.
Disconnect the igniter wire from the igniter. Note: There are two
types of igniters. If you have the round igniter, first remove the
igniter from the bracket by depressing front and rear holding tabs
and lift. Next remove igniter bracket from the gas valve. If you
have the square igniter slide the igniter bracket backwards away
from the gas valve to remove it. Disconnect the thermocouple
(right-hand threads), pilot tube and manifold tube at the gas control
valve/thermostat (Figure 21).
5.
Refer to “Gas Piping” section (Figure 14) and disconnect the
ground joint union in the gas piping. Disconnect the remaining
pipe from the gas control valve/thermostat.
•
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/thermostat that screws into the 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 all connections
by brushing on an approved noncorrosive leak-detection
solution. Bubbles will show 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”.
•
If additional information is required, contact the Service
Department at: 1-800-999-9515
TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.
Operational Checklist
1.
2.
3.
4.
Burner door gasket properly sealed.
Viewport not damaged or cracked.
No leaks at pilot and manifold connection.
Burner door screws securely tightened.
Flue Baffle Installation:
Baffle tab extensions should be oriented toward the outside of
the heater when installed correctly. Refer to Figure 24 for corerct
placement of baffles.
Baffle Tab
Extentions
NOTE: Do not operate this water heater unless the baffles are
installed correctly. Failure to do so can result in poor combustion and
high flue gas temperatures.
FIGURE 24
24
LEAKAGE CHECKPOINTS
Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
Never use this water heater unless it is completely filled with water
to prevent damage to the tank. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
A. Water at the draft hood is water vapor which has condensed out
of the combustion products. This is caused by a problem in the
vent. Contact a qualified service technician.
B. *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
E. *The temperature-pressure relief valve may be leaking at the
tank fitting.
F. Water from a drain valve may be due to the valve being slightly
opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can condense
on the cooler surfaces of the tank. Droplets form and drip onto
the burner or run on the floor. This is common at the time of
start-up after installation and when incoming water is cold.
I. Water in the water heater bottom or on the floor may be from
condensation, loose connections, or the relief valve. DO NOT
replace the water heater until a full inspection of all possible water
sources is made and necessary corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
*
25
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
REPAIR PARTS
Key No.
Part Description
1
Pipe Nipple
2
Burner Tube
3
Burner Head
4
Thermocouple
5
Pilot
6
Draft Hood
7
Inlet Tube
8
Flue Baffle Assembly
9
Anode Rod
10
Outer Door
11
Gas Control Valve/Thermostat
12
T & P Relief Valve
13
Drain Valve
14
Pilot Tube
15
Orifices
16
Metal Drain Pan
*17
8
9
7
12
11
Instruction Manual
* Not Shown.
13
Now that you have purchased this water heater, should a need
ever exist for repair parts or service, simply contact the company
it was purchased from or direct from the manufacturer listed on
the rating plate on the water heater.
10
Be sure to provide all pertinent facts when you call or visit.
DRAIN PAN
16
Selling prices will be furnished on request or parts will
be shipped at prevailing prices and you will be billed
accordingly.
The model number of your Gas Water Heater will be found on the
rating place located above the gas control valve.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
•
•
•
•
4
14
2
3
5
MODEL NUMBER
TYPE GAS (NATURAL)
SERIAL NUMBER
PART DESCRIPTION
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
15
3/4” T&P RELIEF VALVE
AUTOMATIC, SELF-CLOSING TYPES
PRESS
150 LBS.
12
26
A=
2.13”
TEMP
RELIEF
210°F
A
TROUBLESHOOTING GUIDELINES
Problem
WATER LEAKS
LEAKING T&P VALVE
SMELLY WATER
PILOT WILL NOT LIGHT
BURNER WILL NOT STAY LIT
PILOT OUTAGE
NO HOT WATER
NOT ENOUGH HOT WATER
WATER TOO HOT
WATER HEATER SOUNDS
Cause
Solution
Improperly sealed, hot or cold supply connection, relief valve, or thermostat threads.
Tighten thread connections.
Leakage from water lines.
Inspect water lines and connections.
Condensation of flue products.
Refer to “Condensation” section.
Thermal expansion in closed water system.
Install thermal expansion tank (DO NOT plug T&P
valve).
Improperly seated valve.
Check relief valve for proper operation. Replace if
necessary.
(DO NOT plug T&P valve).
High sulfate or mineral content in water supply.
Drain and flush water heater thotoughly, then refill.
Bacteria in water supply.
Chlorinate or aerate water supply.
Gas control knob not positioned correctly.
Refer to “Lighting Instructions”.
Main gas supply off.
Turn off main gas shut-off valve.
Ignitor wire not connected.
Check ignitor wire connection.
Faulty ignitor.
Replace ignitor.
Air in gas line
Bleed the air from the gas line
Dirt in gas line
Notify utility-install dirt trap in gas line
Pilot line or orifice clogged
Clean, locate source and correct
Cold drafts
Locate source and correct
Thermostat ECO switch open
Replace thermostat
Low gas pressure
Check with gas utility company
Combustion air obstructed
See maintenance section for inspection and cleaning of burner
Pilot dirty
Clean pilot
Thermocouple malfunction.
Replace pilot assembly and/or thermocouple.
Defective gas control.
Replace Gas Control
Pilot not lit
Light pilot
Thermostat set too low
Turn temp. dial to desired temperature
No gas
Check with gas utility company
Dirt in the gas lines
Notify utility-inatall trap in gas line
Pilot line clogged
Clean, locate source and correct
Main burner line clogged
Clean, locate source and correct
Non-functioning thermostat
Replace thermostat
Heater installed in a confined area
Provide fresh air veltilation
Thermocouple tip is not in contact with pilot
flame.
Insert thermocouple correctly.
Dirty pilot burner.
Clean pilot assembly.
Thermocouple malfunction.
Replace pilot assembly ond/or thermocouple.
Defective gas control.
Replace gas control.
Pilot not lit or thermostat not on.
Refer to “Lighting Instructions”.
Thermostat set too low.
Refer to “Temperature Regulation”
Low gas pressure.
Contact your gas supplier.
Incoming water is unusually cold.
Allow more time for water heater to re-heat.
Leaking hot water pipes or fixtures.
Have plumber to check and repair leaks.
High temperature limit switch activated.
Contact a service agency to determine cause.
Heater undersized.
Reduce hot water usage.
Thermostat set too high.
Refer to “Temperature Regulation”.
Condensation dripping on burner.
Refer to “Condensation”.
27
TROUBLESHOOTING GUIDELINES
Problem
SIZZLING OR RUMBLING
SOUND
SOOTING
Cause
Solution
Sediment or calcium in bottom of tank.
Clean sediment from tank. Refer to “Draining”
instructions in the maintenance setion of manual.
Improper combustion.
No adjustment available. Contact a service agency
to determine cause.
Lack of sufficient supply air
VENT GAS ODORS
Improperly installed vent piping.
Contact a qualified service agency to determine
cause.
Downdraft.
Poor combustion.
28
NOTES
29
NOTES
30
NOTES
31
ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF
YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-527-1953
COPYRIGHT © 2012, INC. ALL RIGHTS RESERVED.
32