Rheem | PVCG | Service manual | Rheem PVCG Service manual

Rheem PVCG Service manual
INSTALLATION, OPERATION, AND SERVICE MANUAL
POWER VENT STORAGE TYPE GAS WATER HEATER
MODELS PVG/PVCG
Recognize this symbol as an indication of Important Safety
Information.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO
QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION,
ADJUSTMENT AND OPERATION OF THIS WATER HEATER.
READ THESE INSTRUCTIONS THOROUGHLY BEFORE
ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER
INSTALLATION, OPERATION, SERVICE OR MAINTENANCE,
POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, SCALD
INJURY, CARBON MONOXIDE POISONING, EXPLOSION,
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING: If the information in these
instructions is not followed exactly, a fire or
explosion may result causing property damage,
personal injury or death.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
INSTALLER:
• ATTACH THESE INSTRUCTIONS TO OR ADJACENT TO THE
WATER HEATER.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any telephone in your building.
• Immediately call your gas supplier from a
neighbor’s telephone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
• BEFORE LEAVING THE PREMISES REVIEW THIS INSTALLATION,
OPERATION AND SERVICE MANUAL TO BE SURE THE HEATER
HAS BEEN INSTALLED CORRECTLY. START AND OPERATE THE
UNIT FOR ONE COMPLETE CYCLE AND MAKE SURE THE
WATER TEMPERATURE IS ACCEPTABLE TO THE CONSUMER
AT THE FIXTURES.
OWNER:
• RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE
REFERENCE. RETAIN THE ORIGINAL RECEIPT AS PROOF OF
PURCHASE.
THIS MANUAL IS NOT TO BE USED WITH GAS STORAGE TYPE
WATER HEATERS CERTIFIED FOR INSTALLATION IN
MANUFACTURED HOMES (MOBILE HOMES).
AN ODORANT IS ADDED BY THE GAS SUPPLIER TO THE GAS
USED BY THIS WATER HEATER.
WARNING
AN ODORANT IS ADDED BY THE GAS SUPPLIER TO THE GAS USED BY
THIS WATER HEATER. THIS ODORANT MAY FADE OVER AN
EXTENDED PERIOD OF TIME. DO NOT DEPEND UPON THIS ODORANT
AS AN INDICATION OF LEAKING GAS. IF A GAS LEAK IS SUSPECTED,
CHECK FOR LEAKS BY USING A CHLORIDE-FREE SOAP AND WATER
SOLUTION, OR OTHER APPROVED METHOD. IF A LEAK CANNOT BE
FOUND BUT IS STILL SUSPECTED, FOLLOW THE STEPS UNDER
"WHAT TO DO IF YOU SMELL GAS" AS OUTLINED ON THIS PAGE.
FAILURE TO OBSERVE THIS WARNING COULD RESULT IN PROPERTY
DAMAGE, PERSONAL INJURY, OR DEATH.
TO OBTAIN TECHNICAL, WARRANTY OR SERVICE
ASSISTANCE DURING OR AFTER THE INSTALLATION OF
THIS WATER HEATER, CALL TOLL FREE
1-800-999-9515.
WHEN CALLING FOR ASSISTANCE, PLEASE HAVE THE
FOLLOWING INFORMATION READY:
1.
2.
3.
4.
MODEL NUMBER
7 DIGIT PRODUCT NUMBER
SERIAL NUMBER
DATE OF INSTALLATION
WARNING
THIS WATER HEATER MUST BE BRACED, ANCHORED, OR
STRAPPED TO AVOID FALLING OR MOVING DURING AN
EARTHQUAKE. CONTACT LOCAL UTILITIES FOR CODE
REQUIREMENTS IN YOUR AREA OR CALL THE 800 NUMBER
SHOWN ON FRONT OF THIS MANUAL AND REQUEST
INSTRUCTIONS 6600933 FOR EXAMPLES.
6510187
March 2000
Supersedes 6510162
Keep flammable products:
1.
2.
3.
4.
far away from the water heater.
in approved containers,
tightly closed and
out of children’s reach.
Water heater has a main burner and pilot flame. The
pilot flame:
1. is on all the time and
2. will ignite flammable vapors.
Vapors from flammable liquids will explode
and catch fire causing death or severe burns.
Do not use or store flammable products such as
gasoline, solvents or adhesives in the same room or
area near the water heater.
Vapors:
1. cannot be seen,
2. are heavier than air
3. go a long way on the floor and
4. can be carried from other rooms to the pilot flame by
air currents.
Do not install this heater where flammable products
will be stored or used unless the main burner and pilot
flames are at least 18 inches above the floor. This will
reduce but not eliminate the risk of vapors being ignited
by the main burner or pilot flame.
DANGER
DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER
THAN THE ONE LISTED ON THE DATA PLATE. This water
heater is equipped for use with one type gas only. Check the
data plate near the gas control valve for the correct gas.
FAILURE TO USE THE CORRECT GAS CAN CAUSE PROBLEMS
WHICH CAN RESULT IN DEATH, SERIOUS BODILY INJURY OR
PROPERTY DAMAGE. If you have any questions or doubts
consult your gas supplier or gas utility company. Water heaters
using bottled propane or liquefied petroleum gas (LPG) are
different from natural gas models. A natural gas water heater
will not function safely on bottled propane or liquefied
petroleum gas (LPG) and a propane gas water heater will not
function safely on natural gas. Do not attempt to convert a
water heater from natural gas to LPG or from LPG to natural
gas.
WHEN REMOVING PURGED GASES FROM A PIPING SYSTEM, DO
NOT CREATE A
HAZARDOUS CONDITION
BY DISCHARGING THE
GASES INTO A CONFINED
AREA OR IN AN AREA THAT
CONTAINS AN IGNITION
SOURCE.
Water temperature over 125°F can cause severe burns
instantly or death from scalds.
Children, disabled and elderly are at highest risk of being
scalded.
See the instruction manual before setting the water
temperature at the water heater.
Feel the water before bathing or showering.
Temperature limiting valves are available for use.
2
GENERAL SAFETY WARNINGS
BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS WATER HEATER, MAKE SURE YOU READ AND UNDERSTAND THE ENTIRE
INSTALLATION, OPERATION AND SERVICE MANUAL. SPECIAL ATTENTION MUST BE GIVEN TO ALL THE SAFETY WARNINGS PROVIDED
THROUGHOUT THIS MANUAL. FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN A FIRE OR EXPLOSION CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH. IF YOU HAVE DIFFICULTY UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL OR ARE NOT
AN EXPERIENCED INSTALLER, DO NOT PROCEED, BUT GET HELP FROM A QUALIFIED INSTALLATION OR SERVICE TECHNICIAN. FOR ANY
QUESTIONS DURING OR AFTER THE INSTALLATION OF THIS WATER HEATER, CALL 1-800-999-9515.
DANGER
•
TAMPERING WITH THE THERMOSTAT, IGNITER CONTROL, GAS
VALVE OR TEMPERATURE AND PRESSURE RELIEF VALVE IS
DANGEROUS AND MAY RESULT IN SERIOUS INJURY OR DEATH.
TAMPERING VOIDS ALL WARRANTIES. ONLY PROPERLY TRAINED,
QUALIFIED SERVICE PERSONNEL SHOULD SERVICE THESE
COMPONENTS. DO NOT ATTEMPT TO MODIFY OR CHANGE THIS
WATER HEATER IN ANY WAY.
•
DO NOT ATTEMPT TO CONVERT THIS WATER HEATER FROM
NATURAL GAS TO L.P. OR FROM L.P. TO NATURAL GAS. THIS CAN
RESULT IN PROPERTY DAMAGE, FIRE, EXPLOSION, BODILY HARM OR
DEATH.
•
DO NOT INSTALL THIS WATER HEATER IN A MOBILE HOME
•
DO NOT INSTALL THIS WATER HEATER OUTDOORS.
•
RESIDENTIAL AREAS WHERE FLAMMABLE LIQUIDS (GASOLINE,
SOLVENTS, LIQUID PROPANE, BUTANE, ETC.) OR OTHER SUBSTANCES
WHICH EMIT FLAMMABLE VAPORS ARE STORED MAY NOT BE
SUITABLE FOR WATER HEATER INSTALLATION. NATURAL AIR
MOVEMENTS CAN CARRY FLAMMABLE VAPORS SOME DISTANCE
FROM WHERE THEY ARE STORED OR USED. NEAR GROUND LEVEL
VENTS CAN DRAW THESE VAPORS INTO THE WATER HEATER WHERE
THE PILOT FLAME OR MAIN BURNER CAN IGNITE THEM CAUSING
PROPERTY DAMAGE, SERIOUS BURNS OR DEATH. NEVER STORE OR
USE FLAMMABLE SUBSTANCES IN THE SAME ROOM OR AREA
CONTAINING A GAS WATER HEATER. IF SUCH FLAMMABLES MUST
BE USED, ALL GAS BURNING APPLIANCES IN THE VICINITY MUST BE
SHUT OFF AND THEIR PILOT LIGHTS EXTINGUISHED. OPEN THE
DOORS AND WINDOWS FOR VENTILATION WHILE FLAMMABLE
SUBSTANCES ARE IN USE.
•
FLAMMABLE VAPORS MAY BE DRAWN TO THIS WATER HEATER
FROM OTHER AREAS OF THE STRUCTURE BY AIR CURRENTS.
•
WATER HEATERS INSTALLED IN RESIDENTIAL GARAGES MUST BE
INSTALLED SUCH THAT THE PILOT FLAME AND MAIN BURNER
FLAME ARE NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS
TO REDUCE BUT NOT ELIMINATE THE RISK OF IGNITING FLAMMABLE
VAPORS WHICH MAY BE PRESENT IN A GARAGE. THIS WATER
HEATER MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL
DAMAGE BY VEHICLES OR FLOODING.
•
•
THE WATER HEATER IS CERTIFIED FOR INSTALLATION ON A
COMBUSTIBLE FLOOR. HOWEVER WHEN THIS WATER HEATER IS
INSTALLED OVER CARPETING, THE CARPETING MUST BE PROTECTED
BY A METAL OR WOOD PANEL BENEATH THE WATER HEATER AND
EXTENDING BEYOND THE FULL WIDTH AND DEPTH OF THE WATER
HEATER BY AT LEAST THREE INCHES IN ANY DIRECTION. IF THE
WATER HEATER IS INSTALLED IN A CARPETED ALCOVE OR CLOSET,
THE ENTIRE FLOOR MUST BE COVERED BY THE PANEL. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN A FIRE HAZARD.
•
VENTILATION AND COMBUSTION AIR SUPPLIES CANNOT BE TAKEN
FROM AREAS THAT CONTAIN NEGATIVE PRESSURE PRODUCING
DEVICES SUCH AS FIREPLACES, EXHAUST FANS AND AIR
CIRCULATION SYSTEMS. INLET AIR CANNOT BE TAKEN FROM AN
ATTIC EQUIPPED WITH POWER VENTILATION.
•
PROPER VENT PIPE INSTALLATION IS CRITICAL TO THE SAFE
OPERATION OF THIS WATER HEATER. FAILURE TO PROPERLY VENT
THIS WATER HEATER CAN CAUSE AN EXPLOSION, FIRE, OR CARBON
MONOXIDE POISONING WHICH CAN RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
•
CONNECTION OF THE VENT PIPE TO THE OUTLET OF THE VENT
ASSEMBLY BLOWER MUST BE PROPERLY SEALED TO PREVENT
LEAKAGE OF THE PRODUCTS OF COMBUSTION INTO THE LIVING
SPACE.
•
OBSTRUCTIONS OR HOLES IN THE VENT PIPE CAN CAUSE TOXIC
FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE
POISONING OR DEATH. THE VENT PIPE MUST BE REPLACED IF IT IS
LEAKING.
•
NEVER OPERATE AN EMPTY OR PARTIALLY FILLED WATER HEATER.
THIS CAN RESULT IN SERIOUS DAMAGE TO THE TANK.
•
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITH THE
COLD WATER SHUTOFF VALVE CLOSED.
•
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITHOUT A
PROPERLY INSTALLED TEMPERATURE AND PRESSURE RELIEF VALVE.
FAILURE TO INSTALL AND MAINTAIN A NEW AND PROPERLY LISTED
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIMS WHICH MIGHT RESULT FROM
EXCESSIVE TEMPERATURE OR WATER PRESSURE.
•
WATER SUPPLY TO THIS HEATER MUST NOT EXCEED 180° F. WATER
TEMPERATURES IN EXCESS OF 180° F WILL CAUSE THE HIGH LIMIT
CONTROL (ECO) TO OPEN AND SHUT OFF THE GAS SUPPLY TO THE
UNIT. THE HIGH LIMIT CONTROL IS A SINGLE USE TYPE THAT WILL
REQUIRE THE REPLACEMENT OF THE THERMOSTAT BEFORE THE
BURNER CAN OPERATE.
•
THIS WATER HEATER IS EQUIPPED FOR ONE TYPE OF GAS ONLY. DO
NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE
ONE LISTED ON THE DATA PLATE LOCATED NEAR THE GAS
CONTROL. FAILURE TO USE THE CORRECT GAS CAN RESULT IN
PROPERTY DAMAGE, BODILY INJURY OR DEATH.
•
CONTAMINANTS IN THE GAS PIPING MAY FOUL THE GAS CONTROL /
THERMOSTAT CAUSING A MALFUNCTION, FIRE OR EXPLOSION. BE
SURE ALL GAS PIPING IS CLEAN AND CLEAR ON THE INSIDE BEFORE
ATTACHING THE GAS LINE.
•
DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK
GAS PIPING FOR LEAKS.
THIS WATER HEATER AND ANY OTHER GAS FUEL BURNING
APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR
PROPER VENTILATION OF THE FLUE GASES.
3
GENERAL SAFETY WARNINGS
DANGER
•
THE GAS LINE MUST BE OF ADEQUATE SIZE SO AS TO PREVENT
UNDUE PRESSURE DROP AND NEVER SMALLER THAN THE PIPE SIZE
TO THE GAS VALVE ON THE WATER HEATER. FAILURE TO PROPERLY
SIZE THE GAS LINE CAN RESULT IN A FIRE OR EXPLOSION CAUSING
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
•
DO NOT ATTEMPT TO LIGHT THIS WATER HEATER UNTIL IT IS
PROPERLY INSTALLED AND YOU UNDERSTAND ALL OF THE SAFETY
WARNINGS AND PRECAUTIONS.
•
ADJUSTING THE THERMOSTAT PAST THE 120° F BAR ON THE
TEMPERATURE DIAL WILL INCREASE THE RISK OF SCALD INJURY.
SEE SECTION "WATER TEMPERATURE REGULATION".
•
HOUSEHOLDS WITH SMALL CHILDREN, ELDERLY, IMPAIRED OR
DISABLED MEMBERS AND ANYONE WITH TEMPERATURE
SENSITIVE SKIN MAY REQUIRE A LOW TEMPERATURE SETTING TO
REDUCE THE RISK OF SCALD INJURY.
•
HOT WATER CAN PRODUCE FIRST DEGREE BURNS WITHIN:
3 SECONDS AT 140°F (60°C)
20 SECONDS AT 130°F (54°C)
8 MINUTES AT 120°F (49°C)
TABLE OF CONTENTS
SAFETY PRECAUTIONS
.....................................................
GENERAL SAFETY WARNINGS
.......................................................
CONSUMER INFORMATION/RESPONSIBILITIES
............................
TABLE OF CONTENTS ...........................................................................
WATER HEATER
.....................................
MODIFICATION/TAMPERING
LOCATION REQUIREMENTS AND CONSIDERATIONS
....................
VENTILATION AND COMBUSTION AIR SUPPLY
............................
VENT PIPE SYSTEM
.....................................................................
WATER SYSTEM PIPING
.................................................................
SPECIAL APPLICATIONS
.................................................................
GAS SUPPLY AND PIPING
.............................................................
ELECTRICAL CONNECTIONS
..............................................................
INSTALLATION CHECK LIST
...........................................................
START-UP/OPERATION
.................................................................
OPERATIONAL CONDITIONS
...........................................................
MAINTENANCE
..............................................................................
BURNER ASSEMBLY REMOVAL, CLEANING, AND REPLACEMENT
...
GAS CONTROL VALVE/THERMOSTAT REPLACEMENT
THERMOCOUPLE AND PILOT ASSY. REPLACEMENT
.....................
TROUBLESHOOTING GUIDE
....................................
REPAIR PARTS LIST AND ILLUSTRATION
...................................
•
DO NOT ATTEMPT TO BYPASS OR JUMPER THE ECO. THIS WILL
VOID THE WARRANTY AND RELEASE THE MANUFACTURER FROM
ANY LIABILITY FOR ANY ACCIDENT RESULTING FROM ELIMINATING
THE ECO FROM THE WATER HEATER CIRCUIT.
•
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.
•
REPAIR, REPLACEMENT, SERVICE AND CLEANING OF WATER
HEATER PARTS MUST ONLY BE PERFORMED BY A QUALIFIED
SERVICE TECHNICIAN.
PAGE
1,2
3,4
4
4
5
5,6
7,8
9,10
11,12
13
14,15
15,16
16
17-19
20,21
21,22
22
23
23
24,25
26,27
IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT, COMPLETELY READ ALL
INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR THIS PRODUCT. UPON
UNPACKING OF THE WATER HEATER, INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.
CONSUMER INFORMATION
This water heater is design-certified by CSA International as a Category IV, nondirect vented water heater which takes its combustion air either from the
installation area or from air ducted to the unit from the outside.
This water heater should be installed in accordance with the latest edition of the
“National Fuel Gas Code”, ANSI Z223.1, NFPA 54 and the requirements and codes
of the local utilities or other authorities having jurisdiction. This is available from
the following:
4
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269
American Gas Association
1515 Wilson Boulevard
Arlington, VA 22209
Local Authorities (Check your telephone listings.)
CONSUMER RESPONSIBILITIES
This manual has been prepared to acquaint you with the installation, operation and
maintenance of your gas water heater and to provide important safety information
in these areas.
We urge you to read all of the instructions thoroughly before attempting the
installation or operation of this water heater. This manual should be kept for
future reference.
The manufacturer of this water heater will not be liable for any damages caused
by failure to comply with the in-stallation and operating instructions outlined in
this manual.
If you lack the necessary skills required to properly install this water heater or you
have difficulty following the directions, you should not proceed but have a
qualified person perform the installation of this water heater.
A data plate identifying your water heater can be found next to the gas control
valve/thermostat. When referring to your water heater always have the
information listed on the data plate readily available.
Retain your original receipt as proof of purchase.
HIGH ALTITUDE INPUT RATING
The input rating on the data plate of this water heater is for installations up to
2000 feet of elevation. For installations at elevations above 2000 feet, the rating
should be reduced by 4 percent for each 1000 feet above sea level. For correct
orifice at altitudes above 2000 feet: consult the National Fuel Gas Code, your
local utility or water heater supplier.
WATER HEATER MODIFICATION/ TAMPERING
LOCATION REQUIREMENTS AND CONSIDERATIONS
GENERAL INFORMATION
WARNING
DO NOT INSTALL THIS WATER HEATER IN A MOBILE HOME. This water
heater is not approved for installation in a mobile home. DO NOT INSTALL
OUTDOORS. This water heater is certified for indoor installation only. Failure to
follow these instructions could result in FIRE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
DANGER
AREAS WHERE FLAMMABLE LIQUIDS (GASOLINE, SOLVENTS, LIQUID
PROPANE, BUTANE, ETC.) OR OTHER SUBSTANCES WHICH EMIT
FLAMMABLE VAPORS ARE STORED MAY NOT BE SUITABLE FOR WATER
HEATER INSTALLATION. NATURAL AIR MOVEMENTS CAN CARRY
FLAMMABLE VAPORS SOME DISTANCE FROM WHERE THEY ARE STORED
OR USED. NEAR GROUND LEVEL VENTS CAN DRAW THESE VAPORS INTO
THE WATER HEATER WHERE THE PILOT FLAME OR MAIN BURNER CAN
IGNITE THEM CAUSING PROPERTY DAMAGE, SERIOUS BURNS OR DEATH.
NEVER STORE OR USE FLAMMABLE SUBSTANCES IN THE SAME ROOM OR
AREA CONTAINING A GAS WATER HEATER. IF SUCH FLAMMABLES MUST
BE USED, ALL GAS BURNING APPLIANCES IN THE VICINITY MUST BE
SHUT OFF AND THEIR PILOT LIGHTS EXTINGUISHED. OPEN THE DOORS
AND WINDOWS FOR VENTILATION WHILE FLAMMABLE SUBSTANCES ARE
IN USE.
DANGER
TAMPERING WITH THE THERMOSTAT, IGNITER CONTROL, GAS VALVE, OR
TEMPERATURE AND PRESSURE RELIEF VALVE IS DANGEROUS AND MAY
RESULT IN SERIOUS INJURY OR DEATH. TAMPERING VOIDS ALL
WARRANTIES. ONLY PROPERLY TRAINED, QUALIFIED SERVICE
PERSONNEL SHOULD SERVICE THESE COMPONENTS. DO NOT ATTEMPT
TO MODIFY OR CHANGE THIS WATER HEATER IN ANY WAY.
INSULATION BLANKET
Some governing bodies may require the use of external insulation blankets when
water heaters are installed in newly constructed homes and additions. If an
insulation blanket is applied to this water heater CAUTION must be exercised so
as to not restrict its proper function and operation. Please note the following:
•
The space between the base of the water heater and the floor must remain
unobstructed to allow for proper air flow. As time passes, the blanket may
sag and obstruct the air passage resulting in unsafe water heater operation.
•
Do not apply an insulation blanket to the top of the water heater as this may
obstruct the draft hood.
•
Do not cover the temperature and pressure relief valve or any labels or
instruction materials applied to the water heater. These labels must remain
visible for reference by the user. Do not remove these labels as they are a
permanent part of the water heater as required by the certification agencies
and/or the Federal Government.
• Do not cover any access panels leading to burner compartments. Do not
cover the thermostat controls, doors, or the temperature and pressure relief
valve on the water heater.
GAS CONVERSION
DANGER
DO NOT ATTEMPT TO CONVERT THIS WATER HEATER FROM NATURAL
GAS TO L.P. OR FROM L.P. TO NATURAL GAS. THIS CAN RESULT IN
PROPERTY DAMAGE, FIRE, EXPLOSION, BODILY HARM OR DEATH.
VAPORS FROM FLAMMABLE LIQUIDS WILL EXPLODE AND CATCH FIRE
CAUSING DEATH OR SEVERE BURNS.
WARNING
FLAMMABLE VAPORS MAY BE DRAWN TO THIS WATER HEATER FROM
OTHER AREAS OF THE STRUCTURE BY AIR CURRENTS.
IMPORTANT: This water heater should not be installed near a corrosive or
potentially corrosive air supply. Water heater corrosion and component failure can
be caused by the heating and breaking down of airborne chemicals. These
materials are corrosive at low concentration levels with little or no odor to reveal
their presence. Examples of potentially corrosive locations and compounds are:
• Beauty shops, dry cleaning establishments, photo processing labs
• Liquid or powdered bleaches, swimming pool chemicals, spray can
propellants, cleaning solvents
• Refrigerants
• Calcium and sodium chloride
• Waxes and process chemicals
•
Products of this sort should not be stored near the water heater or air inlet.
5
LOCATION REQUIREMENTS AND CONSIDERATIONS
WARNING
IT IS NOT DESIRABLE TO INSTALL A GAS FIRED WATER HEATER IN A
RESIDENTIAL GARAGE. IF INSTALLATION IN A RESIDENTIAL GARAGE IS
YOUR ONLY OPTION, THIS WATER HEATER MUST BE INSTALLED SUCH
THAT THE PILOT FLAME AND MAIN BURNER FLAME ARE NO LESS THAN
18 INCHES ABOVE THE FLOOR (SEE FIGURE 2 BELOW). THIS IS TO
REDUCE BUT NOT ELIMINATE THE RISK OF IGNITING FLAMMABLE
VAPORS WHICH MAY BE PRESENT IN A GARAGE. THE WATER HEATER
MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE
BY VEHICLES OR FLOODING. FAILURE TO FOLLOW THESE
WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
5. The water heater should be located in an area not subject to freezing
temperatures. Water heaters located in unconditioned areas (i.e. attics,
basements, etc.) may require the insulation of the water piping and drain
piping to protect against freezing. The drain and controls must be easily
accessible for operation and service.
Maintain proper clearances as specified.
6. Do not locate the water heater near an airmoving device. The operation of air-moving
devices such as exhaust fans, ventilation
systems, clothes dryers, fireplaces, etc.,
can affect the proper operation of the
water heater. Special attention must be
given to conditions these devices may
create to avoid unsatisfactory operation
of the equipment.
CLEARANCE/ACCESSIBILITY
SITE LOCATION
1. Select a location near the center of the water piping system. It must
be installed indoors and in a vertical position on a level surface. DO
NOT install in bathrooms, bedrooms or any occupied room normally
kept closed.
2. Locate the water heater as close to the chimney or gas vent as is
practical. Consider the vent system piping and combustion air supply
requirements when selecting the water heater location. The venting
system must be able to run from the water heater to the termination
with a minimal length and elbows. THE VENT PIPE CANNOT
EXCEED THE MAXIMUM ALLOWABLE LENGTH OF 40 FEET WITH
3 LONG RADIUS ELLS.
3. Locate the water heater near the existing gas piping. If installing a new
gas line, locate the water heater to minimize the pipe length and
elbows.
IMPORTANT
4. The water heater should be located in an area where leakage of the
tank or connections will not result in damage to the area adjacent to
the water heater or to lower floors of the structure. It is recommended
that a suitable drain pan be installed under the water heater as shown
above. This pan is to protect the property from damage which may
occur from normal condensate formation on the tank jacket or leaks in
the tank and pipe connections. The pan must limit the water level to a
maximum depth of 1 3/4 inches and be two inches wider than the
heater and piped to an adequate drain. Locate the water heater near a
suitable inside drain. Outside drains are subject to freezing
temperatures. The piping should be at least 3/4” ID and pitched for
proper drainage. This pan must not restrict combustion air flow.
UNDER NO CIRCUMSTANCES IS THE MANUFACTURER TO BE
HELD LIABLE FOR ANY WATER DAMAGE IN CONNECTION WITH
THIS WATER HEATER.
6
Minimum clearances from combustible materials are stated on the data plate
adjacent to the thermostat of the water heater. REFER TO THE DATA
PLATE OF THE WATER HEATER FOR THE CORRECT CLEARANCES
FROM COMBUSTIBLE CONSTRUCTION MATERIALS. Figure 3 may be
used as a reference guide to locate the specific clearance locations. A
minimum of 24 inches of front clearance should be provided for inspection and
service.
WARNING
THE WATER HEATER IS CERTIFIED FOR INSTALLATION ON A
COMBUSTIBLE FLOOR. HOWEVER, WHEN THIS WATER HEATER IS
INSTALLED OVER CARPETING, THE CARPETING MUST BE PROTECTED
BY A METAL OR WOOD PANEL BENEATH THE WATER HEATER AND
EXTENDING BEYOND THE FULL WIDTH AND DEPTH OF THE WATER
HEATER BY AT LEAST THREE INCHES IN ANY DIRECTION. IF THE
WATER HEATER IS INSTALLED IN A CARPETED ALCOVE OR CLOSET,
THE ENTIRE FLOOR MUST BE COVERED BY THE PANEL. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN A FIRE HAZARD.
VENTILATION AND COMBUSTION AIR SUPPLY
GENERAL INFORMATION
WARNING
THIS WATER HEATER AND ANY OTHER FUEL BURNING APPLIANCE
MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER
VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE
THAT OUTSIDE AIR BE SUPPLIED INTO THE WATER HEATER AREA.
FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY
DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR
DEATH.
Adequate facilities for providing air for combustion and ventilation must be
provided in accordance with the “National Fuel Gas Code”, ANSI Z223.1Latest Edition, NFPA 54 or the applicable provisions of the local building
codes.
IMPORTANT: Water heaters installed in open spaces in buildings with
unusually tight construction may still require outdoor air to function
properly. In this situation, outside air openings should be sized the same as
for a confined space.
MODERN CONSTRUCTION USUALLY REQUIRES SUPPLYING OUTSIDE AIR
INTO THE WATER HEATER AREA.
CONSULT THE LOCAL CODES OF YOUR AREA FOR
VENTILATION AND COMBUSTION AIR REQUIREMENTS.
SPECIFIC
For the correct and safe operation of this water heater, ample air must be
supplied for the combustion, ventilation and dilution of flue gases. Small
enclosures and confined areas must have two permanent openings so
that sufficient fresh air can be drawn from outside of the enclosure. One
opening shall be within 12 inches of the top and one within 12 inches
of the bottom of the enclosure as shown in Figure 4 below.
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 (but not limited to the following) will
require outdoor air for combustion due to chemical exposure and may
reduce but not eliminate the presence of corrosive chemicals in the air:
•
Beauty shops
•
Photo processing labs
•
Commercial buildings
•
Buildings with indoor pools
•
Water heaters installed in laundry, hobby or craft rooms.
• Water heaters installed near chemical storage areas
Combustion air must be free of acid-forming chemicals such as sulfur,
fluorine, and chlorine. These elements are found in aerosol sprays,
detergents, bleaches, cleaning solvents, air fresheners, paint and varnish
removers, refrigerants, and many other commercial and household
products. When burned, vapors from these products form highly corrosive
acid compounds. These products should not be stored near the water
heater or air inlet.
Combustion and ventilation air requirements are de-termined by the location
of the water heater. The water heater may be located in either an open
(unconfined) area or in a confined area or small enclosure such as a closet
or small room. Confined spaces are areas with less than 50 cubic feet
for each 1,000 BTUH of the total input for all gas-using appliances.
WATER HEATER LOCATION - UNCONFINED SPACE
A water heater in an unconfined space uses indoor air for combustion and
requires at least 50 cubic feet for each 1,000 BTUH of the total input
for all gas appliances. The table below shows a few examples of the
minimum square feet required for various BTUH inputs.
BTUH
INPUT
30,000
45,000
60,000
75,000
90,000
105,000
120,000
135,000
MIN. SQ. FEET
TYPICAL ROOM SIZE
WITH 8’ CEILING
188
281
375
469
563
657
750
844
WITH 8’ CEILING
9 X 21
14 X 20
15 X 25
15 X 31
20 X 28
20 X 33
25 X 30
28 X 30
Areas which are being used for storage or contain large space consuming
items may not be suitable for water heater installation. The area must be
open and be able to provide the proper air requirements to the water
heater.
The size of each opening (free area) is determined by the total Btuh input of
all gas utilization equipment (i.e. water heaters, furnaces, clothes dryers,
etc.) and the method by which the air is provided. The Btuh input can be
found on the water heater data plate. Additional air can be provided by two
methods:
1. All air from inside the building.
2. All air from outdoors.
ALL AIR FROM INSIDE THE BUILDING
When additional air is to be provided to the confined area from additional
room(s) within the building, the total volume of the room(s) must be of
sufficient size to properly provide the necessary amount of fresh air to the
water heater and other gas utilization equipment in the area. If you are
unsure that the structure meets this requirement, contact your local gas
utility company or other qualified agency for a safety inspection.
Each of the two openings shall have a minimum free area of 1 square inch
per 1,000 Btuh of the total input rating of all gas utilization equipment in
the confined area, but not less than 100 square inches (Figure 5).
CAUTION
AIR CANNOT BE TAKEN FROM AREAS THAT CONTAIN NEGATIVE
PRESSURE PRODUCING DEVICES SUCH AS FIREPLACES, EXHAUST
FANS, AND AIR CIRCULATION SYSTEMS.
7
VENTILATION AND COMBUSTION AIR SUPPLY (CONT.)
TABLE 1
MINIMUM FREE AREA OF PERMANENT OPENINGS FOR
VENTILATION AND COMBUSTION AIR SUPPLY - ALL AIR
FROM OUTSIDE ONLY.
OPENING SOURCE
DIRECT TO
OUTDOORS*
VERTICAL DUCTS
HORIZONTAL DUCTS
MINIMUM FREE AREA PER
OPENING (SQ. IN.)
1 SQUARE INCH PER 4000 BTUH
REFERENCE
DRAWING
FIGURE 6
1 SQUARE INCH PER 4000 BTUH
FIGURE 7
FIGURE 8
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
1 SQUARE INCH PER 2000 BTUH
* These openings may communicate directly with the outdoors through a
ventilated attic, a ventilated crawl space, or through an outside wall.
ALL AIR FROM OUTDOORS
Outdoor fresh air can be provided to a confined area either directly or by
the use of vertical and horizontal ducts. The fresh air can be taken from the
outdoors or from crawl or attic spaces that freely communicate with the
outdoors. Attic or crawl spaces cannot be closed and must be properly
ventilated to the outside.
Ductwork must be of the same cross-sectional area as the free area of the
opening to which they connect. The minimum dimension of rectangular air
ducts cannot be less than 3 inches.
The size of each of the two openings is determined by the method in which
the air is to be provided. Refer to Table 1 to calculate the minimum free
area for each opening. Figures 6, 7, and 8 are typical examples of each
method.
CAUTION
INLET AIR CANNOT BE TAKEN FROM AN ATTIC EQUIPPED WITH
POWER VENTILATION.
LOUVERS AND GRILLES
In calculating free area for ventilation and combustion air supply openings,
consideration must be given to the blocking affect of protection louvers,
grilles, and screens. These devices can reduce air flow which in turn may
require larger openings to achieve the required minimum free area. Screens
must not be smaller than 1/4 inch mesh. If the free area through a
particular design of louver or grille is known, it should be used in
calculating the specified free area of the opening. If the design and free
area are not known, it can be assumed that most wood louvers will allow
20 - 25% of free area while metal louvers and grilles will allow 60 - 75% of
free area. Louvers and grilles must be locked open or interconnected with
the equipment so that they are opened automatically during equipment
operation.
Keep louvers and grilles clean and free of debris or other obstructions.
8
VENT PIPING SYSTEM
GENERAL INFORMATION
DANGER
PROPER VENT PIPE INSTALLATION IS CRITICAL TO THE SAFE
OPERATION OF THIS WATER HEATER. FAILURE TO PROPERLY VENT
THIS WATER HEATER CAN CAUSE AN EXPLOSION, FIRE OR CARBON
MONOXIDE POISONING WHICH CAN RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH.
This water heater has been certified by CSA International for use with the
specified plastic pipe material.
This vent pipe system must be installed in accordance with the “National Fuel
and Gas Code”, NFPA 54, ANSI Z223.1 - Latest Edition.
The National Fuel and Gas Code allows the use of plastic pipe for venting if it is
accepted by the local code or the authority having jurisdiction.
Some local jurisdictions may be opposed to plastic vent pipe. Check with your
local code official before installing this system.
Use only 3 inch Schedule 40 PVC, ABS-DWP, or CPVC plastic pipe and fittings
for this vent pipe system. All fittings must be Long Sweep. DO NOT USE SHORT
RADIUS OR MEDIUM SWEEP FITTINGS. THE USE OF SHORT RADIUS
FITTINGS WILL CAUSE THIS WATER HEATER TO MALFUNCTION OR
NUISANCE TRIP ON THE PRESSURE SWITCH CAUSING THE BURNER TO
NOT OPERATE PROPERLY.
Pipe and fittings are available from your water heater dealer or through most
plumbing supply houses.
BLOWER OUTLET ADAPTER
The blower outlet adapter must be secured to the outlet of the power vent
blower opening using silicone
adhesive sealant and sheet metal
screws as shown in Figure 9.
1. Apply an even 1/8 inch bead of
silicone adhesive sealant
around the inside of the
adapter’s square opening.
Locate this bead 1/4 inch from
the top of the opening.
1. Slide the adapter approximately
1/2 inch onto the blower
opening and secure with two
sheet metal screws.
• Vent diameter must not be reduced.
• Support all fittings and pipe runs with proper pipe hold-down hardware at
least every three feet.
• Do not use damaged pipe or fittings.
• All joints must be properly cemented.
• Vent piping installed in unconditioned spaces must be properly insulated
• Make sure the inside of the pipe is clean and free of cuttings and loose dirt.
• Size and cut all piping before cementing. Make clean, square cuts.
• Do not connect this venting system with an existing vent or chimney.
• Do not common vent with the vent pipe of any other water heater or
appliance.
• Do not run plastic vent pipe through a fire break wall.
• Do not screw, nail, rivet or make any holes in the vent pipe or fittings.
• Do not turn on the water heater until the adhesive has completely cured.
DANGER
CONNECTION OF THE VENT PIPE TO THE OUTLET OF THE VENT
ASSEMBLY BLOWER MUST BE PROPERLY SEALED TO PREVENT
LEAKAGE OF THE PRODUCTS OF COMBUSTION INTO THE LIVING SPACE.
IMPORTANT: Fittings such as elbows and couplings must not be attached
directly to the blower outlet. A short length of vent pipe (2 inches minimum)
must be used to connect an elbow or coupling to the blower outlet as shown
in Figure 10.
Use silicone adhesive sealant to secure the vent pipe to the blower outlet. Use
a good grade of pipe cement to secure the vent pipe and fittings to each
other.
For PVC, CPVC, and ABS pipe:
1. Cut the pipe ends square, remove the ragged edges and burrs.
2. Chamfer the pipe end, apply a primer to the fitting and pipe.
3. Apply an even coat of a good grade of pipe cement inside the fitting.
Apply a liberal amount of cement to the outside of the pipe to socket
depth.
4. Assemble the parts quickly while the cement is still wet. Twist the pipe 1/4
turn during insertion and hold together for 30 seconds.
5. Wipe off the excess cement and do not handle for 15 minutes. Cure time
will vary according to temperature, humidity, and fit.
IMPORTANT: This connection must
be properly sealed to prevent the leakage of the products of combustion into the
living area. Excess silicone adhesive inside the adapter can cause enough
restriction in the vent pipe to cause intermittent burner operation.
VENT PIPE INSTALLATION
When installing this vent pipe system, please note the following:
• Use only Schedule 40 PVC, CPVC, or ABS-DWV plastic pipe and fittings.
• Maximum vent pipe length is 40 feet with three 90 degree long sweep
elbows.
• The minimum clearance from plastic vent pipe to combustible materials is 0
(zero) inches.
• Venting should be as direct as possible with a minimum pipe length and
fittings.
9
VENT PIPING SYSTEM (CONT.)
VENT TERMINAL LOCATIONS
The vent outlet must not terminate:
•
near walkways
•
under a covered area or patio
•
into an alley or other publicly accessible areas
•
opposite a window where air currents would
draw the ex-haust into the enclosure.
•
in areas where children or animals could block
the pipe or inhibit the proper operation of the
water heater.
•
in areas where dripping condensate may cause
problems such as above patios, flowerbeds and
planters.
IMPORTANT: Do not use the warm air that
discharges from the vent outlet as a heat source.
Vent termination clearances are as follows:
• 12 inches above roof or grade level and/or twelve inches above
maximum snow level.
• 4 ft. below, 4 ft. horizontally from, or 1 ft. above any door, window or
gravity air inlet to the building.
• 3 feet above any forced air inlet located with 10 feet.
• 2 ft. horizontally from gas or electric meters. Do not install above a
gas meter, regulator, or electric meter.
• 3 ft. from an inside corner formed by two exterior walls
.
VENT TERMINAL INSTALLATION
DANGER
OBSTRUCTIONS OR HOLES IN THE VENT PIPE CAN CAUSE
TOXIC FUMES TO ENTER THE HOME RESULTING IN CARBON
MONOXIDE POISONING OR DEATH.
THROUGH THE WALL
The vent terminal is a 45 degree elbow. This is shipped with the water heater and
must be used as the vent terminal.
Install as follows:
1.
Extend the vent outlet pipe 2 inches beyond the surface of the vertical
outside wall. Caulk the area between the pipe and the outside wall.
2.
Glue the vent terminal onto the vent outlet pipe as shown. Make sure that
the vent terminal outlet is facing downward to the ground.
THROUGH THE ROOF
This water heater may be vented vertically through a roof by using a U-bend pipe
fitting as a vent terminal. Install as follows:
1.
Extend the vent outlet pipe above the roof so that the outlet of the vent terminal will be at
least 12 inches above the roof or anticipated snow level as shown.
2.
Install roof flashing or other approved means to seal the pipe where it exits the roof. Caulk
all gaps and openings to insure a tight seal.
3.
Glue the U-bend vent terminal onto the vent pipe with the outlet of the terminal facing
downward towards the roof.
CAUTION
MOISTURE IN THE FLUE GASES MAY CONDENSE AND FORM ON THE
INTERIOR OF THE GAS VENT PIPE. VENT PIPING INSTALLED IN
UNCONDITIONED SPACES MUST BE INSULATED. IMPROPER LOCATION OR
INSTALLATION CAN CAUSE STRUCTURAL DAMAGE TO THE RESIDENCE.
10
WATER SYSTEM PIPING
GENERAL INFORMATION
Water piping, fittings, and valves must be properly installed for the correct
and safe operation of this water heater. Please note the following:
DO NOT install this water heater with iron piping. The system should
be installed only with new piping that is suitable for potable (drinkable)
water such as copper, CPVC, or polybutylene. DO NOT use PVC water
piping.
DO NOT use any pumps, valves, or fittings that are not compatible
with potable water.
DO NOT use valves that may cause excessive restriction to water
flow. Use full flow ball or gate valves only.
DO NOT use 50/50 tin-lead solder (or any lead based solder) in potable
water lines. Use 95/5 tin-antimony or other equivalent material.
DO NOT tamper with the thermostat, gas valve, ignitor control or
temperature and pressure relief valve. Tampering with any of the
components is DANGEROUS and can result in property damage, severe
injury or death. Tampering voids all warranties. Only qualified
technicians should service these components.
DO NOT use with piping that has been treated with chromates, boiler
seal, or other chemicals.
DO NOT add any chemicals to the system piping which will
contaminate the potable water supply.
DO NOT install check valve type devices in the cold water supply line
to the water heater.
CAUTION
THE TEMPERATURE & PRESSURE RELIEF VALVE:
•
Must not be in contact with any electrical part.
•
Must be connected to an adequate discharge line.
•
Must not exceed the working pressure shown on the data plate of the
water heater.
THE DISCHARGE LINE:
NEVER OPERATE AN EMPTY OR PARTIALLY FILLED WATER
HEATER. THIS CAN RESULT IN SERIOUS DAMAGE TO THE TANK.
•
Must not be smaller than the pipe size of the relief valve.
•
Must not be capped, blocked, plugged or contain any valve between
the relief valve and the end of the discharge line.
TEMPERATURE & PRESSURE RELIEF VALVE
•
Must terminate 6 inches above a floor drain or external to the building.
•
Must be capable of withstanding 250°F (121°C) without distortion.
WARNING
DO NOT ATTEMPT TO OPERATE THIS WATER HEATER WITHOUT A
PROPERLY INSTALLED TEMPERATURE AND PRESSURE RELIEF
VALVE. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
For protection against excessive pressures and temperatures, a
temperature and pressure relief valve must be installed in the opening
marked “T & P RELIEF VALVE” (see Figure 13). This valve must be design
certified by a nationally recognized testing laboratory that maintains
periodic inspection of the production of listed equipment or materials as
meeting the requirements for Relief Valves and Automatic Shut-off Devices
for Hot Water Supply Systems., ANSI Z21.22. The function of the
temperature and pressure relief valve is to discharge water in large
quantities in the event of excessive temperature or pressure developing in
the water heater. The valve must not exceed the working pressure of the
water heater as stated on the data plate. TO PREVENT PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH, THE RELIEF VALVE MUST
BE ALLOWED TO OPERATE PROPERLY.
Only a new temperature and pressure relief valve should be used with your
water heater. Do not use an old or existing valve as they may damaged or
not be adequate for the working pressure of the new water heater. Do not
place any valve between the relief valve and the tank.
• Must be installed to allow complete drainage of both the temperature
and pressure relief valve and discharge line.
WARNING
FAILURE TO INSTALL AND MAINTAIN A NEW PROPERLY LISTED
TEMPERATURE AND PRESSURE RELIEF VALVE WILL RELEASE THE
MANUFACTURER FROM ANY CLAIMS WHICH MIGHT RESULT FROM
EXCESSIVE TEMPERATURE OR WATER PRESSURE.
Manually operate the temperature and pressure relief valve at least once a
year to make sure it is working properly. To prevent water damage, the
valve must be properly connected
to a discharge line which
terminates at an adequate drain.
Standing clear of the outlet
(discharged water may be hot),
slowly lift and release the lever
handle on the temperature and
pressure relief valve to allow the
valve to operate freely and return
to its closed position. If the valve
fails to completely reset and
continues to release water, immediately shut off the manual gas valve and
the cold water inlet valve and call a qualified service technician.
11
WATER SYSTEM PIPING (CONT.)
WARNING
DISCHARGING WATER MAY BE HOT AND CAN CAUSE SCALD INJURIES
AND PROPERTY DAMAGE. DISCHARGE LINES MUST BE PROPERLY
INSTALLED AND PIPED TO AN ADEQUATE DRAIN.
CLOSED SYSTEM/THERMAL EXPANSION
Periodic discharge of the temperature and pressure relief valve may be due to
thermal expansion in a closed water supply system. The water utility supply
meter may contain a check valve, backflow preventer or water pressure
reducing valve. This will create a closed water system. During the heating
cycle of the water heater, the water expands causing pressure inside the water
heater to increase. The temperature and pressure relief valve may discharge hot
water under these conditions which results in a loss of energy and a build-up of
lime on the relief valve seat. To prevent this from happening, there are two
recommendations:
1. Install a 125 PSI pressure relief valve in the cold water supply line. Make
sure the discharge of this valve is directed to an open drain and
protected from freezing.
2. Install a diaphragm-type expansion tank that is suitable for potable water
on the cold water supply line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons of stored water.
Contact the local water supplier or plumbing inspector for information on how
to control this situation. Do not plug the temperature and pressure relief valve.
PIPING INSTALLATION
Piping, fittings, and valves should be installed according to the installation
drawing (Figure 14). If the indoor installation area is subject to freezing
temperatures, the water piping must be protected by insulation.
Water supply pressure should not exceed 80% of the working pressure of the
water heater. The working pressure is stated on the water heater’s data plate.
If this occurs a pressure limiting valve with a by-pass may need to be installed
in the cold water inlet line. This should be placed on the supply to the entire
house in order to maintain equal hot and cold water pressures.
IMPORTANT: Heat cannot be applied to the water fittings on the heater as
they may contain nonmetallic parts. If solder connections are used, solder the
pipe to the adapter before attaching the adapter to the hot and cold water
fittings.
IMPORTANT: Always use a good grade of joint compound and be certain that
all fittings are drawn up tight.
1. Install the water piping and fittings as shown in the Figure 14. Connect the
cold water supply (3/4 NPT) to the fitting marked “C”. Connect the hot
water supply (3/4 NPT) to the fitting marked “H”. Make sure the dip tube
is in the cold water fitting before connecting the hot and cold water lines.
(Note: 75T75 has 1"NPT)
IMPORTANT: Some models may contain energy saving heat traps to prevent
the circulation of hot water within the pipes. Do not remove the pink and blue
inserts within the heat traps.
2. Installation of unions in both the hot and cold water supply lines is
recommended for ease of removing the water heater for service or
replacement.
3. The manufacturer of this water heater recommends installing a tempering
valve or an anti-scald device in the domestic hot water line as shown in
Figure 15. These valves reduce the point of use temperature of the water
by mixing cold and hot water and are readily available for use. Contact a
licensed plumber or the local plumbing authority.
12
4. If installing the water heater in a closed water system, install a relief valve
or expansion tank in the cold water line as specified under “Closed
System/Thermal Expansion”.
5. Install a shutoff valve in the cold water inlet line. It should be located
close to the water heater and be easily accessible. Know the location of
this valve and how to shut off the water to the heater.
6. Install a temperature and pressure relief valve and discharge line in the
opening marked “T & P RELIEF VALVE”. Install as specified under
“Temperature and Pressure Relief Valve, pg. 11 “.
7. After piping has been properly connected to the water heater, open the
nearest hot water faucet and allow the tank to completely fill with water.
To purge the lines of any excess air and sediment, keep the hot water
faucet open for 3 minutes after a constant flow of water is obtained. Close
the faucet and check all connections for leaks.
SPECIAL APPLICATIONS
COMBINATION SPACE
HEATING/POTABLE WATER
HEATING SYSTEM
Some water heater models are equipped with
inlet/outlet tappings for use with space heating
applications. If this water heater is to be used to
supply both space heating and domestic potable
(drinking) water, the instructions listed below must
be followed.
•
Be sure to follow the manual(s) shipped with
the air handler system.
•
This water heater is not to be used as a
replacement for an existing boiler
installation.
•
Do not use with piping that has been
treated with chromates, boiler seal or
other chemicals.
•
This water piping contains potable
(drinkable) water. Do not add boiler
treatment or any chemicals to any water
heater piping.
•
If the space heating system requires water
temperatures in excess of 120°F, a tempering valve or an anti-scald
device should be installed per its manufacturer’s instructions in the
domestic (potable) hot water supply to limit the risk of scald injury.
•
Pumps, valves, and fittings must be compatible with potable water
piping.
•
Some jurisdictions may require a backflow preventer in the incoming
cold water line. This may cause the temperature and pressure relief
SOLAR INSTALLATION
If this water heater is used as a SOLAR STORAGE HEATER OR AS A
BACKUP FOR THE SOLAR SYSTEM, the water supply temperatures to
the water heater tank may be in excess of 120°F. A tempering valve or
other temperature limiting valve must be installed in the water supply line
to limit the supply temperature to 120°F. An anti-scald device must be
installed in the domestic hot water supply line to limit the risk of scald
injury.
valve on the water heater to discharge or weep due to expansion of
the heated water. A diaphragm-type expansion tank suitable for
potable water will normally eliminate this weeping condition. Please
read and follow the manufacturer’s instructions for the installation of
such tanks.
•
Also see “General Information, Water System Piping”, pg. 11 for
additional instructions on the safe and correct installation and
operation of this water heater.
WARNING
WATER SUPPLY TO THIS HEATER MUST NOT EXCEED 180°F.
WATER TEMPERATURE IN EXCESS OF 180°F WILL CAUSE THE
HIGH LIMIT CONTROL TO OPEN AND SHUT OFF THE GAS SUPPLY
TO THE UNIT. THE HIGH LIMIT CONTROL IS A SINGLE USE TYPE
THAT WILL REQUIRE THE REPLACEMENT OF THE THERMOSTAT
BEFORE THE BURNER CAN OPERATE.
Solar Water Heating Systems can often supply water with temperatures
exceeding 180°F and may result in water heater malfunction. Please read
the following warning.
13
GAS SUPPLY AND PIPING
GENERAL INFORMATION
DANGER
THIS WATER HEATER IS EQUIPPED FOR ONE TYPE OF GAS ONLY.
DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN
THE ONE LISTED ON THE DATA PLATE LOCATED NEAR THE GAS
CONTROL. FAILURE TO USE THE CORRECT GAS CAN RESULT IN
PROPERTY DAMAGE, BODILY INJURY, OR DEATH.
This water heater must only be connected to gas supplied by a
commercial utility.
GAS PIPING
Install the gas piping according to all local and state codes or with the
”National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)-Latest Edition.
Do not use copper and brass piping and fittings (except tin-lined copper
tubing) if the gas contains more than 0.3 grains of hydrogen sulfide per
100 standard cubit feet of gas. Contact your local gas utility company if
you are unsure about this.
Table 2 and or Table 3 are provided as a sizing reference for commonly
used gas pipe materials. Consult the “National Fuel and Gas Code” for the
recommended gas pipe size of other materials.
DANGER
THE GAS LINE MUST BE OF ADEQUATE SIZE SO AS TO PREVENT
UNDUE PRESSURE DROP AND NEVER SMALLER THAN THE PIPE
SIZE TO THE GAS VALVE ON THE WATER HEATER. FAILURE TO
PROPERLY SIZE THE GAS LINE CAN CAUSE A FIRE OR EXPLOSION
RESULTING IN PROPERTY DAMAGE, BODILY INJURY OR DEATH.
TABLE 2
NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in.
and specific gravity of 0.60 (natural gas).
Nominal
Length of Pipe, Feet
Iron Pipe
Size, Inches
10
20
30
40
50
60
70
80
90
100
1/2
132
92
73
63
56
50
46
43
40
38
3/4
278
190
152
130
115
105
96
90
84
79
1
520
350
285
245
215
195
180
170
160
150
1-1/4
1050
730
590
500
440
400
370
350
320
305
1-1/2
1600
1100
890
760
670
610
560
530
490
460
After the length of pipe has been determined, select the pipe size which will provide the minimum cubit feet per
hour required for the gas input rating of the water heater. By formula:
Gas Input of Water Heater (BTU/HR)
Cu. Ft. Per Hr. Required =
Heating Value of Gas (BTU/FT³)
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas
(BTU/FT3) may be determined by consulting the local natural gas utility.
WARNING
CONTAMINANTS IN THE GAS PIPING
MAY FOUL THE THERMOSTAT CAUSING
A MALFUNCTION, FIRE, OR EXPLOSION.
BE SURE ALL GAS PIPING IS CLEAN AND
CLEAR ON THE INSIDE BEFORE
ATTACHING THE GAS LINE.
TABLE 3
LP GAS PIPE CAPACITY TABLE
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column pressure). Based on a
Pressure Drop of 0.5 Inch Water Column.
Nominal iron
Length of Pipe, Feet
pipe size, in.
10
20
30
40
50
60
70
80
90
100
125
150
1/2
275
189
152
129
114
103
96
89
83
78
69
63
3/4
567
393
315
267
237
217
196
185
173
162
146
132
1
1071
732
590
504
448
409
378
346
322
307
275
252
1-1/4
2205
1496
1212
1039
913
834
771
724
677
630
567
511
Example: Input BTU requirement of the water heater, 100,000 BTUH
When installing gas piping, use a pipe joint compound that is resistant
to the action of propane (LPG) gases. Apply the compound to male
threads only. Do not apply the compound to the first 2 threads. Do not
use TEFLON tape.
Do not use pipe joint compound or TEFLON tape on the union
connection.
When making pipe connections, use a back-up wrench to prevent any
twisting of the control valve/thermostat assembly. Do not use
excessive force when tightening the pipe joint at the thermostat inlet.
Refer to Figure 16 and install as follows:
1.
14
Install a readily accessible manual shutoff valve in the gas
supply line as recommended by the local utility. Know the
location of this valve and how to turn off the gas to this unit.
Total pipe length, 80 feet = 3/4" IPS required.
GAS SUPPLY AND PIPING (CONT.)
2.
Install a drip leg (if not already incorporated as part of the water
heater) as shown. The drip leg must be no less than 3 inches long for
the accumulation of dirt, foreign material and water droplets.
3. Install a ground joint union between the gas valve/thermostat and the
manual shutoff valve. This is to allow easy removal of the gas valve/
thermostat.
IMPORTANT: Refer to the "Gas Pressure Testing" section on this page before
pressure testing the gas lines.
4. Turn the gas supply on and check for leaks. Use a chloride-free soap
and water solution (bubbles forming indicate a leak) or other approved
method. Do not use an open flame. ALL LEAKS MUST BE FIXED
IMMEDIATELY.
IMPORTANT: Air may be present in the gas lines and could prevent the
pilot from lighting on initial start-up. The gas lines should be purged of air
by a qualified service technician after installation of the gas piping system.
The gas supply pressure must not exceed the maximum supply pressure as
stated on the water heater’s data plate. The minimum supply pressure is
for the purpose of input adjustment
GAS PRESSURE TESTING
IMPORTANT: Subjecting the gas valve/thermostat to pressures
exceeding 14” W.C. (1/2 psi, 3.7 kPa) may cause damage resulting in
an extremely hazardous condition.
•
If the code requires the gas lines to be tested at a pressure exceeding
14” W.C., the water heater and its manual shutoff valve must be
disconnected from the gas supply piping system and the line
capped.
•
If the gas lines are to be tested at a pressure less than 14” W.C. the
water heater must be isolated from the gas supply piping system by
closing its manual shutoff valve.
DANGER
DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK
GAS PIPING FOR LEAKS. IF LEAKING GAS IS PRESENT, AN
EXPLOSION OR FIRE MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
IMPORTANT: This water heater’s gas controls and its gas connection
must be leak tested before placing the appliance in operation.
A U.L. RECOGNIZED FUEL GAS AND CO DETECTOR(S) ARE
RECOMMENDED IN ALL APPLICATIONS AND THEIR INSTALLATION
SHOULD BE IN ACCORDANCE WITH THE MANUFACTURER’S
RECOMMENDATIONS AND/OR LOCAL LAWS, RULES, REGULATIONS,
OR CUSTOMS.
ELECTRICAL CONNECTIONS
WARNING
ELECTRICAL WIRING CONNECTIONS MUST ONLY BE
PERFORMED BY A QUALIFIED ELECTRICIAN.
The electrical rating of this water heater is 115 volts and less than
5 amps. All electrical wiring and connections must be properly
grounded in accordance with the local codes or in the absence of
local codes, with the National Electric Code ANSI/NFPA 70 - Latest
Edition. In Canada, all electrical connections must be in accordance
with the Canadian Electrical Code Part 1-022.1.
The electrical service to the water heater must be equipped
with the proper overload fuse or breaker protection for the
specified electrical rating.
The power vent module is supplied with a flexible, grounded power
cord and connects to a standard three wire, grounding type
receptacle. Do not use an extension cord.
WARNING
THIS WATER HEATER MUST BE ELECTRICALLY GROUNDED
IN ACCORDANCE WITH THE PREVAILING ELECTRICAL CODE.
15
ELECTRICAL CONNECTIONS (CON'T)
Some local codes may prohibit the use of a flexible power cord. If
wiring in conduit is required:
1. TURN OFF THE POWER TO THE ELECTRICAL SERVICE.
2. Remove the two screws holding the top cover plate onto the
control box. Remove the cover plate and set aside.
3. Cut the flexible power cord on the inside of the control box as near
to the strain relief as possible. Remove the strain relief and power
cord from the control box housing.
4. Install a listed conduit into the hole in the housing. If needed,
enlarge the hole accordingly to accommodate the conduit. Feed the
field wire through the conduit and into the control box.
5. Splice the field wiring into the existing wiring using a method in
accordance with the prevailing local or national codes. DO NOT REVERSE
THE ELECTRICAL CONNECTIONS. REVERSING THE ELECTRICAL
CONNECTIONS WILL CAUSE AN ELECTRICAL SHOCK HAZARD.
• Black - Line or “Hot”
• White - Neutral
• Green - Ground
6. Replace the top cover plate and secure with two screws.
7. Restore the power to the electrical service.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING
CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION.
Verify proper operation after servicing.
INSTALLATION CHECKLIST
WATER HEATER LOCATION
◊
◊
◊
◊
◊
◊
Centrally located with the water piping system. Located close to the gas
piping and vent pipe system as possible.
Located indoors and in a vertical position. Protected from freezing
temperatures.
Proper clearances from combustible surfaces maintained and not installed
directly on a carpeted floor.
Provisions made to protect the area from water damage.
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.
VENTILATION AND COMBUSTION AIR SUPPLY
◊
◊
◊
◊
Sufficient fresh air supply for proper water heater operation.
Fresh air not taken from areas that contain negative pressure producing
devices.
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
◊ Installed with 3 inch, Schedule 40, PVC, ABS-DWP, or CPVC plastic pipe
◊
16
and fittings only. Do not use Foam Core PVC pipe and fittings.
No short radius or medium sweep fittings. Use only long sweep fittings
and elbows.
◊
◊
◊
◊
Maximum vent pipe length of 40 feet maximum with three 90° long sweep
ells not exceeded. Vent pipe supported and secure.
Vent pipe terminal opening facing downward and installed with proper
clearances.
Vent pipe system in accordance with “National Fuel Gas Code”, NFPA 54,
ANSI Z223.1-Latest Edition or prevailing provisions of local codes.
Flue baffle engaged in slots provided in the flue tube.
◊ 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 or anti-scald device installed per manufacturer’s
instructions
GAS SUPPLY AND PIPING
◊
◊
◊
◊
Gas supply is the same type as listed on the water heater data plate.
Gas line equipped with shut-off valve, union and drip leg.
Approved pipe joint compound used.
Adequate pipe size and of approved material.
◊
Chloride-free soap and water solution or other approved means used to
check all connections and fittings for possible gas leaks.
ELECTRICAL
◊ Installed in accordance with the prevailing electrical codes.
SEQUENCE OF OPERATION
When the thermostat senses a need for hot water, a valve is opened which
allows gas to flow to the closed solenoid valve. As gas pressure builds up
within the solenoid, the gas pressure switch closes and 24 VAC flows to
the blower relay.
The blower relay contacts close and send 115 VAC to the vent blower
which turns it on. Air flow from the vent blower closes the air pressure
switch sending 24 VAC to the solenoid valve. The solenoid valve opens
and allows gas to flow to the burner which is lit by the pilot.
START-UP / OPERATION
WARNING
8.
IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR
EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PER-SONAL
INJURY OR LOSS OF LIFE.
Read these directions thoroughly before attempting to light or relight the
pilot. Check the data plate near the gas valve control/thermostat for the
correct gas. Do not use this water heater with any gas other than the one
listed on the data plate. If you have any questions or doubts consult your
gas supplier or gas utility company.
DO NOT:
Do not go back into the building . Wait for help to arrive outside of
the building.
L.P.G. (BOTTLED PROPANE) MODELS
Liquefied Petroleum Gas is over 50% heavier than air and in the occurrence
of a leak in the system the gas will settle at FLOOR LEVEL. Basements,
crawl spaces, skirted areas under mobile homes (even when ventilated),
closets and areas below ground level will serve as pockets for the
accumulation of gas. Before lighting an L.P. gas water heater, smell all
around the appliance at floor level. If you smell gas, follow the directions
as given above.
When your L.P. tank runs out of fuel, turn off the gas at all gas appliances
including pilot lights. After the tank is refilled, all appliances must be re-lit
according to their manufacturer’s instructions.
•
Operate the water heater if it has been subjected to physical
damage, flooding, or fire.
•
Operate the water heater unless the tank is filled with water.
•
Operate the water heater if the cold water supply inlet valve is
closed.
•
Allow flammable liquids such as gasoline or paint thinner to be stored
or used near this water heater.
•
Allow combustible materials such as newspapers, rags or mops to
accumulate near this water heater.
•
Set or store anything on top of this water heater as it may block the
blower air intake.
•
Light this water heater until all lighting instructions are understood
and followed. Lighting instructions are clearly given in this manual
and on the water heater label.
•
Light this water heater if you smell gas around the appliance area.
1.
Open the windows.
CHECKING THE DRAFT
2.
Get all people out of the building.
3.
Do not light matches or any other appliance. Do not smoke.
4.
Do not touch any electrical switches (on or off) or use any phones in
your residence.
After successfully lighting the
water heater, allow the unit to
operate for 15 minutes and check
the blower module for proper draft.
Pass a match flame around the
relief opening of the blower module.
A steady flame drawn into the
opening indicates proper draft. If
the flame flutters or is blown out,
combustion products are escaping
from the relief opening. If this
occurs, do not operate the water heater until proper adjustments or repairs
are made to the vent pipe system.
IF YOU SMELL GAS:
5.
Extinguish any open flames immediately.
6.
Shut off the gas at the manual shut-off valve. (If using liquid propane
gas, shut off the gas at the L.P. tank outside of your residence.)
7.
Use an outside phone and immediately call the gas company and the
fire department. Give your name and address and ask for
instructions.
WATER EXPOSURE
Do not try to light this water heater if the gas valve, main burner, or pilot
have been exposed to water in any way. Immediately call a qualified
service technician to inspect the water heater. DO NOT attempt to repair
these parts. Water heaters subjected to flood conditions or anytime the
main burner, gas controls, or pilot have been submerged in water require
replacement of the entire water heater.
LIGHTING THE WATER HEATER
WARNING
DO NOT ATTEMPT TO LIGHT THIS WATER HEATER UNTIL IT IS
PROPERLY INSTALLED AND YOU UNDERSTAND ALL OF THE SAFETY
WARNINGS AND PRECAUTIONS.
Check the Gas Control Valve/Thermostat and determine which model is
being used for your water heater. Refer to either Figure 17A or 17B and
light the water heater according to its directions.
17
FIGURE 17A : LIGHTING INSTRUCTIONS (ROBERTSHAW THERMOSTAT)
FOR YOUR SAFETY READ BEFORE LIGHTING
WA R N I N G
If you do not follow these directions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by hand. When
lighting the pilot, follow these instructions exactly.
B. BEFORE LIGHTING smell all around the appliance area for gas.
Be sure to smell next to the floor because some gas is heavier
than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in
your building.
• Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or move by hand,
don’t try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance. Water heaters subjected to flood conditions or
anytime the gas controls, main burner or pilot have been
submerged in water require replacement of the entire water
heater.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety warnings
before lighting the pilot.
2. Remove outer and inner doors.
3. Turn the temperature dial counterclockwise
setting.
4. Turn
to its lowest
gas control knob
clockwise
position.
to the “OFF”
5. To clear any gas that may
have accumulated wait ten
(10) minutes. If you then smell gas, STOP! Follow “B” in the
safety warning above. If you do not smell gas go to the next
step.
7. Turn the gas control knob
counterclockwise
“PILOT”.
to
8. Light match and hold to pilot.
Depress the reset button all
the way in; hold until pilot
lights. Repeat immediately if pilot does not light on the first
try. Continue to hold the button for about (1) minute after the
pilot is lit. Release the reset button and it will pop back up.
Pilot should remain lit. If the pilot light goes out, repeat steps 3
- 8.
IMPORTANT: If the pilot will not stay lit after several tries, turn
gas control knob to “OFF” and call your service technician or gas
supplier.
IMPORTANT: If the reset button does not pop up when released,
stop and immediately shut off the gas at the line valve or tank. Call
your service technician or gas supplier.
9. Replace the inner door.
10. Turn the gas control knob counterclockwise
11. Set the temperature dial to the
desired setting.
12. Replace the outer door.
to “ON”.
6. Find pilot - follow the smaller
metal
tube
from
the
thermostat to the pilot.
TO TURN OFF GAS TO APPLIANCE
1. Turn the temperature dial counterclockwise
setting.
18
to its lowest
2. Turn the gas control knob clockwise
to the “OFF” position.
FIGURE 17B : LIGHTING INSTRUCTIONS (WHITE-RODGERS THERMOSTAT)
FOR YOUR SAFETY READ BEFORE LIGHTING
WA R N I N G
If you do not follow these directions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by a hand.
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 technic-ian to inspect the
appliance. Water heaters subjected to flood conditions or any
time the gas controls, main burner or pilot have been
submerged in water require replacement of the entire water
heater.
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all the safety warnings
before lighting the pilot.
2. Remove outer and inner doors.
3. Set the thermostat to its lowest setting. (Rotate clockwise
).
4. Depress the gas control knob slightly and turn clockwise
to “OFF”. If the knob is “ON”, turn it clockwise
to “PILOT” then depress the knob slightly and turn clockwise
to “OFF”.
6. Find the pilot - Follow the smaller metal tube from thermostat
to the pilot.
7. Turn the gas control knob
counterclockwise
to “PILOT”.
8. Light the match and hold to the pilot. Depress the control
knob all the way; hold until pilot lights. Continue to hold the
control knob down for about (1) minute after the pilot is lit.
Release knob and it will pop back up. Pilot should remain lit.
If the pilot light goes out, repeat steps 3 -8.
IMPORTANT: If the pilot will not stay lit after several tries, turn
gas control knob to “OFF” and call your service technician or gas
supplier.
IMPORTANT: If the knob does not pop up when released, turn
the knob to “OFF”, stop and immediately call your service
technician or gas supplier.
9. Replace the inner door.
10. Turn the gas control knob counterclockwise
NOTE: Knob cannot be turned from “PILOT” to “OFF” unless knob
is depressed slightly. Do not use tools or excessive force.
5. To clear any gas that may have accumulated wait ten (10)
minutes. If you then smell gas, STOP! Follow “B” in the
safety warning above. If you do not smell gas go to the next
step.
to “ON”.
11. Set the temperature dial to the desired setting.
12. Replace the outer door.
TO TURN OFF THE GAS TO APPLIANCE
1. Set the thermostat to its lowest setting.
to “PILOT”.
2. Turn gas control knob clockwise
3. Depress the gas control knob slightly and turn clockwsie
“OFF”. Do not use tools or force.
to
19
START-UP/OPERATION (CONT.)
BURNER FLAMES
Inspect the burner flames and
compare them to the drawings in
Figure 18. A properly operating
burner should produce a soft blue
flame. Blue tips with yellow inner
cones are satisfactory. The tips of
the flame may have a slight yellow
tint. The flame should not be all
yellow or have a sharp blue-orange
color. Contaminated air may cause
an orange colored flame. A main
burner adjustment is provided for
L.P. gas water heaters only. This is
a primary air controlling device and
is located at the end of the burner
venturi. (See Figure 19). Loosen the
screw and open the device to
sharpen the flame. Close the device
to soften the flame. Retighten the
screw after adjusting the flame. Natural gas models do not have a field
adjustment. Contact a qualified service technician if the flame is not
satisfactory.
WATER TEMPERATURE REGULATION
The thermostat is adjusted to its lowest temperature when it is shipped from
the factory. Water temperature can be regulated by moving the temperature dial
to the preferred setting. The preferred starting point is 120°F. Align the
index bar on the thermostat with the desired water temperature as shown in
Figures 20 and 21. There is a hot water scald potential if the thermostat
is set too high.
WARNING
ADJUSTING THE THERMOSTAT PAST THE 120°F BAR ON THE
TEMPERATURE DIAL WILL INCREASE THE RISK OF SCALD INJURY.
During low demand periods when hot water is not being used, a lower
thermostat setting will reduce energy losses and may satisfy your normal hot
water needs. If hot water use is expected to be more than normal, a higher
thermostat setting may be required to meet the increased demand.
When leaving your home for extended periods (vacations, etc.) turn the
temperature dial to its lowest setting. This will maintain the water at low
temperatures with minimum energy losses and prevent the tank from freezing
during cold weather.
WARNING
HOT WATER CAN PRODUCE FIRST DEGREE BURNS WITHIN:
3 SECONDS AT 140°F (60°C)
20 SECONDS AT 130°F (54°C)
8 MINUTES AT 120°F (49°C)
WARNING
HOUSEHOLDS WITH SMALL CHILDREN, ELDERLY, IMPAIRED OR
DISABLED MEMBERS AND ANYONE WITH TEMPERATURE SENSITIVE
SKIN MAY REQUIRE A LOWER TEMPERATURE SETTING TO REDUCE THE
RISK OF SCALD INJURY.
STACKING
Stacking occurs when short draws of hot water (3 gallons or less) are taken
from the water heater tank. This causes increased cycling of the burner and can
result in increased water temperatures at the hot water outlet. Always install
an anti-scald device in the hot water supply line to reduce the risk of scald
injury.
EMERGENCY SHUT DOWN
IMPORTANT: Should overheating occur or the gas supply fail to shut off, turn
off the water heater’s manual gas control valve and call a qualified service
technician.
OPERATINAL CONDITIONS
CONDENSATION
Moisture from the products of combustion condenses on the tank surface and
forms drops of water which may fall onto the burner or other hot surfaces. This
will produce a “sizzling” or “frying” noise. This condensation is normal and
should not be confused with a leaking tank. Condensation may increase or
decrease at different times of the year.
High efficient Energy Saver water heaters will produce larger amounts of
condensation on initial light up or when a large amount of hot water is being
used. Do not confuse this with a “tank leak”. Once the water reaches a
temperature of 120°F and the tank warms up (usually 30 - 45 minutes), the
condensation will stop.
Operating the water heater at the lowest thermostat setting may increase the
amount of condensation. Adjusting the thermostat slightly higher may eliminate
this problem.
IMPORTANT: It is always recommended that a suitable drain pan be installed
under the water heater to protect the area from water damage resulting from
normal condensation production or a leaking tank or piping connections (See
pages 5 and 6, “Location Requirements and Considerations”). Under no
circumstances is the manufacturer to be held responsible for any water damage
in connection with this water heater.
WATER HEATER SOUNDS
During the normal operation of the water heater, sounds or noises may be
heard. These noises are common and may result from the following:
1. Normal expansion and contraction of metal parts during periods of heat-up
and cool-down .
2.
20
Condensation causes sizzling and popping within the burner area and
should be considered normal.
OPERATIONAL CONDITIONS (CON'T)
3.
Sediment build-up in the tank bottom will create varying amounts of noise
and may cause premature tank failure. Drain and flush the tank as
directed under “Draining and Flushing”.
MAINTENANCE
BLOWER MOTOR
1. Lubricate the motor every 6 months
with 4 drops of S.A.E. 20 oil in the
openings as shown. DO NOT
OVEROIL.
SMOKE/ODOR
The water heater may give off a small amount of smoke and odor during the
initial start-up of the unit. This is due to the burning off of oil from the metal
parts of a new unit and will disappear after a few minutes of operation.
2. Remove any foreign materials from
the vent pipe system before
operating the blower. The blower
wheel must be clear of debris or
soot and allowed to rotate freely.
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).
A flame-sensing thermocouple is used to determine if a pilot flame is present
and will immediately shut off the gas supply to the main burner and the pilot
burner if the flame is absent.
A high temperature limit switch or ECO (Energy Cut Off) is used to shut off the
unit if the water temperature exceeds 180°F (83°C). The ECO is a single use
switch and requires complete replacement of the entire thermostat. If the ECO
should function, the water heater cannot be used until the thermostat is
replaced by a qualified service agency. Contact your local dealer for service
information.
DANGER
DO NOT ATTEMPT TO BY-PASS OR JUMPER THE ECO AS THIS CAN
RESULT IN PROPERTY DAMAGE, BODILY INJURY OR DEATH. THIS WILL
VOID THE WARRANTY AND RELEASE THE MANUFACTURER FROM ANY
LIABILITY FOR ANY INCIDENT RESULTING FROM ELIMINATING THE ECO
FROM THE WATER HEATER CIRCUIT.
WATER ODOR
Each water heater contains at least one anode rod which will slowly dissipate
while protecting the tank from corrosion. Certain water conditions will cause a
reaction between this rod and the water. The most common complaint
associated with the anode rod is one of a “rotten egg smell” produced from the
presence of hydrogen sulfide gas dissolved in the water. Do not remove this
rod as it will void any warranties, stated or implied. The parts list includes
a special anode that can be ordered if water odor or discoloration occurs. This
rod may reduce but not eliminate water odor problems. The water supply
system may require special filtration equipment from a water conditioning
company to successfully eliminate all water odor problems
HYDROGEN GAS BUILD-UP
DANGER
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM THAT
HAS NOT BEEN USED FOR A LONG PERIOD OF TIME (GENERALLY TWO
WEEKS OR MORE). HYDROGEN GAS IS EXTREMELY FLAMMABLE AND
CAN IGNITE WHEN EXPOSED TO A SPARK OR FLAME. TO PREVENT THE
POSSIBILITY OF INJURY UNDER THESE CONDITIONS, WE RECOMMEND
THE HOT WATER FAUCET BE OPENED FOR SEVERAL MINUTES AT THE
KITCHEN SINK BEFORE USING ANY ELECTRICAL APPLIANCE WHICH IS
CONNECTED TO THE HOT WATER SYSTEM. IF HYDROGEN IS PRESENT,
THERE WILL PROBABLY BE AN UNUSUAL SOUND SUCH AS AIR
ESCAPING THROUGH THE FAUCET AS WATER BEGINS TO FLOW. DO
NOT SMOKE OR HAVE ANY OPEN FLAME NEAR THE FAUCET AT THE
TIME IT IS OPEN.
DRAINING AND FLUSHING
The water heater should be drained if being shut down during freezing
temperatures. It is recommended that the tank be drained, flushed and cleaned
every 6 months to remove sediment which may build-up during operation. To
drain the tank perform the following steps:
1.
Turn off the gas to the water heater at the Manual Gas Shutoff Valve.
2.
Close the cold water inlet valve.
3.
Open a nearby hot water faucet.
4.
Open the water heater drain valve and allow all the water to drain from
the tank.
5.
Flush the tank with water as needed to remove sediment.
6.
Close the drain valve, refill the tank, and restart the heater as directed
under “Start-Up/Operation”.
If the water heater is going to be shut down for an extended period, the drain
valve should be left open.
NOTE: Condensation may occur when refilling the tank and should not be
confused with a tank leak.
DANGER
WATER DRAINING FROM THIS HEATER MAY BE HOT AND CAN RESULT
IN SCALD INJURY. DO NOT ALLOW ANYONE TO COME IN CONTACT
WITH THE DRAINING WATER AND TERMINATE THE DRAIN HOSE TO AN
ADEQUATE DRAIN
3 MONTH INSPECTION
At least every 3 months a visual inspection should be made of the venting and
air supply system, piping systems, main burner and pilot burner. Check the
water heater for the following:
•
Obstructions, damage, or deterioration in the venting system. Make sure
the ventilation and combustion air supplies are not obstructed.
•
Build-up of soot and carbon on the main burner and pilot burner. Check for
a soft blue flame.
•
Leaking or damaged water and gas piping.
•
Presence of flammable or corrosive materials in the installation area.
IMPORTANT: VERIFY PROPER OPERATION AFTER SERVICING THIS WATER
HEATER.
21
MAINTENANCE (CON'T)
WARNING
OBSTRUCTIONS OR HOLES IN THE VENT PIPE CAN CAUSE TOXIC
FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE
POISONING OR DEATH. THE VENT PIPE MUST BE REPLACED IF IT IS
LEAKING.
6.
Grasp the manifold tube and push down slightly to free the manifold,
pilot tube, bleed tube and thermocouple. Pull the burner out slightly to
free it from the holding bracket. Tilt the burner to one side and remove
it from the burner compartment (Figure 23).
7.
Check the burner to see if it is dirty or clogged. The burner may be
cleaned with soap and hot water. If a sooty condition exists, refer to the
Troubleshooting Chart , “Smoking and Carbon Formation”.
REPLACEMENT PARTS
Replacement parts may be ordered through your plumber or the local
distributor. Parts will be shipped at prevailing prices and billed accordingly.
When ordering replacement parts, always have the following information
ready:
1. Model, serial and product number.
2. Type of gas.
3. Item number.
4. Parts Description.
See page 26 for a list of available repair parts.
TROUBLESHOOTING
Water heater service should only be performed by a qualified service
technician. Refer to the Trouble-shooting Chart on pages 24 and 25 for
determining the cause of water heater problems.
SELF-CLEANING (SOME MODELS)
Some water heaters may include a self-cleaning “DE-LIMER” device that
inhibits the build-up of lime and other sediment on the metal surfaces of the
water heater. By installing a series of magnets in the dip tube, a magnetic
field is formed which automatically suspends lime-causing particles and
sediment as cold water passes into the tank. This controls sediment and lime
build-up within the tank resulting in higher efficiencies and lower operation
costs.
REMOVING THE BURNER ASSEMBLY
REPLACING THE BURNER ASSEMBLY
1.
2.
WARNING
REMOVAL AND REPLACEMENT OF THE BURNER ASSEMBLY INVOLVES
THE DISCONNECTION OF GAS PIPING AND LEAK TESTING. THE
FOLLOWING PROCEDURES SHOULD ONLY BE PERFORMED BY A
QUALIFIED SERVICE TECHNICIAN.
3.
1.
Turn the gas control knob on the combination gas control
valve/thermostat clockwise to the “OFF” position.
2.
Disconnect
electrical
power to water heater.
4.
3.
Label all wires before
disconnecting. Disconnect
wires from the pressure
switch and solenoid valve.
5.
4.
Remove the outer and
inner doors.
5.
Disconnect
the
thermocouple, pilot tube,
bleed tube and manifold
extension
at
the
thermostat (Figure 22).
Note that L.P. gas
systems use reverse (lefthanded) threads on the
manifold tube.
22
6.
Insert the burner into the burner compartment making sure that the
manifold tab engages with the
holding bracket inside the burner
compartment (Figure 24). The tab
is located at the bottom of the
burner for L.P. models. The
manifold tube will now line up
with the thermostat connection.
Reconnect the manifold extension,
bleed tube and pilot tube. Do not
cross thread these fittings. L.P.
gas systems use reverse (lefthanded) threads on the manifold tube. Do not apply any thread sealant
(pipe dope, Teflon tape, etc.) to these connections.
Reconnect the thermocouple. The thermocouple nut should be started
and turned all the way in by hand. An additional quarter turn with a 3/8”
open end wrench will then be sufficient to seat the lockwasher.
IMPORTANT: Overtightening may damage the thermocouple or the
thermostat.
Reconnect wires to pressure switch and solenoid valve. Turn on
electrical power to water heater.
Relight the water heater according to the lighting instructions in Figure
17A or 17B..
Check for gas leaks with a chloride-free soap and water solution or
other approved method. FIX ALL LEAKS IMMEDIATELY.
DANGER
DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK GAS
PIPING FOR LEAKS. IF LEAKING GAS IS PRESENT, AN EXPLOSION OR
FIRE MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY
OR DEATH.
NOTE:
The burner assembly shown in Fig. 23, and 25 are typical for Natural Gas
models. LPG models and models equipped with Low Nox burners will vary in
appearance.
REMOVAL AND REPLACEMENT OF THE GAS CONTROL VALVE/ THERMOSTAT
WARNING
CAUTION
REMOVAL AND REPLACEMENT OF THE GAS CONTROL VALVE /
THERMOSTAT INVOLVES THE DISCONNECTION OF GAS PIPING,
MANIFOLD TUBE, PILOT TUBE, BLEED TUBE AND THERMOCOUPLE.
IT IS RECOMMENDED THAT THIS PROCEDURE BE PERFORMED BY A
QUALIFIED SERVICE TECHNICIAN.
WHEN REMOVING THE GAS CONTROL VALVE / THERMOSTAT DO NOT
USE PIPE WRENCH OR VISE TO GRIP BODY OR ANY TYPE OF BLUNT
INSTRUMENT INTO THE INLET OR OUTLET CONNECTIONS. USING
THESE TYPE TOOLS MAY RESULT IN DAMAGE TO THE GAS CONTROL
VALVE / THERMOSTAT.
1. On the gas control valve/thermostat turn the temperature dial
7.
2. Disconnect electrical power to water heater.
To replace the gas control valve/ thermostat repeat the
previous procedure in reverse order.
counterclockwise to its lowest setting. Turn the gas control knob
clockwise to the "OFF" position. See Figures 20 and 21 page 20.
3. Turn off the gas at the manual shutoff valve on the gas supply pipe.
See Figure 16 on page 14.
4. Drain the water heater. Refer to section "Draining and Flushing" on
page 21 and follow procedure.
5. Disconnect the thermocouple, pilot tube, bleed tube and manifold
extension at the thermostat. See Figure 22 page 22. Note that L.P. gas
systems use reverse (left-handed) threads on the manifold tube
extension.
6. Refer to Gas Piping Figure 16 on page 14 and disconnect the ground
joint union in the gas piping. Disconnect the remaining pipe from the gas
valve/thermostat.
Turn the gas control valve/thermostat counterclockwise. Remove 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 gas valve that screws into
tank.
• Be sure to remove the pilot ferrule nut from the new gas control valve/
thermostat.
• Turn gas supply on and check for leaks. Use a chloride-free soap and
water solution (bubbles forming indicate a leak) or other approved method.
Do not use an open flame. ALL LEAKS MUST BE FIXED
IMMEDIATELY.
• Be sure tank is completely filled with water before lighting and activating
the water heater. Refer to Figure 17A or 17B for lighting procedure.
• If additional information is required, contact the Service Department at
the 800 number shown on the front of this manual.
THERMOCOUPLE AND/OR PILOT ASSEMBLY REPLACEMENT
Reference Figures 25 and 26 for the following procedures.
1.
Remove the burner assembly as directed in “Removal of the Burner
Assembly”, page 22.
If the thermocouple will not disengage from the pilot assembly, the entire
pilot assembly must be replaced:
2.
Grasp the thermocouple line and gently pull the thermocouple from
the pilot assembly.
1.
Remove the No. 8-32 screw which holds the pilot assembly and pilot
shield (if provided) to the main burner.
3.
Push the replacement thermocouple through the hole in the pilot
bracket until it snaps in place. The end of the thermocouple should
extend approximately 1/4 inch past the tip of the pilot assembly.
2.
Install the replacement pilot assembly to the main burner making sure
the pilot shield (if provided) is in the correct location.
4.
Replace the burner assembly as directed in "Replacing the Burner
Assembly" on page 22.
23
TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
HIGH OPERATION COSTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Improper calibration
Thermostat set too high
Sediment or lime in tank
Heater too small for job
Wrong piping connections
Leaking faucets
Gas leaks
Wasted hot water
Long runs of exposed piping
Hot water piping in exposed wall
No flue baffle
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Replace thermostat
Set temperature dial to lower setting.
Drain/Flush-Provide water treatment if needed
Install adequate heater
Correct piping-dip tube must be in cold inlet
Repair faucets
Check with utility-repair at once
Advise customer
Insulate piping
Insulate piping
Install flue baffle
PILOT WILL NOT LIGHT OR REMAIN
LIT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Low gas pressure
Air in gas line
No gas
Dirt in gas lines
Pilot line or orifice clogged
Thermocouple connection loose
Defective thermocouple
Cold drafts
Thermostat ECO switch open
Pilot and bleed tubes switched at the thermostat
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Check with gas utility company
Bleed air from gas line.
Check with gas utility company
Notify utility-install dirt trap in gas line
Clean, locate source and correct
Finger tighten-then 1/4 turn with wrench
Replace thermocouple
Locate source and correct
Replace thermostat
Switch pilot and bleed tube at the fittings located on the
thermostat bottom.
BLOWER NOT
OPERATING
1.
2.
No gas.
No pilot light.
1.
2.
3.
4.
5.
6.
Blower unplugged.
No power at outlet.
Defective control cable.
Defective gas pressure switch.
3.
4.
5.
6.
Check with the gas utility company.
Light the pilot or troubleshoot as directed under “Pilot Will Not
Remain Lit”.
Plug power cord int a 115 VAC outlet.
Check breaker or fuse. Restore power to outlet
Replace control cable.
Temporarily jumper across the two terminal on the switch. If the
blower operates, replace the switch.
7.
8.
Defective blower relay.
Defective blower.
7.
8.
Check voltages. Replace if defective.
Replace blower.
1.
Insufficient air flow to the air pressure switch.
1.
2.
3.
Main burner line clogged.
Low gas pressure
2.
3.
4.
5.
6.
Defective thermostat
Heater installed in a confined area.
Defective air pressure switch.
4.
5.
6.
7.
Defective solenoid.
7.
Check for the following:
a) Short ells used in vent system.
b) Low voltage to the blower motor.
c) Maximum vent pipe length exceeded.
d) Obstructions within the vent pipe system.
Clean, locate source and correct.
Check gas pressure for minimum requirements as stated on the
data plate.
Replace thermostat
Provide fresh air ventilation.
Temporarily jumper across the two terminals on the switch. If
the burner ignites, replace the switch.
Replace the solenoid.
HIGH VENT PIPE TEMPERATURE OR
MELTING
1.
2.
3.
Lack of combustion air.
Overfiring
Missing or wrong flue baffle.
IMMEDIATELY TAKE THE UNIT OUT OF SERVICE AND CONTACT AN
AUTHORIZED SERVICE REPRESENTATIVE OR THE FACTORY
BURNER FLAME FLOATS AND LIFTS
OFF PORTS
1.
2.
3.
4.
5.
High gas pressure
Orifice too large
Flue clogged
Heater installed in a confined area
Cold drafts
1.
2.
3.
4.
5.
Check with utility
Replace with correct orifice
Clean flue and burner-locate source & correct
Provide fresh air ventilation
Locate source and correct
BURNER FLAME YELLOW-LAZY
1.
2.
3.
4.
5.
6.
7.
Insufficient secondary air
Low gas pressure
Flue clogged
Main burner line clogged
Heater installed in a confined area
Obstruction in main burner orifice
Main burner needs adjusting (L.P. only)
1.
2.
3.
4.
5.
6.
7.
Provide ventilation to water heater
Check with gas utility company
Clean, locate source and correct
Clean, locate source and correct
Provide fresh air ventilation
Clean or replace orifice
See page 20, “Burner Flames” for flame adjustment.
BLOWER OPERATES, BURNER WILL
NOT IGNITE
24
TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
BURNER FLAME TOO HIGH
1.
2.
Insufficient secondary air
Orifice too large
1.
2.
Provide ventilation to water heater
Replace with correct orifice
FLAME BURNS AT ORIFICE
1.
2.
Low gas pressure
Defective thermostat
1.
2.
Check with gas utility company
Replace thermostat
PILOT FLAME
TOO SMALL
1.
2.
3.
Low gas pressure
Pilot line or orifice clogged
Wrong pilot burner
1.
2.
3.
Check with utility
Clean, locate source and correct
Replace with correct burner
PILOT FLAME TOO LARGE
1.
INSUFFICIENT HOT WATER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Low gas pressure
Orifice too small
Improper calibration
Thermostat set too low
Sediment or lime in tank
Water heater too small
Wrong piping connections
Leaking faucets
Wasted hot water
Long runs of exposed piping
Hot water piping in outside wall
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Check with gas utility company
Replace with correct orifice
Replace thermostat
Turn temperature dial to higher setting
Drain/flush-provide water treatment if needed
Install adequate heater
Correct piping-dip tube must be in cold inlet
Repair faucets
Advise customer
Insulate piping
Insulate piping
SLOW HOT WATER RECOVERY
1.
Insufficient secondary air
1.
2.
3.
4.
5.
6.
7.
8.
9.
Low gas pressure
Orifice too small
Improper calibration
Thermostat set too low
Heater too small
Wrong piping connections
Wasted hot water
Flue clogged
2.
3.
4.
5.
6.
7.
8.
9.
Provide ventilation to water heater. Check flue way , flue baffle
and burner.
Check with gas utility company
Replace with correct orifice
Replace thermostat
Turn temperature dial to lower setting
Install adequate heater
Correct piping-dip tube must be in cold inlet
Advise customer
Clean flue, locate source and correct
DRIP FROM RELIEF VALVE
1.
2.
3.
Excessive water pressure
Heater stacking
Closed water system
1.
2.
3.
Use a pressure reducing valve and relief valve.
Lower the thermostat setting
See page 12, “Closed System/Thermal Expansion”.
THERMOSTAT FAILS TO SHUT
OFF
1.
2.
Defective thermostat
Improper calibration
1.
2.
Replace thermostat
Replace thermostat
CONDENSATION
1.
Temperature setting too low
1.
Increase the temperature setting. See page 20.
COMBUSTION ODORS
1.
2.
3.
4.
Insufficient secondary air
Flue clogged
Heater installed in a confined area
House too “tight”
1.
2.
3.
4.
Provide fresh air ventilation to the water heater
Clean, locate source and correct.
Provide fresh air ventilation to the water heater
Provide fresh air ventilation to the water heater
SMOKING AND CARBON
FORMATION (SOOTING)
1.
Insufficient secondary air
1.
2.
3.
4.
5.
6.
7.
Low gas pressure
Orifice too large
Flue clogged
Defective thermostat
Heater installed in a confined area
Burner flame yellow-lazy
2.
3.
4.
5.
6.
7.
Provide ventilation to water heater. Check flue way, flue baffle,
and burner.
Check with gas utility company
Replace with correct orifice
Clean, locate source and correct
Replace thermostat
Provide fresh air ventilation.
See “Burner Flame Yellow-Lazy” above.
SMELLY WATER
1.
Sulfides in the water
1.
Replace the anode with a special anode.
DISCOLORATION OF JACKET
ABOVE COMBUSTION AREA
1.
2.
3.
Burner orifice too large
Flue clogged
High gas pressure
1.
2.
3.
Replace with correct orifice
Clean, locate source and correct
Adjust pressure to proper setting by qualified service personnel
only.
Wrong pilot burner
1.
Replace with correct burner
25
REPAIR PARTS
The following parts may be ordered through your plumber or the local
distributor. Parts will be shipped at prevailing prices and billed accordingly.
When ordering repair parts always give the following information:
1. Model ,serial and product number
2. Type of gas
3. Item number
4. Parts description
IMPORTANT: PARTS ARE NOT FIELD REPAIRABLE.
DEFECTIVE PARTS MUST BE REPLACED WITH THE
ORIGINAL FACTORY REPLACEMENT PARTS.
REFER TO THE PARTS ILLUSTRATION ON THE
FOLLOWING PAGE.
LEGEND
V Special anode rod (see page 21)
Q Temperature and Pressure Relief Valve is required, but may not be
factory installed.
+ It is imperative the replacement main burner, orifice, manifold, pilot
burner, and the thermostat be ordered for the proper gas type. Natural
gas thermostat will be marked "FOR NATURAL GAS ONLY". Propane
gas thermostats will be marked “FOR L.P. GAS ONLY”.
26
REPAIR PARTS LIST
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
13A
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
PARTS DESCRIPTION
BLOWER MOTOR ASSEMBLY
BLOWER OUTLET ADAPTER
BAFFLE ASSEMBLY
HEAT TRAP (COLD) - SOME MODELS
HEAT TRAP (HOT) - SOME MODELS
COLD WATER DIP TUBE
ANODE ROD
V
TEMPERATURE & PRESSURE RELIEF VALVE (LOCATED TOP
OR SIDE)
Q
DRAIN VALVE
THERMOSTAT
+
MANIFOLD
+
ORIFICE
+
MAIN BURNER
+
BURNER NATURAL LOW NOx
PILOT ASSEMBLY
+
PILOT TUBE
THERMOCOUPLE
SCREW 8-32 X .375 RH PH TYPE F
SCREW 8-32 X .250 SELF TAPPING
INNER DOOR
OUTER DOOR
ALTERNATE OUTER DOOR- SOME MODELS
PILOT SHIELD - SOME MODELS
AIR SHUTTER - L.P. MODELS ONLY
BLEED TUBE
TRANSFORMER
AIR PRESSURE SWITCH
AIR HOSE
BLOWER RELAY
GAS PRESSURE SWITCH
GAS VALVE SOLENOID
MANIFOLD EXTENSION
SCREW 8-32 X .750 PH RH MS
HEX NUT KEPS
REPAIR PARTS (CONT.)
PARTS ILLUSTRATION
27
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