CGN065 065 I & S Manual

CGN065 065 I & S Manual
Instruction Manual
COMMERCIAL GAS WATER HEATERS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
300 Maddox Simpson Parkway
Lebanon, TN 37090
Phone: 615-889-8900 • Fax: 615-547-1000
Technical Services email: [email protected]
www.lochinvar.com
GAMA certification applies
to all residential gas water
heaters with capacities of 20
to 100 gallons with input rating
of 75,000 BTU/Hr. or less.
LOW LEAD
COMPLIANT
®
C3 Technology ® Gas Water Heaters meet the new
ANSI Z21.10.1 standard that deals with the accidental or
unintended ignition of flammable vapors, such as those
emitted by gasoline.
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.
IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1-615-889-8900 OR VIA E-MAIL AT [email protected]
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
PRINTED 0911
1
322835-000
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
• Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
design features and use of flammable vapor ignition resistant water heaters, and have a thorough understanding of
this instruction manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing,
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines
provided by the manufacturer.
• Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of
gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also
offer service and inspection of appliances within the building.
2
GENERAL SAFETY
3
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE............................2
GENERAL SAFETY..................................................................3
TABLE OF CONTENTS............................................................4
INTRODUCTION ......................................................................4
Preparing for the New Installation .....................................4
TYPICAL INSTALLATION..................................................... 5-6
LOCATING THE NEW WATER HEATER .................................7
Facts to Consider About Location ................................. 7-8
Insulation Blankets ............................................................8
Combustion Air and Ventilation for Appliances
Located in Unconfined Spaces .........................................8
Combustion Air and Ventilation for Appliances
Located in Confined Spaces ......................................... 8-9
INSTALLING THE WATER HEATER ......................................10
Water Piping ..............................................................10-11
Temperature-Pressure Relief Valve ................................11
Filling the Water Heater ..................................................12
Venting ...................................................................... 12-13
Gas Piping ................................................................ 13-14
Sediment Traps ...............................................................14
LIGHTING & OPERATING LABEL .........................................15
TEMPERATURE REGULATION ............................................16
FOR YOUR INFORMATION ............................................. 16-17
Start Up Conditions .........................................................16
Draft Hood Operation ......................................................16
Condensate............................................................... 16-17
Smoke/Odor ....................................................................17
Thermal Expansion .........................................................17
Strange Sounds ..............................................................17
OPERATIONAL CONDITIONS ...............................................18
Smelly Water ...................................................................17
“Air” in Hot Water Faucets ..............................................17
High Temperature Shut Off System ................................17
PERIODIC MAINTENANCE ...................................................18
Venting System Inspection..............................................18
Burner Inspection ............................................................18
Burner Cleaning ..............................................................18
Housekeeping ........................................................... 18-19
Anode Rod Inspection.....................................................19
Temperature-Pressure Relief Valve Operation ...............19
Draining...........................................................................19
Drain Valve Washer Replacement ............................ 19-20
Service ............................................................................20
LEAKAGE CHECKPOINTS ....................................................20
REPAIR PARTS ......................................................................21
TROUBLESHOOTING ...........................................................22
NOTES ...................................................................................23
WARRANTY ......................................................................Insert
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
2. The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54. This publication is available from the Canadian
Standards Association, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
Abbreviations Found In This Instruction Manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility
or the manufacturer whose name appears on the rating plate.
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
4. Carefully plan the place where you are going to put the water
heater. Correct combustion, vent action, and vent pipe installation
are very important in preventing death from possible carbon
monoxide poisoning and fires, see Figures 1 and 2.
This gas-fired water heater is design certified by CSA INTERNATIONAL
under American National Standard/CSA Standard for Gas Water
Heaters ANSI Z21.10.1 • CSA 4.1 (current edition).
PREPARING FOR THE INSTALLATION
Examine the location to ensure the water heater complies with
the “Locating the New Water Heater” section in this manual.
1. Read the “General Safety” section, page 3 of this manual first and
then the entire manual carefully. If you don’t follow the safety rules,
the water heater will not operate properly. It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
5. For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. See instructions for correct installation procedures.
Instructions may be obtained from California Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired water heater. It also contains warnings
throughout the manual that you must read and be aware of. All
warnings and all instructions are essential to the proper operation
of the water heater and your safety. Since we cannot put everything
on the first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
7. Complies with SCAQMD rule #1121 and districts having equivalent
NOx requirements.
4
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
G
H
I
Vent Pipe
Drafthood
Anode
Hot Water Outlet
Outlet
Insulation
Gas Supply
Manual Gas Shut-off Valve
Ground Joint Union
J
K
L
M
N
O
P
Q
R
Drip Leg (Sediment Trap)
Inner Door
Outer door
Union
Inlet Water Shut-off Valve
Cold Water Inlet
Inlet Dip Tube
Temperature-Pressure Relief Valve
Rating Plate
* INSTALL IN ACCORDANCE
WITH LOCAL CODES.
S
T
U
V
W
X
Y
Z
ZZ
Flue Baffle
Thermostat
Drain Valve
Pilot and Main Burner
Flue
Drain Pan
Piezo Ignitor
Air Intake Screen
Thermostat Shield (optional)
(V) PILOT & MAIN BURNER
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
TO VENT TERMINATION
ON ROOF
(T) THERMOSTAT
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
FIGURE 1.
5
TYPICAL INSTALLATION
MIXING VALVE USAGE
FIGURE 2.
This appliance has been design certified as complying with American
National Standard/CSA Standard for water heaters and is considered
suitable for:
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing, and other sanitizing needs can scald and permanently injure
you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly, children,
the infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is a local
code or state law requiring a certain temperature water at the hot
water tap, then you must take special precautions. In addition to
using the lowest possible temperature setting that satisfies your
hot water needs, a means such as a *Mixing Valve, shall be used
at the hot water taps used by these people or at the water heater.
Mixing valves are available at plumbing supply or hardware stores.
Consult a Qualified Installer or Service Agency. Follow mixing valve
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the “Temperature
Regulation” section in this manual, see Figures 14 and 15.
Water (Potable) Heating and Space Heating: All models are
considered suitable for water (potable) heating and space heating.
6
LOCATING THE NEW WATER HEATER
flammable substances should never be stored or used in the same
vicinity or area containing a gas water heater or other open flame
or spark producing appliance.
FACTS TO CONSIDER ABOUT THE LOCATION
Carefully choose an indoor location for the new water heater, because
the placement is a very important consideration for the safety of the
occupants in the building and for the most economical use of the
appliance. This water heater is not for use in manufactured
(mobile) homes or outdoor installation.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
Whether replacing an old water heater or putting the water heater
in a new location, the following critical points must be observed:
1. Select a location indoors as close as practical to the gas vent or
chimney to which the water heater vent is going to be connected,
and as centralized with the water piping system as possible.
2. Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install
the water heater in an attic or upper floor. When such locations cannot
be avoided, a suitable drain pan should be installed under the water
heater. Drain pans are available at your local hardware store. Such a
drain pan must have a minimum length and width of at least 2 inches
(51 mm) greater that the water heater dimensions and must be piped
to an adequate drain. The pan must not restrict combustion air flow.
Water heater life depends upon water quality, water pressure and
the environment in which the water heater is installed. Water heaters
are sometimes installed in locations where leakage may result in
property damage, even with the use of a drain pan piped to a drain.
However, unanticipated damage can be reduced or prevented by
a leak detector or water shut-off device used in conjunction with a
piped drain pan. These devices are available from some plumbing
supply wholesalers and retailers, and detect and react to leakage
in various ways:
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath the
appliance extending beyond the full width and depth of the appliance
by at least 3 inches (76.2 mm) in any direction, or if the appliance is
installed in an alcove or closet, the entire floor must be covered by
the panel. Failure to heed this warning may result in a fire hazard.
• Sensors mounted in the drain pan that trigger an alarm or turn off
the incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to
the entire home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
• Devices that will turn off the gas supply to a gas water heater while
at the same time shutting off its water supply.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES,
STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such
as gasoline, solvents, propane (LP or butane, etc.) and other
substances (such as adhesives, etc.) emit flammable vapors which
can be ignited by a gas water heater’s pilot light or main burner.
The resulting flashback and fire can cause death or serious burns
to anyone in the area. Even though this water heater is a flammable
vapors ignition resistant water heater and is designed to reduce
the chances of flammable vapors being ignited, gasoline and other
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 4 inches (102 mm)
at the front, and 6 inches (153 mm) from the vent pipe. Clearance
from the top of the jacket is 12 inches (305 mm) on most models.
Note that a lesser dimension may be allowed on some models, refer
to the label attached adjacent to the gas control valve on the water
heater, see Figure 3.
7
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
FIGURE 3.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Do not install in a confined area such as a
closet, unless you provide air as shown in the “Locating The New
Water Heater” section. Never obstruct the flow of ventilation air. If
you have any doubts or questions at all, call your gas supplier. Failure
to provide the proper amount of combustion air can result in a fire or
explosion and cause death, serious bodily injury, or property damage.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the draft hood.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
• Do not allow insulation to come within 2” (50.8 mm) of the floor to
prevent blockage of combustion air flow to the burner.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels from the manufacturer
for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air flow.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 cm per kW) of the aggregate
input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered
a part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of tight construction (for example, weather
stripping, heavily insulated, caulked, vapor barrier, etc.), additional
air may need to be provided using the methods described in
“Combustion Air and Ventilation for Appliances Located in Confined
Spaces.”
FIGURE 4.
If this water heater will be used in beauty shops, barber shops, cleaning
establishments, or self-service laundries with dry cleaning equipment,
it is imperative that the water heater or water heaters be installed so
that combustion and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly flammable in many cases, will also change to corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SPACES
CONFINED SPACE is a space whose volume is less than 50 cubic
feet per 1,000 Btu per hour (4.8 cm per kW) of the aggregate input
rating of all appliances installed in that space.
INSULATION BLANKETS
Insulation blankets are available to the general public for external
use on gas water heaters but are not necessary with these products.
The purpose of an insulation blanket is to reduce the standby heat
loss encountered with storage tank heaters. Your water heater
meets or exceeds the National Appliance Energy Conversation Act
standards with respect to insulation and standby loss requirements,
making an insulation blanket unnecessary.
A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 4 and 5)
The confined space shall be provided with two permanent openings
communicating directly with an additional room(s) of sufficient volume so
that the combined volume of all spaces meets the criteria for an unconfined
space. The total input of all gas utilization equipment installed in the
8
combined space shall be considered in making this determination. Each
opening shall have a minimum free area of one square inch per 1,000
Btu per hour (22 cm2/kW) of the total input rating of all gas utilization
equipment in the confined space, but not less than 100 square
inches (645 cm2). One opening shall commence within 12 inches
(30 cm) of the top and one commencing within 12 inches (30 cm)
of the bottom of the enclosures.
FIGURE 7.
FIGURE 5.
B. ALL AIR FROM OUTDOORS: (See Figures 6, 7 and 8)
The confined space shall be provided with two permanent openings,
one commencing within 12 inches (30 cm) of the top and one
commencing within 12 inches (30 cm) from the bottom of the enclosure.
The openings shall communicate directly, or by ducts, with the outdoors
or spaces (crawl or attic) that freely communicate with the outdoors.
•
FIGURE 8.
When directly communicating with the outdoors, each opening
shall have a minimum free area of 1 square inch per 4,000 Btu
per hour (5.5 cm2/kW) of total input rating of all equipment in the
enclosure, see Figure 6.
•
When ducts are used, they shall be of the same cross-sectional
area as the free area of the openings to which they connect. The
minimum short side dimension of rectangular air ducts shall not
be less than 3 inches (76.2 mm), see Figure 9.
FIGURE 9.
FIGURE 6.
•
When communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 square inch
per 4,000 Btu per hour (5.5 cm2/kW) of total input rating of all
equipment in the enclosure, see Figure 8.
•
When communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 square inch
per 2,000 Btu per hour (11 cm2/kW)) of total input rating of all
equipment in the enclosure, see Figure 9.
•
Alternatively a single permanent opening may be used when
communicating directly with the outdoors, or with spaces that
freely communicate with the outdoors. The opening shall have a
minimum free area of 1 square inch per 3,000 BTU per hour (8.3
cm2/kW) of total input rating of all equipment in enclosure. See
Figure 7.
9
•
Louvers and Grilles: In calculating free area, consideration shall be given
to the blocking effect of louvers, grilles or screens protecting openings.
Screens used shall not be smaller than 1/4 inch (6.4 mm) mesh. If
the free area through a design of louver or grille is known, it should be
used in calculating the size opening required to provide the free area
specified. If the design and free area is not known, it may be assumed
that wood louvers will be 20-25 percent free area and metal louvers
and grilles will have 60-75 percent free area. Louvers and grilles shall
be fixed in the open position or interlocked with the equipment so that
they are opened automatically during equipment operation.
•
Special Conditions Created by Mechanical Exhausting or Fireplaces:
operation of exhaust fans, ventilation systems, clothes dryers or
fireplaces may create conditions requiring special attention to avoid
unsatisfactory operation of installed gas utilization equipment.
INSTALLING THE NEW WATER HEATER
WATER PIPING
As water is heated, it expands (thermal expansion) and closed systems
do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of the
water heater’s temperature-pressure relief valve is reached, the valve
will relieve the excess pressure. The temperature-pressure relief
valve is not intended for the constant relief of thermal expansion.
This is an unacceptable condition and must be corrected.
It is recommended that any devices installed which could create a
closed system have a by-pass and/or the system have an expansion
tank to relieve the pressure built by thermal expansion in the water
system. Expansion tanks are available for ordering through a local
plumbing contractor. Contact the local water supplier and/or a service
agency for assistance in controlling these situations.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing, cleaning and other sanitizing needs can scald and permanently
injure you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly, children, the
infirm, or physically/mentally handicapped. If anyone using hot water in
your home fits into one of these groups or if there is a local code or state
law requiring a certain temperature water at the hot water tap, then you
must take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means such as
a *mixing valve, shall be used at the hot water taps used by these people
or at the water heater, see Figure 2. Valves for reducing point of use
temperature by mixing cold and hot water are also available. Consult
a Qualified Installer or Service Agency. Follow manufacturer’s
instructions for installation of the valves. Before changing the factory
setting on the thermostat, read the “Temperature Regulation” section
in this manual.
This water heater shall not be connected to any heating systems
or component(s) used with a non-potable water heating appliance.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall not be
introduced into this system.
When the system requires water for space heating at temperatures
higher than required for domestic water purposes, a tempering valve
must be installed. Please refer to Figure 2 for suggested piping
arrangement.
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among others,
have installed devices such as pressure reducing valves, check valves,
back flow preventers, etc. to control these types of problems. When
these devices are not equipped with an internal by-pass, and no other
measures are taken, the devices cause the water system to be closed.
FIGURE 10.
10
The valve must be marked with a maximum set pressure not to
exceed the marked hydrostatic working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity not less than the water
heater input rate as shown on the model rating plate.
Figure 10 shows the typical attachment of the water piping to the
water heater. The water heater is equipped with 3/4 inch NPT water
connections.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the cold water inlet connection. Do not
solder the cold water supply line directly to the cold water inlet.
It will harm the dip tube and damage the tank.
For safe operation of the water heater, the relief valve must not be
removed from its designated opening nor plugged.
The temperature-pressure relief valve must be installed directly into
the fitting of the water heater designed for the relief valve. Position
the valve downward and provide tubing so that any discharge will
exit only within 6 inches (153 mm) above, or at any distance below
the structural floor. Be certain that no contact is made with any live
electrical part. The discharge opening must not be blocked or reduced
in size under any circumstances. Excessive length, over 30 feet (9.14
m), or use of more than four elbows can cause restriction and reduce
the discharge capacity of the valve, see Figure 11.
T & P Valve and Pipe Insulation
Remove insulation for T & P valve and pipe connections from carton.
No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect tubing directly to discharge drain unless
a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or
property damage, the relief valve must be allowed to discharge water
in quantities should circumstances demand. If the discharge pipe is
not connected to a drain or other suitable means, the water flow may
cause property damage.
FIGURE 10A.
Fit pipe insulation over the incoming cold water line and the hot water
line. Make sure that the insulation is against the top cover of the heater.
Fit T & P valve insulation over valve. Make sure that the insulation
does not interfere with the lever of the T & P valve.
Secure all insulation using tape.
TEMPERATURE-PRESSURE RELIEF VALVE
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Shall terminate at an adequate drain.
• Shall not have any valve between the relief valve and tank.
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
The valve is certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed equipment of
materials as meeting the requirements for Relief Valves for Hot Water
Supply Systems, ANSI Z21.22 • CSA 4.4, and the code requirements
of ASME.
The temperature-pressure relief valve must be manually operated at least
once a year. Caution should be taken to ensure that (1) no one is in front
of or around the outlet of the temperature-pressure relief valve discharge
line, and (2) the water manually discharged will not cause any bodily
injury or property damage because the water may be extremely hot.
If replaced, the valve must meet the requirements of local codes, but
not less than a combination temperature and pressure relief valve
certified as indicated in the above paragraph.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.
11
FIGURE 11.
To insure proper venting of this gas-fired water heater, the correct
vent pipe diameter must be utilized. Any additions or deletions of
other gas appliances on a common vent with this water heater may
adversely affect the operation of the water heater. Consult your gas
supplier if any such changes are planned.
FILLING THE WATER HEATER
For proper venting in certain installations, a larger diameter vent pipe
may be necessary. Consult your gas supplier to aid you in determining
the proper venting for your water heater from the vent tables in the
current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54.
Periodically check the venting system for signs of obstruction or
deterioration and replace if needed.
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
The combustion and ventilation air flow must not be obstructed.
The water heater with draft hood installed must be connected to a
chimney or listed vent pipe system, which terminates to the outdoors.
Never operate the water heater unless it is vented to the outdoors
and has adequate air supply to avoid risks of improper operation,
explosion or asphyxiation.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the
right (clockwise). The drain valve is on the lower front of the water
heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when
the water heater is in use.
3. To insure complete filling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow is
obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as needed.
For proper drafthood attachment, the drafthood legs may be angled
slightly inward.
Obstructed or deteriorated vent systems may present serious health
risk or asphyxiation.
The vent pipe from the water heater must be no less than the diameter
of the draft hood outlet on the water heater and must slope upward
at least 1/4 inch per linear foot (21 mm per meter), see Figure 12.
VENTING
All vent gases must be completely vented to the outdoors of the
structure (dwelling). Install only the draft hood provided with the
new water heater and no other draft hood.
VENT DAMPERS - Any vent damper, whether it is operated thermally
or otherwise must be removed if its use inhibits proper drafting of
the water heater.
Thermally Operated Vent Dampers: Gas-fired water heaters having
thermal efficiency in excess of 80% may produce a relatively low flue
gas temperature. Such temperatures may not be high enough to
properly open thermally operated vent dampers. This would cause
spillage of the flue gases and may cause carbon monoxide poisoning.
Vent pipes must be secured at each joint with sheet metal screws.
Vent dampers must bear evidence of certification as complying with
the current edition of the American National Standard ANSI Z21.68
(ANSI Z21.66 & 67, respectively, cover electrically and mechanically
actuated vent dampers). Before installation of any vent damper,
consult the local gas utility for further information.
For replacement heater installations where using pre-existing venting,
venting must be inspected for obstructions and if deterioration is
present venting must be replaced.
FIGURE 12.
12
There must be a minimum of 6 inches (153 mm) clearance between
single wall vent pipe and any combustible material. Fill and seal any
clearance between single wall vent pipe and combustible material
with mortar mix, cement, or other noncombustible substance. For
other than single wall, follow vent pipe manufacturer’s clearance
specifications. To insure a tight fit of the vent pipe in a brick chimney,
seal around the vent pipe with mortar mix cement.
If the main gas line Shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code ANSI Z223.1/NFPA
54 and your gas supplier concerning pipe size.
Failure to have required clearances between vent piping and
combustible material will result in a fire hazard.
There must be:
Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
• A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
• A drip leg (sediment trap) ahead of the gas control valve to help
prevent dirt and foreign materials from entering the gas control valve.
• A flexible gas connector or a ground joint union between the shut
off valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the water
heater. Use a soapy water solution, not a match or open flame.
Rinse off soapy solution and wipe dry.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
GAS PIPING
Water heaters covered in this manual have been tested and approved
for installation at elevations up to 7,700 feet (2,347 m) above sea level.
For installation above 7,700 feet (2,347 m), the water heater’s Btu input
should be reduced at the rate of 4 percent for each 1,000 feet (305
m) above sea level which requires replacement of the burner orifice
in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA
54. Contact your local gas supplier for further information.
Failure to replace the standard orifice with the proper high altitude
orifice when installed at elevations above 7,700 feet (2,347 m)
could result in improper and inefficient operation of the appliance,
producing carbon monoxide gas in excess of the safe limits. This
could result in serious injury or death. Contact your local gas supplier
for any specific changes that may be required in your area.
Make sure the gas supplied is the same type listed on the model
rating plate. The inlet gas pressure must not exceed 14 inch water
column (2.6 kPa) for natural and propane gas (L.P.). The minimum
inlet gas pressure shown on the rating plate is that which will permit
firing at rated input.
If the gas control valve is subjected to pressures exceeding 1/2 pound
per square inch (3.5 kPa), the damage to the gas control valve could
result in a fire or explosion from leaking gas.
13
(3.5 kPa). It shall be isolated from the gas supply piping system
by closing its individual manual Shut-off valve during any pressure
testing of the gas supply piping system at test pressures equal to
or less than 1/2 pound per square inch (3.5 kPa).
Use pipe joint compound or teflon tape marked as being resistant
to the action of petroleum [Propane (L.P.)] gases.
The appliance and its gas connection must be leak tested before
placing the appliance in operation.
The appliance and its individual Shut-off valve shall be disconnected
from the gas supply piping system during any pressure testing of
that system at test pressures in excess of 1/2 pound per square inch
Connecting the gas piping to the gas control valve of the water
heater can be accomplished by either of the two methods shown in
Figures 13 and 14.
FIGURE 13. GAS PIPING WITH
FLEXIBLE CONNECTOR.
FIGURE 14. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
SEDIMENT TRAPS
A sediment trap shall be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The
sediment trap shall be either a tee fitting with a capped nipple in the
bottom outlet or other device recognized as an effective sediment
trap. If a tee fitting is used, it shall be installed in conformance with
one of the methods of installation shown in Figures 13 and 14.
Contaminants in the gas lines may cause improper operation of the
gas control valve that may result in fire or explosion. Before attaching
the gas line be sure that all gas pipe is clean on the inside. To trap any
dirt or foreign material in the gas supply line, a drip leg (sometimes
called a sediment trap) must be incorporated in the piping. The drip
leg must be readily accessible. Install in accordance with the “Gas
Piping” section. Refer to the current edition of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54.
14
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
• If you cannot reach your gas supplier, call the fire
department.
A. This appliance has a pilot which is lit by a piezo-electric
spark gas ignition system. Do not open the inner door
of the appliance and try to light the pilot by hand.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don’t try to repair it, call a qualified service
technician . Force or attempted repair may result in a
fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately contact a qualified installer or
service agency to replace a flooded water heater. Do
not attempt to repair the unit! It must be replaced!
LIGHTING INSTRUCTIONS
GAS CONTROL
1.
2.
3.
4.
5.
6.
7.
8.
TOP KNOB
STOP! Read the safety information
above on this label.
Set the thermostat to lowest setting (PILOT LIGHTING).
Turn thermostat dial fully clockwise
until it stops.
Push the gas control knob down slightly and turn
clockwise
to “OFF”, see Figure “A”..
NOTE: Knob CANNOT be turned from “PILOT” to “OFF”
unless it is pushed down slightly. Do not force.
Remove the outer burner door located below the gas
control.
Wait five (5) minutes to clear out any gas. If you then smell
gas,
STOP! Follow “B” in the safety information above
on this label. If you don’t smell gas, go to next step.
This unit is equipped with a push button pilot ignitor,
which is used to light the pilot. Locate the ignitor on the
gas control.
Turn gas control knob counterclockwise
to “PILOT”,
see Figure “B”.
The pilot is located on the right side of the burner. It can
be located by looking through the glass view port while
pressing the piezo ignitor button several times. Look for
a spark at the pilot location, see Figure “D”.
9.
10.
11.
12.
13.
FIGURE “D”
Once the pilot has been found, push the gas knob all
the way down. Immediately press the pilot ignitor button
rapidly (4) to (5) times. If the pilot will not light, repeat step
(3) through (9).
Continue to hold the gas control knob down for about one
(1) minute after the pilot is lit. Release the gas control
knob and it will pop back up. Pilot should remain lit. If it
goes out, repeat step (3) through (9). It may take several
minutes for air to clear the lines before the pilot will light.
• If knob does not pop up when released, stop and
immediately call your service technician or gas supplier.
• If the pilot will not stay lit after several tries, turn the
gas control knob clockwise
to “OFF” and call your
service technician or gas supplier, see Figure “A”.
Once the pilot flame is established replace the outer
burner door.
A t a r m s l e n g t h a w a y, t u r n g a s c o n t r o l k n o b
counterclockwise
to “ON”, see Figure “C”.
Set thermostat to desired setting.
DANGER: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature.
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat to the lowest setting (PILOT LIGHTING).
2. Push gas control knob down slightly and turn clockwise
to “OFF”, see Figure “A”. Do not force.
15
TEMPERATURE REGULATION
NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is
recommended by most dishwasher manufacturers.
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30F° (16.7 C°) higher
or lower at the point of use such as, bathtubs, showers, sink, etc.
The thermostat of this water heater has been factory set at its lowest
position (PILOT LIGHTING). It is adjustable and must be reset to
the desired temperature setting to reduce the risk of scald injury.
The mark ( ) indicative of approximately 120°F (49°C) is preferred
starting point. Some States have a requirement for a lower setting.
) to decrease the
Turn the water temperature dial clockwise (
) to increase the temperature.
temperature, or counterclockwise (
Should overheating occur or the gas supply fail to shut off, turn off
the manual gas control valve to the appliance.
HOTTER WATER CAN SCALD: Water heaters are intended to
produce hot water. Water heated to a temperature which will satisfy
space heating, clothes washing, dish washing, and other sanitizing
needs can scald and permanently injure you upon contact. Some
people are more likely to be permanently injured by hot water than
others. These include the elderly, children, the infirm, or physically/
mentally handicapped. If anyone using hot water in your home
fits into one of these groups or if there is a local code or state law
requiring a certain temperature water at the hot water tap, then
you must take special precautions. In addition to using the lowest
possible temperature setting that satisfies your hot water needs,
a means such as a mixing valve, shall be used at the hot water
taps used by these people or at the water heater. Mixing valves
are available at plumbing supply or hardware stores, see Figure
2. Follow manufacturer’s instructions for installation of the valves.
Before changing the factory setting on the thermostat, see Figures
15 and 16.
FIGURE 15.
Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended
in a bathtub or shower.
Temperature
Setting
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
VERY HOT = APPROX. 180°F (82°C)
D = APPROX. 160°F (71°C)
C = APPROX. 150°F (66°C)
B = APPROX. 140°F (60°C)
A = APPROX. 130°F (54°C)
= APPROX. 120°F (49°C)
LOW = APPROX. 100°F (38°C)
Nearly instantaneous
About 1/2 second
About 1 1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
--------
FIGURE 16.
FOR YOUR INFORMATION
START UP CONDITIONS
will form while the burner is on. A water heater may appear to
be leaking when in fact the water is condensation. This usually
happens when:
DRAFT HOOD OPERATION
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters, particularly
high efficiency models where flue temperatures are lower.
c. Large amounts of hot water are used in a short time and the refill
water in the tank is very cold.
Check draft hood operation by performing a worst case
depressurization of the building. With all doors and windows closed,
and with all air handling equipment and exhaust fans operating such
as furnaces, clothes dryers, range hoods and bathroom fans, a match
flame should still be drawn into the draft hood of the water heater with
its burner firing. If the flame is not drawn toward the draft hood, shut
off water heater and make necessary air supply changes to correct.
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the burner
or other hot surfaces to produce a “sizzling” or “frying” noise.
CONDENSATE
Excessive condensation can cause pilot outage due to water running
down the flue tube onto the main burner and putting out the pilot.
Whenever the water heater is filled with cold water, some condensate
16
Because of the suddenness and amount of water, condensation
water may be diagnosed as a “tank leak”. After the water in the
tank warms up (about 1-2 hours), the condition should disappear.
OPERATIONAL CONDITIONS
SMELLY WATER
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
In each water heater there is installed at least one anode rod (see
parts sections) for corrosion protection of the tank. Certain water
conditions will cause a reaction between this rod and the water.
The most common complaint associated with the anode rod is one
of a “rotten egg smell” in the hot water. This odor is derived from
hydrogen sulfide gas dissolved in the water. The smell is the result
of four factors which must all be present for the odor to develop:
An undersized water heater will cause more condensation. The water
heater must be sized properly to meet the family’s demands for hot
water including dishwashers, washing machines and shower heads.
Excessive condensation may be noticed during the winter and early
spring months when incoming water temperatures are at their lowest.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated within the
water heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosion protective action of the anode.
Good venting is essential for a gas fired water heater to operate
properly as well as to carry away products of combustion and water
vapor.
SMOKE / ODOR
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material, and
then chlorinating the water heater tank and all hot water lines. Contact
the local water heater supplier or service agency for further information
concerning an Anode Replacement Kit and this chlorination treatment.
THERMAL EXPANSION
If the smelly water persists after the anode replacement and
chlorination treatment, we can only suggest that chlorination or
aeration of the water supply be considered to eliminate the water
problem.
Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.
“AIR” IN HOT WATER FAUCETS
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among others,
have installed devices such as pressure reducing valves, check valves,
back flow preventers, etc. to control these types of problems. When
these devices are not equipped with an internal by-pass, and no other
measures are taken, the devices cause the water system to be closed.
As water is heated, it expands (thermal expansion) and closed systems
do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point
of the water heater’s temperature-pressure relief valve is reached,
the valve will relieve the excess pressure. The temperaturepressure relief valve is not intended for the constant relief of
thermal expansion. This is an unacceptable condition and must be
corrected. It is recommended that any devices installed which could
create a closed system have a by-pass and/or the system have an
expansion tank or device to relieve the pressure built by thermal
expansion in the water system. Expansion tanks are available for
ordering through a local plumbing contractor. Contact the local
water heater supplier or service agency for assistance in controlling
these situations.
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances
which are connected to the hot water system are used (such as a
dishwasher or washing machine). If hydrogen gas is present, there
will probably be an unusual sound similar to air escaping through the
pipe as the hot water faucet is opened. There must be no smoking
or open flame near the faucet at the time it is open.
STRANGE SOUNDS
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
This water heater is equipped with an automatic gas Shut-off system.
This system works when high water temperatures are present.
Turn “OFF” the entire gas supply to the water heater. The high
temperature Shut-off is built into the gas control valve. It is nonresettable. If the high temperature Shut-off activates, the gas control
valve must be replaced. Contact your gas supplier or service agency.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered normal.
See “Condensation” in this section.
17
PERIODIC MAINTENANCE
VENTING SYSTEM INSPECTION
You should check for sooting. Soot is not normal and will impair
proper combustion.
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until repairs
are made, because failure to correct the cause of the sooting can
result in a fire causing death, serious injury, or property damage.
FIGURE 17.
BURNER CLEANING
At least once a year a visual inspection should be made of the venting
system. You should look for:
In the event your burner needs cleaning, follow these instructions:
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
If inspection of the burner shows that cleaning is required, turn the gas
) to the “OFF” position, depressing slightly.
control knob clockwise (
2. Damage or deterioration which could cause improper venting or
leakage of combustion products.
NOTE: The knob cannot be turned from “PILOT” to “OFF” unless
knob is depressed slightly. DO NOT FORCE.
3. Rusted flakes around top of water heater.
The burner needs to be removed for cleaning. Call a service agency
to remove and clean the burner and correct the problem that required
the burner to be cleaned.
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gasses which could cause deadly asphyxiation.
HOUSEKEEPING
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
If after inspection of the vent system you found sooting or
deterioration, something is wrong. Call the local gas utility to
correct the problem and clean or replace the flue and venting before
resuming operation of the water heater.
BURNER INSPECTION
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a qualified installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit! It must be replaced!
AT LEAST ONCE EVERY SIX MONTHS A VISUAL
INSPECTION SHOULD BE MADE OF THE AIR
INTAKE SCREEN. CLEAN IF LINT ACCUMULATIONS
ARE NOTICED.
At least once a year a visual inspection should be made of the main
burner and pilot burner, see Figure 17.
18
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.
INSTALLED IN SUITABLE AREA: To insure sufficient ventilation
and combustion air supply, proper clearances from the water heater
must be maintained. See “Locating the New Water Heater” section.
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent to
the water heater which can cause a fire.
If the temperature-pressure relief valve on the appliance weeps or
discharges periodically, this may be due to thermal expansion. You
may have a check valve installed in the water line or a water meter
with a check valve. Consult your local water supplier or service
agency for further information. Do not plug the temperaturepressure relief valve.
ANODE ROD INSPECTION
DRAINING
The anode rod is used to protect the tank from corrosion. Most hot
water tanks are equipped with an anode rod. The submerged rod
sacrifices itself to protect the tank. Instead of corroding the tank,
water ions attack and eat away the anode rod. This does not affect
the water’s taste or color. The rod must be maintained to keep the
tank in operating condition.
The water heater should be drained if being shut down during
freezing temperatures. Also periodic draining and cleaning of
sediment from the tank may be necessary.
Anode deterioration depends on water conductivity, not necessarily
water condition. A corroded or pitted anode rod indicates high water
conductivity and should be checked and/or replaced more often than
an anode rod that appears to be intact. Replacement of a depleted
anode rod can extend the life of your water heater. Inspection should
be conducted by a qualified technician, and at a minimum should be
checked annually after the warranty period.
1. Turn the gas control knob to the “OFF” position.
2. CLOSE the cold water inlet valve to the water heater.
3. OPEN a nearby hot water faucet and leave open to allow for
draining.
TEMPERATURE-PRESSURE
RELIEF VALVE OPERATION
4. Connect a hose to the drain valve and terminate to an adequate
drain.
5. OPEN the water heater drain valve to allow for tank draining.
NOTE: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
6. CLOSE the drain valve.
7. Follow instructions in the “Filling The Water Heater” section.
8. Follow the lighting instructions on the label or see page 15 under
“Lighting Instructions” to restart the water heater.
The temperature-pressure relief valve must be manually operated
at least once a year.
DRAIN VALVE WASHER REPLACEMENT
(See Figure 19)
1. Turn “OFF” gas supply to water heater.
2. Follow “Draining” instructions.
3. Turning counterclockwise (
screw handle.
), remove the hex cap below the
4. Remove the washer and put the new one in place.
FIGURE 18.
5. Screw the handle and cap assembly back into the drain valve
and retighten using a wrench. DO NOT OVER TIGHTEN.
When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of the
temperature-pressure relief valve discharge line, and (2) that the
water discharge will not cause any property damage, as the water
may be extremely hot, see Figure 18.
6. Follow instructions in the “Filling The Water Heater” section.
7. Check for leaks.
19
8. Follow the lighting instructions in the “Lighting” section to restart
the water heater.
SERVICE
If a condition persists or you are uncertain about the operation of
the water heater contact a service agency.
Use this guide to check a “Leaking” water heater. Many suspected
“Leakers” are not leaking tanks. Often the source of the water can
be found and corrected.
If you are not thoroughly familiar with gas codes, your water heater,
and safety practices, contact your gas supplier or qualified installer
to check the water heater.
FIGURE 19.
LEAKAGE CHECKPOINTS
Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
Never use this water heater unless it is completely filled with water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater.
A. Water at the draft hood is water vapor which has condensed out
of the combustion products. This is caused by a problem in the
vent. Contact the gas utility.
B. *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
E. *The temperature-pressure relief valve may be leaking at the
tank fitting.
F. Water from a drain valve may be due to the valve being slightly
opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can condense
on the cooler surfaces of the tank. Droplets form and drip onto
the burner or run on the floor. This is common at the time of
start-up after installation and when incoming water is cold.
I. Water in the water heater bottom or on the floor may be from
condensation, loose connections, or the relief valve. DO NOT
replace the water heater until a full inspection of all possible water
sources is made and necessary corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
*
20
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
REPAIR PARTS LIST
Key No. Part Description
1
Burner Assembly
2
Burner Head
3
Burner Orifice
4
Burner Tube
5
Pilot Assembly
6
Inner Door
7
Inner Door Gasket
8
Flue Baffle
9
Flue Restrictor
10
Drafthood
11
Air Intake Screen
12
Inlet Tube
13
Gas Control Valve
14
Drain Valve
15
Drain Valve Washer
16
Outer Door (may appear different than shown)
17
Piezo Ignitor Generator
18
Piezo Ignitor Bracket
19
Anode Rod
20
Temperature-Pressure Relief Valve
21
Viewport Bracket
22
Viewport Glass
23
Viewport Insulation
24
20” Dia. Drain Pan w/Side Drain (optional)
22” Dia. Drain Pan w/Side Drain (optional)
24” Dia. Drain Pan w/Side Drain (optional)
BURNER ASSEMBLY
26” Dia. Drain Pan w/Side Drain (optional)
25
*26
OUTER DOOR
(OPTIONAL)
Thermostat Shield (optional)
Instruction Manual
27A
Nipple with Heat Trap
27B
Secondary Anode with Heat Trap
* Not Shown.
Now that you have purchased this water heater, should a need
ever exist for repair parts or service, simply contact the company
it was purchased from or direct from the manufacturer listed on
the rating plate on the water heater.
16
1
Be sure to provide all pertinent facts when you call or visit.
DRAIN PAN
THERMOSTAT SHIELD
Selling prices will be furnished on request or parts will be
shipped at prevailing prices and you will be billed accordingly.
The model number of your Gas Water Heater will be found on the
rating place located above the gas control valve.
24
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
•
•
•
•
MODEL NUMBER
TYPE GAS (NATURAL OR PROPANE (L.P.)
SERIAL NUMBER
PART DESCRIPTION
25
®
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
21
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent. When calling for service notify the service agent
that this is a “Flammable Vapor Ignition Resistant” Product.
Problem
WATER LEAKS
LEAKING T&P VALVE
Cause
Solution
Improperly sealed, hot or cold supply connection,
relief valve, drain valve, or thermostat threads.
Leakage from other appliances or water lines.
Condensation of flue products.
Thermal expansion in closed water system.
Improperly seated valve.
Tighten threaded connections.
High sulfate or mineral content in water supply.
Inspect other appliances near water heater.
Refer to CONDENSATE.
Install thermal expansion tank (DO NOT plug T&P valve).
Check relief valve for proper operation
(DO NOT plug T&P valve).
Drain and flush heater thoroughly, then refill.
SMELLY ODORS
PILOT WILL NOT LIGHT
BURNER WILL NOT
STAY LIT
PILOT OUTAGE
NOT ENOUGH
HOT WATER
WATER TOO HOT
WATER HEATER SOUNDS
SIZZLING - RUMBLING
SOOTING
VENT GAS ODORS
Bacteria in water supply.
Gas control knob not positioned correctly.
Main gas supply off.
Igniter tip more than 1/8” from pilot hood.
Thermocouple malfunction.
Thermocouple TCO malfunction.
Melted insulation on ignitor wire or shorting
of ignitor wire.
High ambient room temperature.
Chlorinate or aerate water supply.
Refer to LIGHTING INSTRUCTIONS.
Turn on main gas Shut-off valve.
Adjust ignitor tip.
Replace pilot assembly.
Replace pilot assembly.
Contact a service agency to determine cause.
Wire disconnected from spark ignitor.
Broken electrode or electrical wire.
Piezo Ignitor generator fails to operate or
malfunctions.
Thermocouple TCO malfunction.
High ambient room temperature.
Reconnect wire connector to spark ignitor.
Replace pilot assembly.
Replace Piezo Ignitor generator.
Dirty or clogged air intake screen.
Flame arrestor openings blocked.
Defective Gas Control.
Dirty pilot burner.
Dirty or clogged air intake screen.
Thermocouple tip is not in contact with pilot flame.
Thermocouple malfunction.
Thermocouple TCO malfunction.
Defective Gas Control.
Heater not lit or thermostat not on.
Thermostat set too low.
Heater undersized.
Low gas pressure.
Incoming water is unusually cold.
Leaking hot water pipes or fixtures.
High temperature limit switch activated.
Thermostat set too high.
Condensation dripping on burner.
Sediment or calcium in bottom of heater tank.
Improper combustion.
Lack of supply air.
Improperly installed vent piping.
Downdraft.
Poor combustion.
Contact a service agency to determine cause.
Replace pilot assembly.
Contact a service agency to
determine cause.
Clean and reinstall air intake screen.
Contact a service agency to
determine cause.
Replace Gas Control.
Clean pilot assembly.
Clean and reinstall air intake screen.
Insert thermocouple correctly.
Replace pilot assembly.
Replace pilot assembly.
Replace Gas Control.
Refer to LIGHTING INSTRUCTIONS.
Refer to TEMPERATURE REGULATION.
Reduce hot water use.
Contact your gas supplier.
Allow more time for heater to re-heat.
Have plumber check and repair leaks.
Contact a service agency to
determine cause.
Refer to TEMPERATURE REGULATION.
Refer to CONDENSATE above.
Clean sediment from tank. Refer to DRAINING
instructions in Maintenance section of manual.
No adjustment available. Contact a service agency
to determine cause.
Contact a service agency to determine cause.
22
NOTES:
23
300 Maddox Simpson Parkway
Lebanon, TN 37090
Phone: 615-889-8900 • Fax: 615-547-1000
Technical Services email: [email protected]
www.lochinvar.com
Copyright © 2011 Lochinvar LLC. All rights reserved.
24
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