!
WARNING: This water heater is not suitable
for use in manufactured (mobile) homes!
Use & Care Manual
With Installation Instructions for the Installer
Compliant with South Coast Air Quality Management District Rule 1121 10 ng/J NOx Emissions
Residential Gas - Low NOx Emissions
Water Heaters
WITH DAMPER & ELECTRONIC CONTROL
Residential 40 and 50 Gallon
FVIR Certified
The purpose of this manual is twofold: one, to provide the installer with the basic directions
and recommendations for the proper installation and adjustment of the water heater; and two,
for the owner–operator, to explain the features, operation, safety precautions, maintenance and
troubleshooting of the water heater. This manual also includes a parts list.
It is imperative that all persons who are expected to install, operate or adjust this water heater
read the instructions carefully so they may understand how to perform these operations. If you
do not understand these instructions or any terms within it, seek professional advice.
Any questions regarding the operation, maintenance, service or warranty of this water heater
should be directed to the seller from whom it was purchased. If additional information is
required, refer to the section on “If you need service.”
Do not destroy this manual. Please read carefully and keep in a safe place for future
reference.
Recognize this symbol as an indication of Important Safety Information!
!
!
!
California Proposition 65 Warning: This product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm.
ARNING: If the information in these instructions is not followed exactly, a fire or
W
explosion may result causing property damage, personal injury or death.
FOR YOUR SAFETY!
— Do not store or use gasoline or other
flammable vapors or liquids or other
combustible materials in the vicinity of this or
any other appliance. To do so may result in an
explosion or fire.
!
— 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.
● I f you cannot reach your gas supplier, call the
fire department.
●D
o not return to your home until authorized
by the gas supplier or fire department.
— Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury, or death. Refer to
this manual. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.
DO NOT RETURN this water heater to the store or place of purchase.
DESIGN
If you need technical or installation assistance, please call the Technical Support
Lines at 1-866-279-4566.
CER
TIFIED
Printed in USA
®
AP16876 (06/13)
Safety Information
Safety Precautions. . . . . . . 3–6
LP Gas Models . . . . . . . . . . . . 5
FOR YOUR RECORDS
Write the model and serial numbers here:
#
Installation Instructions
Location. . . . . . . . . . . . . . . . . . 7
Water Supply Connections. . . 9
Flue Damper . . . . . . . . . . . . . 10
Gas Supply. . . . . . . . . . . . . . . 11
#
You can find them on a label on the appliance.
Staple sales slip or cancelled check here.
Proof of the original purchase date is needed to obtain service under
the warranty.
Pipe Insulation. . . . . . . . . . . . 14
Heat Traps . . . . . . . . . . . . . . . 14
Installation Checklist. . . . . . . 16
Potable/Space Heating . . . . 17
Operating Instructions
Lighting Instructions. . . . . . 18
Water Temperature . . . . . 19, 20
Care and Cleaning
Draining. . . . . . . . . . . . . . . . 21
Maintenance. . . . . . . . . . . . . 21
Burner Inspection . . . . . . . . 22
Extended Shut-Down. . . . . . 22
Troubleshooting Tips
Before You Call
For Service. . . . . . . . . . . 23, 24
LED Codes
25, 26
READ THIS MANUAL
Inside you will find many helpful hints on how to use and
maintain your water heater properly. A little preventive care
on your part can save you time and money over the life of your
water heater.
You’ll find many answers to common problems in
the Troubleshooting Guide. If you review the chart of
Troubleshooting Tips first, you may not need to call for service.
READ THE SAFETY INFORMATION
Your safety and the safety of others are very important. There
are many important safety messages in this manual and on your
appliance. Always read and obey all safety messages.
!
This is the safety alert symbol. Recognize this symbol as an
indication of Important Safety Information!
This symbol alerts you to potential hazards that can kill or hurt
you and others.
All safety messages will follow the safety alert symbol and
either the word “DANGER”, “WARNING”, “CAUTION” or
“NOTICE”.
These words mean:
An imminently hazardous situation ! DANGER
that will result in death or serious injury.
! WARNING
Customer Service
Parts List. . . . . . . . . . . . . . . . 27
If You Need Service . . . . . . . 28
A potentially hazardous situation that could result in death or serious injury and/or damage to property.
! CAUTION
A potentially hazardous situation that may result in minor or moderate
injury.
Notice:
Attention is called to observe a specified procedure or maintain a specific condition.
2
IMPORTANT SAFETY INFORMATION
READ ALL INSTRUCTIONS BEFORE USING
Be sure to read and understand the entire Use and Care Manual before attempting to install or
operate this water heater. It may save you time and money. Pay particular attention to the Safety
Instructions. Failure to follow these warnings could result in serious bodily injury or death. Should
you have problems understanding the instructions in this manual, or have any questions, STOP,
and get help from a qualified service technician, or the local gas utility.
!
DANGER!
INSTALL THE DRAFT HOOD AND PROPERLY VENT THE
WATER HEATER…
Failure to install the draft hood and properly vent the water heater to the outdoors
as outlined in the Venting Section of the Installation Instructions in this manual can
result in unsafe operation of the water heater. To avoid the risk of fire, explosion,
or asphyxiation from carbon monoxide, never operate this water heater unless it is
properly vented and has an adequate air supply for proper operation. Be sure to
inspect the vent system for proper installation at initial start-up; and at least annually
thereafter. Refer to the Care and Cleaning section of this manual for more information
regarding vent system inspection.
!
WARNING!
Gasoline, as well as other flammable materials and liquids which include, but are not
limited to (adhesives, solvents, paint thinners etc.), and the vapors they produce are
extremely dangerous. DO NOT handle, use or store gasoline or other flammable or
combustible materials anywhere near or in the vicinity of a water heater or any other
appliance. Be sure to read and follow warning label pictured below and other labels on
the water heater, as well as the warnings printed in this manual. Failure to do so can
result in property damage, bodily injury or death.
!
FLAMMABLES
WARNING
Flammable Vapors
FIRE AND EXPLOSION HAZARD
!
Can result in serious injury or death.
Do not store or use gasoline or other flammable vapors and liquids
in the vicinity of this or any other appliance. Storage of or use of gasoline
or other flammable vapors or liquids in the vicinity of this or any other
appliance can result in serious injury or death.
3
IMPORTANT SAFETY INFORMATION
READ ALL INSTRUCTIONS BEFORE USING
!
DANGER!
WATER TEMPERATURE SETTING
Safety and energy conservation are factors to be considered when selecting the water
temperature setting of a water heater’s gas control. Water temperatures above 125°F
can cause severe burns or death from scalding. Be sure to read and follow the warnings
outlined on the label pictured below. This label is also located on the water heater.
Time/Temperature Relationship in Scalds
W
ater Temperature
Time To Produce a Serious Burn
120°F
125°F
130°F
135°F
140°F
145°F
150°F
155°F
More than 5 minutes
11/2 to 2 minutes
About 30 seconds
About 10 seconds
Less than 5 seconds
Less than 3 seconds
About 11/2 seconds
About 1 second
Table courtesy of Shriners Burn Institute
NOTICE: Mixing valves are recommended for reducing
point of use water temperature by mixing hot and
cold water in branch water lines. It is recommended
that a mixing valve complying with the Standard for
Temperature Actuated Mixing Valves for Hot Water
Distribution Systems, ASSE 1017 be installed. See pages 17
& 19 for more details and contact a licensed plumber or
the local plumbing authority for further information.
Valve Set
Point
LOW
●
●
●
HOT
A
B
C
VERY HOT
4
Estimated
Temperature
90°F
98°F
105°F
113°F
120°F
130°F
140°F
150°F
160°F
Burns on Adult Skin
--------------------------------------------------------------------------------------------More than 5 minutes
About 30 seconds
Less than 5 seconds
About 1-1/2 seconds
About 1/2 second
The chart shown above may be used as a guide in
determining the proper water temperature for your
home.
! DANGER: Households with small children, disabled, or
elderly persons may require a 120°F or lower gas control
(thermostat) setting to prevent contact with “HOT” water.
Maximum water temperatures occur just after the
burner has shut off. To find water temperature
being delivered, turn on a hot water faucet and
place a thermometer in the water stream and read
the thermometer. For additional information see the
"Water Temperature Setting" section of this manual.
The temperature of the water in the heater can be
regulated by setting the temperature dial on the front
of the gas control (thermostat). To comply with
safety regulations the gas control(thermostat) was
set at its lowest setting before the water heater was
shipped from the factory.
he table at the left details the approximate water
T
temperature for each mark on the Gas Control
(Thermostat) Temperature Dial.
! DANGER: Hotter water
increases the potential for Hot
Water SCALDS.
!
DANGER!
LIQUEFIED PETROLEUM (LP)
AND NATURAL GAS MODELS
LP and Natural gas have an odorant added to aid in detecting a gas leak. Some people may
not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar
with the smell of LP or natural gas, ask the gas supplier. Other conditions, such as “odorant
fade”, which causes the odorant to diminish in intensity, can also hide or camouflage a gas
leak.
● Water heaters utilizing LP gas are
! DANGER: If a gas leak is present or
different from natural gas models. A
suspected:
natural gas water heater will not function
● DO NOT attempt to find the cause
safely on LP gas and vice versa.
yourself.
● No attempt should ever be made to
● DO NOT try to light any appliance.
convert the water heater from natural
gas to LP gas. To avoid possible
● DO NOT touch any electrical switch.
equipment damage, personal injury or
● DO NOT use any phone in your building.
fire, do not connect the water heater to a
fuel type not in accordance with the unit
● Leave the house immediately and make
data plate. LP for LP units. Natural gas
sure your family and pets leave also.
for natural gas units. These units are not
● Leave the doors open for ventilation
certified for any other fuel type.
and contact the gas supplier, a qualified
● LP appliances should not be installed
service agency or the fire department.
below grade (for example, in a basement)
● Stay away from the house (or building)
if such installation is prohibited by
until the service call has been made, the
federal, state and/or local laws, rules,
leak is corrected and a qualified agency
regulations or customs.
has determined the area to be safe.
● LP gas must be used with great caution.
It is heavier than air and will collect first
in lower areas making it hard to detect at
nose level.
● Before attempting to light the water
heater, make sure to look and smell for
gas leaks. Use a soapy solution to check
all gas fittings and connections. Bubbling
at a connection indicates a leak that must
be corrected. When smelling to detect a
gas leak, be sure to sniff near the floor
also.
● Gas detectors are recommended in LP
& natural gas applications and their
installation should be in accordance
with the detector manufacturer’s
recommendations and/or local laws,
rules, regulations or customs.
● It is recommended that more than one
method, such as soapy solution, gas
detectors, etc., be used to detect leaks in
gas applications.
5
IMPORTANT SAFETY INFORMATION
READ ALL INSTRUCTIONS BEFORE USING
!
WARNING!
For your safety, the information in this manual must be followed to minimize the risk of fire
or explosion, electric shock, or to prevent property damage, personal injury, or loss of life.
FOR INSTALLATIONS IN THE STATE OF CALIFORNIA
California Law requires that residential water heaters must be braced, anchored or
strapped to resist falling or horizontal displacement due to earthquake motions. For
residential water heaters up to 52-gallon capacity, a brochure with generic earthquake
bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street,
Suite 5100, Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater
dealer.
However, applicable local codes shall govern installation. For residential water heaters of
a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable
bracing procedures.
SAFETY PRECAUTIONS
Have the installer show you the location of the gas shut-off valve and how to shut it off
if necessary. Turn off the manual shut-off valve if the water heater has been subjected to
overheating, fire, flood, physical damage or if the gas supply fails to shut off.
● Read this manual entirely before installing
or operating the water heater.
●U
se this appliance only for its intended
purpose as described in this Use and Care
Manual.
●D
O NOT attempt to repair or replace
any part of your water heater unless it is
specifically recommended in this manual.
All other servicing should be referred to a
qualified technician.
● Be sure your appliance is properly installed
in accordance with local codes and the
provided installation instructions.
READ AND FOLLOW THIS SAFETY INFORMATION
CAREFULLY.
SAVE THESE INSTRUCTIONS
6
Installing the water heater
This water heater must be installed in accordance with these instructions, local codes, utility company
requirements, and/or in the absence of local codes, use the latest edition of the American National
Standard/National Fuel Gas Code. A copy can be purchased from either the American Gas Association,
400 N. Capitol Street NW, Washington, DC 20001 as ANSI standard Z223.1 or National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269 as booklet NFPA 54.
Combustion Air Inlet
Openings
Max.
2”
Diameter of
water heater
plus 2” min.
Flammable
Vapor
Sensor
The auxiliary catch pan
installation MUST conform
to local codes.
Top View Alcove
Rear
Front Open
The water heater should not be located
in an area where leakage from the tank
or connections will result in damage to
the area adjacent to the heater or to lower
floors of the structure.
When such areas cannot be avoided it is
recommended that a suitable catch pan,
adequately drained, must be installed under
the water heater.
The pan must not restrict air flow to the
combustion air inlet openings (perforation
openings) located around the lower perimeter
of the water heater.
Catch pan kits are available from the store
where the water heater was purchased, or
any water heater distributor.
Make certain the floor underneath the water
heater is strong enough to sufficiently
support the weight of the water heater once
it is filled with water.
Sides
Top View Closet
Rear
Front Enclosed
Location
A gas fired water heater or any other
appliance should not be installed in a space
where liquids which give off flammable
vapors are to be used or stored. Such
liquids include gasoline, LP gas (butane
or propane), paint or adhesives and their
thinners, solvents or removers.
When installed in a closet, DO NOT block
or obstruct any of the combustion air inlet
openings located around the perimeter
of the water heater. A minimum of 1” is
required between these combustion air inlet
openings and any obstruction.
Sides
! WARNING: Combustible
construction refers to
adjacent walls and ceilings
and should not be confused
with combustible or
flammable products and
materials. Combustible
and/or flammable products
and materials should never
be stored in the vicinity of
this or any gas appliance.
DO NOT obstruct or block the Flammable
Vapor Sensor.
Because of natural air movement in a room
or other enclosed space, flammable vapors
can be carried some distance from where
liquids which give off flammable vapors
are to be used or stored. The open flame
of the water heater’s pilot or main burner
can ignite these vapors and create a shut
down condition of the water heater which
will not allow the water heater to ignite
until examined by a Qualified Service
Technician.
FVIR certified gas water heaters can be
installed on a residential garage floor
without the use of an 18-inch stand in
accordance with the National Fuel Gas
Code, NFPA 54, ANSI Z223.1, unless
otherwise directed by State and Local
code requirements. The water heater must
be located so it is not subject to physical
damage, for example, by moving vehicles,
area flooding, etc
● The water heater should be installed
as close as practical to the gas vent or
chimney.
● Hot water lines should be insulated to
conserve water and energy.
● The water heater and water lines should
be protected from exposure to freezing
temperatures.
● DO NOT install this water heater in
bathrooms, bedrooms, any occupied
rooms normally kept closed, or in
unprotected outdoor areas.
● Minimum clearance from combustible
construction:
Location Front Sides Rear
Top
3”
0”
0”
12”
Alcove
(7.6 cm) (0 cm) (0 cm) (30.5 cm)
Closet
3”
1”
0”
12”
(7.6 cm) (2.5 cm) (0 cm) (30.5 cm)
If the clearances stated on the
Instruction/Warning Label, located on
the front of the heater differ, install the
water heater according to the clearances
stated on the label.
● If the water heater is installed in an
alcove or closet, the entire floor must
be covered by a wood or metal panel.A
minimum of 24” clearance from the front
and top should be available for adequate
inspection and servicing.
● The water heater may be installed on
combustible floors, but not directly on
carpeting. If the water heater must be
installed on carpeting, place a metal or
wood panel beneath the water heater,
extending beyond its full width and
depth at least 3” in all directions.
7
Installing the water heater
Inspect Shipment
Carefully inspect the water heater for damage before proceeding with the installation.
Of specific interest should be any dents or damage to the draft hood and/or flue damper
assembly. If you find damage, DO NOT install or attempt any repair to the water heater.
Contact the manufacturer as detailed under the "IF YOU NEED SERVICE" section of
this manual.
Combustion and Ventilation Air
Proper operation of the water heater
requires air for combustion and
ventilation. Provisions for combustion
and ventilation air must comply with
referenced codes and standards.
NOTICE: If the water heater is installed
in an unconfined space within a building
of conventional frame, masonry or metal
construction, infiltration air is normally
adequate for proper combustion and
ventilation. If the water heater is installed in
a confined space, provisions for combustion
and ventilation air must be made.
A confined space is one having a volume
of less than 50 cubic feet per 1000 Btuh
of the aggregate input of all appliances
within that space.
The air must be supplied through two
permanent openings of equal area. One is
to be located within 12” above the floor
and the other is to be located within 12”
from the ceiling.
The minimum net free area of each opening
must not be less than one square inch
per 1000 Btuh of the total input rating
of all the appliances in the enclosure
(but not less than 100 square inches), if
each opening communicates with other
unconfined areas inside the building.
NOTICE: The water heater
should not be installed near
an air supply containing
halogenated hydrocarbons.
If air is supplied from outdoors, directly or
through vertical ducts, there must be two
openings located as specified above and
each must have a minimum net free area
of not less than one square inch per 4000
Btuh of the total input rating of all the
appliances in the enclosure.
If horizontal ducts are used to
communicate with the outdoors, each
opening must have a minimum net free
area of not less than one square inch per
2000 Btuh of the total input rating of all
the appliances in the enclosure. If ducts
are used, the minimum dimensions of
rectangular air ducts shall not be less than
3”.
NOTICE: If the duct openings which supply
combustion and ventilation air are to be
covered with a protective screen or grill,
the net free area (openings in the material)
of the covering material must be used
in determining the size of the openings.
Protective screening for the openings MUST
NOT be smaller than 1/4”mesh to prevent
clogging by lint or other debris.
Corrosive Atmospheres
The air in beauty shops, dry cleaning
establishments, photo processing labs,
and storage areas for liquid and powdered
bleaches or swimming pool chemicals often
contain such halogenated hydrocarbons.
An air supply containing halogenated
hydrocarbons may be safe to breathe,
but when it passes through a gas flame
corrosive elements are released that
will shorten the life of any gas burning
appliance.
8
Buildings of unusually tight construction
shall have the combustion and ventilation
air supplied from outdoors, or a freely
ventilated attic or crawl space.
Propellants from common spray cans or gas
leaks from A/C and refrigeration equipment
are highly corrosive after passing through
a flame.
The water heater warranty is voided when
failure of the heater is due to operation in a
corrosive atmosphere.
Thermal Expansion
Determine if a check valve exists in the
inlet water line. Check with your local water
utility company. It may have been installed
in the cold water line as a separate back flow
preventer, or it may be part of a pressure
reducing valve, water meter or water softener.
A check valve located in the cold water inlet
line can cause what is referred to as a “closed
water system”. A cold water inlet line with
no check valve or back flow prevention
device is referred to as an “open” water
system.
As water is heated, it expands in volume and
creates an increase in the pressure within the
water system. This action is referred to as
“thermal expansion”. In an “open” water
system, expanding water which exceeds the
capacity of the water heater flows back into
the city main where the pressure is easily
dissipated.
A “closed water system”, however, prevents
the expanding water from flowing back
into the main supply line, and the result of
“thermal expansion” can create a rapid
and dangerous pressure increase in the
IMPORTANT: DO
NOT apply heat to
the HOT or COLD
water connections. If
sweat connections are
used, sweat tubing to
adapter before fitting
adapter to the cold water
connections on heater.
Any heat applied to the
cold water supply fittings
will permanently damage
the dip tube and the heat
traps in the hot/cold
nipples.
water heater and system piping. This rapid
pressure increase can quickly reach the
safety setting of the relief valve, causing
it to operate during each heating cycle.
Thermal expansion, and the resulting rapid,
and repeated expansion and contraction of
components in the water heater and piping
system can cause premature failure of the
relief valve, and possibly the heater itself.
Replacing the relief valve will not correct the
problem!
The suggested method of controlling thermal
expansion is to install an expansion tank in
the cold water line between the water heater
and the check valve (see illustration below).
The expansion tank is designed with an air
cushion built in that compresses as the system
pressure increases, thereby relieving the
over pressure condition and eliminating the
repeated operation of the relief valve. Other
methods of controlling thermal expansion
are also available. Contact your installing
contractor, water supplier or plumbing
inspector for additional information regarding
this subject.
Water Supply Connections
Refer to the illustration below for suggested
typical installation. The installation of
unions or flexible copper connectors is
recommended on the hot and cold water
connections so that the water heater may be
easily disconnected for servicing if necessary.
The HOT and COLD water connections
are clearly marked and are 3/4” NPT on all
models. Install a shut-off valve in the cold
water line near the water heater.
Typical Installation
Vent connector to
chimney
Pitch up 1/4”
per foot
Union
Heat trap
6” minimum
Draft hood
Anode
Hot water outlet to
fixtures
Union
Water Heater Jacket
Temperature and
pressure relief valve
Manual gas shut-off
To gas supply
NOTICE: The National
Fuel Gas Code (NFGC)
mandates a manual
gas shut-off valve: See
(NFGC) for complete
instructions. Local codes
or plumbing authority
requirements may vary
from the instructions or
diagrams provided and
take precedent over these
instructions.
Ground joint union
Sediment trap
Cap
Electronic control
Jacket door
Heat trap
6” minimum
Shut-off
valve
To cold water
supply
Thermal
expansion
tank (if
required)
Drain
valve
Shut-off valve
Relief valve discharge
line to suitable open
drain.
Combustion Air
Inlet Openings
Flammable vapor sensor
Auxiliary catch pan
Drain Pan Pipe to suitable drain.
6” Air gap
9
Installing the water heater
A new combination temperature and pressure relief valve, complying with the Standard for Relief Valves
and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22, is supplied and must
remain in the opening provided and marked for the purpose on the water heater. No valve of any type
should be installed between the relief valve and the tank. Local codes shall govern the installation of relief
valves.
Relief Valve
The pressure rating of the relief valve must
not exceed 150 PSI, the maximum working
pressure of the water heater as marked on
the rating plate.
The Btuh rating of the relief valve must
equal or exceed the Btuh input of the water
heater as marked on its rating plate.
Position the outlet of the relief valve above
a suitable open drain to eliminate potential
water damage. Piping used should be of a
type approved for hot water distribution.
WARNING: The tank
must be full of water before
heater is turned on. The
water heater warranty does
not cover damage or failure
resulting from operation
with an empty or partially
empty tank.
The discharge line must be no smaller
than the outlet of the valve and must
pitch downward from the valve to allow
complete drainage (by gravity) of the relief
valve and discharge line.
The end of the discharge line should not
be threaded or concealed and should be
protected from freezing. No valve of any
type, restriction, or reducer coupling should
be installed in the discharge line.
To Fill the Water Heater
Make certain that the drain valve is closed,
then open the shut-off valve in the cold
water supply line.
Open each hot water faucet slowly to allow
the air to vent from the water heater and
piping.
Condensation
Condensation can form on the tank when
it is first filled with water. Condensation
might also occur with a heavy water
draw and very cold inlet water
temperatures.
A steady flow of water from the hot water
faucet(s) indicates a full water heater.
DO NOT allow flammable vapor sensor to
become submerged in water.
This condition is not unusual, and will
disappear after the water becomes heated.
If, however, the condensation continues,
examine the piping and fittings for possible
leaks.
Drops of water falling on the burner can
produce a sizzling or pinging sound.
Flue Damper
Follow these instructions for proper installation and operation
This water heater has a factory installed
flue damper device for increased energy
efficiency. Removal of the flue damper
connections will render the heater
inoperable. DO NOT operate the water
heater without the damper housing in
place on the damper assembly. A draft
hood is shipped with this water heater.
10
The draft hood must be installed on the
damper housing using the holes provided
for alignment and fastening. The damper
must be in open position as shown in the
figure when water heater main burner is
operating. See trouble shooting instructions
if a condition other than this occurs.
Gas Supply
WARNING: DO
NOT attempt to
convert this water
heater for use with a
different type of gas
other than the type
shown on the rating
plate. Such conversion
could result in
hazardous operating
conditions.
The branch gas supply line to the water
heater should be clean, properly sized,
steel pipe or other approved gas piping
material.
shall be installed downstream of the
equipment shutoff valve as close to the
inlet of the appliance as practical at the
time of the appliance installation.
A union or ANSI design certified semirigid or flexible gas appliance connector
should be installed in the gas line close to
the water heater. The National Fuel Gas
Code (NFGC) mandates a manual gas
shut-off valve: See (NFGC) for complete
instructions.
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 flexible connectors are used, the
maximum length shall not exceed 36"
(91.4 cm) and must meet the requirements
in ANSI Z21.24/CSA 6.10- Connectors for
Gas Appliances.
Compound used on the threaded joints
of the gas piping must be of the type
resistant to the action of LP gas. Use
compound sparingly on male threads only.
Where a sediment trap is not incorporated
as part of the appliance, a sediment trap
DO NOT use excessive force over [31.5
ft. lbs. (42.7 Nm)] in tightening the pipe
joint at the gas control inlet, particularly if
teflon pipe compound is used, as the valve
body may be damaged.
The inlet gas pressure to the water heater
must not exceed 14.0 in. w.c. (3.5 kPa)
w.c. for natural gas. For purposes of
input adjustment, the minimum inlet gas
pressure (with main burner on) is shown
on the water heater rating plate. If high or
low gas pressures are present, contact your
gas supplier for correction.
Leak Testing
WARNING: Never
use an open flame to
test for gas leaks, as
property damage,
personal injury, or
death could result.
The water heater and its gas connections
must be leak tested at normal operating
pressures before it is placed in operation.
urn on the manual gas shut-off
T
valve near the water heater.
The factory connections to the gas
control (thermostat) should also be leak
tested after the water heater is placed in
operation.
se a soapy water solution to test for
U
leaks at all connections and fittings.
Bubbles indicate a gas leak that must
be corrected.
Pressure Testing the Gas Supply System
The water heater and its individual shut
off valve must be disconnected from the
gas supply piping system during any
pressure testing of that system at test
pressures in excess of 1/2 psi (3.5 kPa).
The water heater must be isolated from
the gas supply piping system by closing
it's 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 psi (3.5 kPa)
High Altitude
This water heater is suitable and certified
for use at high altitude. Refer to the
altitude label on the water heater for
maximum allowable installation altitude.
! WARNING: Installations above the
rated altitude as specified on the
altitude label are not authorized and
may result in improper and inefficient
operation of the appliance, producing
carbon monoxide gas in excess of
acceptable limits, which could result in
serious injury or death.
11
Installing the water heater
Wiring Diagram
This water heater is factory installed with a 3-pin 24 VAC wall transformer. A 19 foot long length of wire is
provided for easy access to an outlet. DO NOT use an extension cord for powering this water heater. If the
supplied power cord is insufficient to reach a power outlet, a 30 foot power cord assembly is available as an
accessory. Contact the service department to obtain and replace the power cord assembly that was shipped with
the heater.
CONNECTION DIAGRAM
SCHEMATIC
R
C
<
3 x 2 CONNECTOR
DAMPER
VALVE
BL
END SWITCHES
R
Y
M
W
BK
G
24 VAC
NEUTRAL
GROUND
BK
BK
5
4
3
2
1
P1
1
2
3
4
5
TS1
1
2
3
W
P3
1
2
WV 4460E CONTROL
W
1
SPARK
120 VAC
GROUND
NEUTRAL
120
VAC
1
2
3
TSTAT
DISPLAY
LCD DISPLAY OPTIONAL
N
G
L
M
END SWITCHES
TS2
FV
TRANSFORMER
>
24 VAC
TS1
1
2
3
P2
TS2
FV
1
2
E1
1
GND
PILOT
ELECTRODE
ASSY
P4
BK = BLACK
BL = BLUE
G = GREEN
R = RED
W = WHITE
Y = YELLOW
1
2
3
TSTAT
DISPLAY
OPTIONAL
24 VAC
120 VAC
L
N
AX5044
CAUTION! Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING!
12
Insulation Blankets
WARNING: If local codes Insulation blankets, available to the
require external application general public, for external use on gas
of insulation blanket kits the water heaters are not necessary. The
manufacturer’s instructions purpose of an insulation blanket is to
included with the kit must reduce the standby heat loss encountered
be carefully followed.
with storage tank heaters. This water
heater meets or exceeds the National
Appliance Energy Conservation Act
standards with respect to insulation and
standby loss requirements making an
insulation blanket unnecessary.
The manufacturer’s warranty does not
cover any damage or defect caused
by installation, attachment or use of
any type of energy saving or other
unapproved devices (other than those
authorized by the manufacturer) into,
onto or in conjunction with the water
heater. The use of unauthorized energy
saving devices may shorten the life of
the water heater and may endanger life
and property.
The manufacturer disclaims any
responsibility for such loss or injury
resulting from the use of such
unauthorized devices.
CAUTION: If local codes require
the application of an external
insulation blanket to this water
heater, pay careful attention to the
following so as not to restrict the
proper function and operation of the
water heater:
● DO NOT cover the operating or
warning labels attached to the water
heater or attempt to relocate them on
the exterior of insulation blanket.
DO NOT apply insulation to the top
of the water heater. This will interfere
with the safe operation of the draft
hood.
 DO NOT cover the burner access
door, jacket door, gas control
(thermostat), or temperature and
pressure relief valve.
 DO NOT apply insulation to the
bottom of the water heater or the
area where the combustion air inlet
openings are located. This area must
be unobstructed so as not to restrict
combustion air flow to the burner.
 Inspect the insulation blanket
frequently making certain it has not
sagged and is restricting the air flow
to the combustion air inlet openings
(perforation holes) located around the
lower perimeter of the water heater
jacket. This could result in an unsafe
operating condition.
The water heater must be installed with the factory supplied draft hood in place.
DANGER: Failure to
install the draft hood and
properly vent the water
heater to the outdoors as
outlined in the Venting
section of this manual will
result in unsafe operation of
the water heater causing
bodily injury, explosion, fire
or death. To avoid the risk
of fire, explosion, or
asphyxiation from carbon
monoxide, NEVER operate
the water heater unless it is
properly vented and has
adequate air supply for
proper operation as outlined
in the Venting section of this
manual.
Venting
Vent connectors must be attached to the
draft hood outlet to connect the water
heater to the gas vent or chimney. The
vent connectors must be the same size
(diameter) as the draft hood or larger,
never smaller.
1/4” per linear foot of length. Single
wall vent connectors must be at least 6”
from adjacent unprotected combustible
surface. Vent joints must be securely
fastened by sheet metal screws or other
approved method.
For proper venting in certain
installations a larger vent connector
size may be needed. It is recommended
that a double wall B-Vent connector be
used for venting purposes. Consult the
Vent Tables in Appendix G of the latest
version of the National Fuel Gas Code
(ANSI Z223.1/NFPA 54.)
Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use a flame of a match or
candle or smoke. The flame or smoke
should be pulled into the draft hood’s
relief opening(s). If the flame or smoke
is not pulled into the draft hood's relief
opening, shut off the water heater and
make proper adjustments/repairs to the
venting system.
Horizontal vent connectors must be
pitched upward to the chimney at least
13
Installing the water heater
G
v
H
A
D
E
V
B
B
B
RA
OPE
C
V
L
LE
RAB
OPE
F
I
v
B
A
M
X
K
X
v
B
v
v
ED
FIX D
SE
CLO
v
ED
FIX ED
S
CLO
v
BLE
J
B
V Vent Terminal
X Air Supply Inlet
Area Where Terminal Is Not Permitted
US Installations
A - Clearance above grade, veranda, porch,
12 in. (30 cm)
deck or balcony
B - Clearance to window or door that may be 4 ft. (1.2 m) below or to side of opening; 1 ft (300 m) above
opened
opening
C - Clearance to permanately closed window
*
D - Vertical clearance to ventilated soffit
*
located above the terminal within a horizontal distance of 2 feet (61 cm) from the
center line of the terminal
E - Clearance to unventilated soffit
*
F - Clearance to outside corner
*
G - C
learance to inside corner
*
H - C
learance to each side of centerline
*
extended above meter/regulator assembly
I - Clearance to service regulator vent outlet
*
J - Clearance to nonmechanical air supply in- 4 ft. (1.2 m) below or to side of opening; 1 ft (30 cm) above
let to building or the combustion air inlet opening
to any other appliance
K - C
learance to a mechanical air supply
3 ft. (91 cm) above if within 10 ft. (3 m) horizontally
inlet
L - Clearance above paved sidewalk or
*
paved driveway located on public property
M - Clearance under veranda, porch, deck,
*
or balcony
1
1 In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
* For clearances not specified in ANSI Z223.1/ NFPA 54 the following statement shall be included:
"Clearance in accordance with local installation codes and the requirements of the gas supplier and the manfacture's installation
instructions"
14
Hot and Cold Pipe Insulation Installation
Typical vertical piping arrangement
For increased energy efficiency, some water
heaters have been supplied with two 24”
sections of pipe insulation.
T&P Insulation Installation
Typical horizontal piping arrangement
Please install the insulation, according to
the illustrations above, that best meets your
requirements.
For increased energy efficiency, this water heater
has been supplied with a 2 3/8” section of T&P
insulation. Please install the insulation as shown
below.
Typical Side Connect T & P Arrangement.
Slip the insulation cover over the T&P Valve
through the center hole and align the hole in
the side with the opening of the T&P Valve.
Typical Top Connect T & P Arrangement.
Ensure the T&P Valve opening is not
obstructed by the insulation.
Heat Traps
For increased energy efficiency, some water
heaters have been supplied with factory installed
3/4” NPT heat traps in the hot outlet line and
cold water inlet line
These heat traps may require a minimum of
one (1) 90° 3/4” NPT elbow and may require
an additional 90° 3/4” NPT elbow or a 3/4”
coupling depending on your installation needs.
See Illustration of nipples and heat traps on
page 27.
During Installation of this water heater
DO
❑ DO check inlet gas pressure to ensure that it is
within the range specified on the rating plate.
❑ DO provide adequate air for combustion and
ventilation as discussed in the Use and Care Manual
and the National Fuel Gas Code.
❑ DO maintain proper clearances to combustibles as
specified on the rating plate.
❑ DO ensure that the venting system complies with
the guidelines found in the Use and Care Manual and
National Fuel Gas Code.
❑ DO contact a qualified service technician if the pilot
or main burner will not stay lit. The burner chamber
is designed to be sealed utilizing a gasket and tamper
resistant screws.
❑ DO ensure that the flue damper is not obstructed
and is free of debris.
DON’T
❑ DON’T block or restrict Combustion Air Inlet
Openings located around the lower portion of the water
heater jacket.
❑ DON’T remove the Burner Access Door unless
absolutely necessary. This should only be done by a
qualified service technician. A new burner access door
gasket must be installed on any burner access door that
has been removed.
❑ DON’T install this water heater where standing
water may occur. The base of the water heater is
meant to be mounted on a dry surface.
❑ DON’T operate the water heater if the sight glass
or burner access door grommet is damaged or broken.
Sight
❑DON'T
Glass
manually
Burner Access
open or
close the Door Grommet
Flammable
damper.
Vapor Sensor
15
Installation Checklist
A. Water Heater Location
❑ Close to area of vent.
❑Indoors and protected from freezing
❑Provisions made to protect area from water
damage.
❑ Sufficient room to service heater.
❑Proper clearance from combustible surfaces
❑Combustible materials, such as clothing,
❑Sufficient fresh air supply for proper
❑Air supply free of corrosive elements and
❑Clearances from combustion air inlet
openings observed refer to the "Location"
section of the "Installing the Water Heater"
portion of this manual.
temperatures.
observed and water heater not installed on
carpeted floor.
operation of water heater.
flammable vapors.
cleaning materials, rags, etc. clear of the base
of the heater.
❑ Flammable vapor sensor is not blocked.
❑Gas Company inspected installation (if
B. Water Supply
❑ Water heater completely filled with water.
❑ Air purged from water heater and piping.
❑ Water connections tight and free of leaks.
C. Gas Supply
❑Gas line equipped with shut-off valve, union
and sediment trap.
required).
❑ Approved pipe joint compound used.
❑Soap and water solution used to check all
connections and fittings for possible gas
leak.
D. Relief Valve
❑Temperature and Pressure Relief Valve
properly installed and discharge line run to
open drain.
❑ Discharge line protected from freezing.
E. Venting
❑Flue baffle properly hung in water heater’s
flue tube.
❑Vent connector(s) securely fastened together
with screws.
❑Draft hood properly installed on flue damper
❑Single wall vent connector(s) at least 6” from
❑Vent connector(s) pitched upward to chimney
❑Flue damper properly installed and operating
housing.
(¼" per linear foot minimum) .
combustible material.
normally..
F. Wiring
❑ Correct power supply (24 VAC)
transformer.
16
❑ Electrical connection tight.
❑Heater properly grounded and proper
polarity observed.
Supplemental instructions for gas water heaters installed
in potable/space heating applications
Local codes or plumbing authority requirements may vary from the instructions or diagrams provided in
this manual and take precedent over these instructions.
Combination Potable and Space Heating Application
Hot water
supply to
house
Hot water
supply to
heating
unit
From HOT
outlet on
water heater
Tee fitting for vertical hot
water supply lines.
From HOT
Hot water
outlet on
supply to
water heater
house
Hot water supply
to heating unit
Tee fitting for horizontal hot
water supply lines.
Tee fitting must be installed as shown.
This ensures that any air in the water lines
will be purged through the domestic water
faucets and showers.
DANGER: When this system
requires water for space heating at
elevated temperatures (above 125°F
[52°C.]), a mixing valve complying with
the Standard for Temperature Actuated
Mixing Valves for Hot Water
Distribution Systems, ASSE 1017 must
be installed in the hot water supply line
to the house in order to reduce the scald
hazard potential.
DANGER: Any piping or components
used in the installation of this water
heater in a combination potable and
space heating application must be
suitable for use with drinking water.
DO NOT use for space heating
application only.
DANGER: If this water heater is
installed in an application intended to
supply domestic hot water needs and
hot water for space heating purposes,
DO NOT connect the heater to an
existing heating unit or components of a
heating system that have previously
been used with a non drinking water
system. Toxic chemicals such as those
used for boiler treatment may be
present and will contaminate the
drinking water supply causing possible
health risks. Never introduce toxic
chemicals, such as those used for boiler
treatment, into this system.
Notice: 50' - 0" maximum distance
from water heater to fan coil
(developed length) is required for
NOTICE: Suitable for (potable) water
Massachusetts State.
heating and space heating applications.
Typical Piping Diagram for Combination Potable/Space Heating Installation
Pressure Gauge
Nominal 3/4" size mixing or tempering valve
(refer to warning above). Follow mixing or
tempering valve manufacturer’s instructions for
installation of the valve.
Minimum of 2'-0" developed length of
3/4" type "L" copper from the water
heater connection.
Air vent
Spring loaded check valve in heating unit
hot water supply line and cold water return
line (not supplied with water heater)
Heat Trap
6” Min.
2 Gallon Thermal
Expansion Tank (if
required-not supplied
with water heater)
3/4" ShutOff Valve
(Typ.)
Isolation valve in hot water supply line
to heating unit (not supplied with water
heater)
Hot water
to space heater
Hot water coil
See diagrams above for proper
pipe application for vertical
or horizontal supply lines.
°F
140
Temperature and Pressure Relief
Valve, tie to location approved by
local code
°
120
Gas line to water heater
to
All bronze pump.
Check valve
internal in pump.
°F
130
Air bleed valve.
Water Sample Tap.
3/4" HWS & HWR
to Heating Coil.
To HVAC Unit.
T FAN
ON
OFF
HEAT
COOL
Drain valve
(not supplied with
water heater)
Temperature and pressure relief
valve discharge line
Gas Fired
Water Heater
Water Heater to be in accordance with
the Local and State Energy Code
3/4" cold water supply Piping loop between water
heater and fan coil shall
be flow guard gold CPVC
or equal
3/4" Shut-Off Valve (Typ.)
NOTE: This check valve is incorporated
in some heating units. Refer to the
installation instructions supplied with
specific heating unit to determine if it is
required.
Water Heater drain pan installed in
accordance with the Local and State
Code
3/4" Check Valve with 1/8" Hole
3/4" Shut-Off Valve (Typ.)
3/4" Tempered
domestic hot water
supply to house.
Isolation valve in
cold water return line
from heating unit (not
supplied with water
heater)
Air Handler
Gas Vent discharge must
comply with Local and
State Code
Combustion Air Inlet
Openings
All water piping shall be insulated in
accordance with Local and State Energy
Code.
6” Air Gap
Vacuum Relief Valve
(Not Supplied)
Electronically controlled pump timer.
Activates every 6 hours for 60 seconds.
Wire to bronze pump.
If required, install per local codes
and valve manufacturer’s
instructions.
17
Lighting the water heater
Before operating this water heater, be sure to read and follow the instructions on the label pictured below
and all other labels on the water heater, as well as the warnings printed in this manual. Failure to do so
can result in unsafe operation of the water heater resulting in property damage, personal injury, or death.
Should you have any problems reading or following the instructions in this manual, STOP, and get help
from a qualified person.
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions and use the Use & Care
Manual instructions exactly, a fire or explosion may result causing property damage,
personal injury or loss of life.
A. This appliance is equipped with an
ignition device which automatically lights
the pilot. DO NOT try to light the pilot by
hand.
B. BEFORE PUTTING THIS APPLIANCE INTO
SERVICE - 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.
instuctions.
If you cannot reach your gas supplier,
call the fire department.
C. Use only your hand to turn the thermostat
dial. Never use tools. If the dial will
not turn by hand, do not try to repair it,
call a qualified service technician. Force
or attempted repair may result in fire or
explosion.
WHAT TO DO IF YOU SMELL GAS
D. Do not use this appliance if any part has
been under water. Immediately call a
Do not try to light any appliance.
Do not touch any electric switch; do not
qualified installer or service agency to
use any phone in your building.
replace a flooded water heater. Do not
Immediately call your gas supplier from a
attempt to repair the unit! It must be
neighbor’s phone. Follow the gas suppliers
replaced!
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above 9. Set the thermostat dial to the desired
on this label.
setting.
2. Set the thermostat dial to the lowest
setting
3. Slide the “ON/OFF” switch located on
the gas control to the “OFF” position.
10. If the appliance will not operate,
follow the instructions “TO TURN OFF
GAS TO APPLIANCE” and call your
service technician or gas supplier.
4. Turn off all electric power to the
appliance.
5. This appliance is equipped with an
ignition device which automatically
lights the pilot. DO NOT attempt to light
the pilot by hand.
6. Wait five (5) minutes to clear out any gas.
If you smell gas, STOP! Follow “B’ in the
safety information above on this label. If
you do not smell gas, go to the next step.
7. Turn on electric power to the appliance.
8. Slide the ”ON/OFF” switch located on
the gas control to the “ON” position.
TO TURN OFF GAS TO APPLIANCE
1.
2.
3.
4.
18
Set the thermostat dial to the lowest setting.
Slide the “ON/OFF” switch located on the gas control to the “OFF” position.
Turn off all electric power to the appliance if service is to be performed.
Close the manual gas shut-off valve.
Operating the water heater
CAUTION: Hydrogen gas can be produced in a hot water system served by this water heater that has not been used
for a long period of time (generally two weeks or more). HYDROGEN GAS IS EXTREMELY FLAMMABLE!! To
dissipate such gas and to reduce risk of injury, it is recommended that the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is
present, there will be an unusual sound such as air escaping through the pipe as the water begins to flow. DO NOT
smoke or use an open flame near the faucet at the time it is open.
Safety Precautions
D
o turn off manual gas shut-off valve if water
heater has been subjected to over heating, fire,
flood, physical damage or if the gas supply fails to
shut off.
O NOT store or use gasoline or other flammable
D
vapors and liquids, such as adhesives or paint
thinner, in vicinity of this or any other appliance. If
such flammables must be used, open doors and
windows for ventilation, and all gas burning
appliances in the vicinity should be shut off
including their pilot burners, to avoid vapors
lighting.
DO NOT turn on water heater unless it is
completely filled with water.
DO NOT turn on water heater if cold water supply
shut-off valve is closed.
DO NOT allow combustible materials such as
newspaper, rags or mops to accumulate near water
heater.
NOTICE: Flammable vapors can be drawn by air
currents from surrounding areas to the water heater.
If there is any difficulty in understanding or
following the Operating Instructions or the Care
and Cleaning section, it is recommended that a
qualified person or serviceman perform the work.
Operating Procedure
This water heater is equipped with an
ignition device which automatically
lights the pilot. DO NOT try to light
the pilot by hand. On initial start-up,
it is recommended that the outer door
be removed (leave inner door in place
for safety) to determine if the pilot and
main burner are operating properly.
Once filled with water, plug in the
electrical supply cord and slide the
“ON/OFF” switch located on the front
of the combination gas control to the
Water Temperature Setting
DANGER: Hotter water
increases the Potential for
Hot Water SCALDS.
Households with small
children, disabled, or
elderly persons may
require a 120°F or lower
gas control (thermostat)
setting to prevent contact
with HOT water.
“ON” position. Set the thermostat dial
to the desired setting.
After the pilot and main burner ignite,
replace the outer door. If no pilot and
main burner flames are established, the
combination gas control will go through
three trials for ignition before going into
a “lock-out” mode. A warning light will
alert the user of this “lock-out” mode
condition. If this happens, refer to the
“Gas valve LED codes.”
The temperature of the water in the
water heater can be regulated by setting
the temperature dial on the front of the
gas control (thermostat).
scalding. Be sure to read and follow the
warnings outlined in this manual and
on the label located on the water heater
near the gas control thermostat.
Safety and energy conservation
are factors to be considered when
selecting the water temperature
setting of the water heater’s gas
control (thermostat(s)). The lower the
temperature setting, the greater the
savings in energy and operating costs.
Mixing valves are recommended for
reducing point of use water temperature
by mixing hot and cold water in
branch water lines. It is recommended
that a mixing valve complying
with the Standard for Temperature
Actuated Mixing Valves for Hot Water
Distribution Systems, ASSE 1017 be
installed. See page 4 for more details
and contact a licensed plumber or the
local plumbing authority for further
information.
To comply with safety regulations, the
gas control (thermostat) was set at its
lowest setting before the water heater
was shipped from the factory. The
recommended starting point temperature
is 120°F.
Water temperatures above 125°F can
cause severe burns or death from
The chart on the next page may be used
as a guide in determining the proper
water temperature for your home.
19
Water Temperature Setting
Maximum water temperatures occur just after the burner has
shut off. To determine the water temperature, turn on a hot
water faucet and place a thermometer in the water stream.
A condition known as “stacking” or “layering” can occur
when a series of short and frequent hot water draws are
taken.
The hottest temperature water will be at the top of the tank,
closest to the outlet pipe delivering hot water to the home.
Stacking can cause this top layer of water to be hotter than
the water toward the bottom of the tank near the gas control
(thermostat). Therefore, always remember to test the water
temperature with your hand before use and remember that
hotter water increases the risk of scald injury. Also, always
supervise young children or others who are incapacitated.
The gas control (thermostat) is also equipped with a gas
shutoff device that will shut off the gas supply to the burner
if the water heater exceeds normal operating temperatures.
Refer to the “Before You Call For Service” section of this
manual, or contact your dealer.
! WARNING: Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
valve to the appliance
NOTICE: Replace any part of the gas control system
which has been under water.
If the water heater has been subjected to fire, flood or physical damage, turn off the manual gas control (shutoff) valve
and DO NOT operate the water heater again until it has been
checked by a qualified service technician.
The gas control (thermostat) is constructed with a built in
safety shutoff device designed to shut off the gas supply to
the burner if the main burner is extinguished for any reason.
Time/Temperature Relationship in Scalds
Water Temperature
150°F
160°F
Table courtesy of Shriners Burn Institute
140°F
130°F
120°F
113°F
105°F
98°F
90° F
Temperatures are approximate
20
120°F
125°F
130°F
135°F
140°F
145°F
150°F
155°F
Time To Produce a Serious Burn
More than 5 minutes
11/2 to 2 minutes
About 30 seconds
About 10 seconds
Less than 5 seconds
Less than 3 seconds
About 11/2 seconds
About 1 second
Care and cleaning of the water heater
Draining the Water Heater
! CAUTION: Shut off gas to the water
heater at the gas control (thermostat)
gas cock or manual shut-off valve before
draining water.
! DANGER: Before manually operating
the temperature and pressure relief valve,
make certain no one will be exposed to the
hot water released by the valve. The water
drained from the tank may be hot enough
to present a scald hazard and should be
directed to a suitable drain to prevent injury
or damage.
! DANGER: Before
manually operating the
relief valve, make certain no
one will be exposed to the
danger of the hot water
released by the valve. The
water may be hot enough to
create a scald hazard. The
water should be released
into a suitable drain to
prevent injury or property
damage.
! DANGER: Hotter water
increases the potential for
Hot Water Scalds.
! DANGER: Failure to
perform the recommended
Routine Preventative
Maintenance can harm the
proper operation of this
water heater, which can
cause carbon monoxide
dangers, excessive hot
water temperatures and
other potentially hazardous
conditions.
! DANGER: Combustible
materials, such as clothing,
cleaning materials, or
flammable liquids, etc., must
not be placed against or next
to the water heater.
Before turning off the cold water supply to
the water heater, open a hot water faucet
allowing sufficient cold water into the
tank to prevent the risk of a scald injury
while draining the water heater. Once the
water in the tank is no longer hot, turn off
the cold water supply to the water heater.
Open a hot water faucet or lift the handle
on the relief valve to admit air to the tank.
Attach a garden hose to the drain valve on
the water heater and direct the stream of
water to a drain. Open the valve.
Routine Preventative Maintenance
Properly maintained, your water heater will
provide years of dependable trouble-free
service.
It is recommended that a periodic
inspection of the gas control (thermostat),
burner, relief valve, internal flue-way and
venting system should be made by service
personnel qualified in gas appliance repair.
It is suggested that a routine preventative
maintenance program be established and
followed by the user.
Periodically, lift and release the lever
handle on the temperature pressure relief
valve, located near the top of the water
heater, to make certain the valve operates
freely. Allow several gallons to flush
through the discharge line to an open drain.
NOTICE: If the temperature and
pressure relief valve on the hot water
heater discharges periodically, this may
be due to thermal expansion in a closed
water system. Contact the water supplier
or your plumbing contractor on how
to correct this. DO NOT plug the relief
valve outlet.
A water heater’s tank can act as a settling
basin for solids suspended in the water. It
is therefore not uncommon for hard water
deposits to accumulate in the bottom of
the tank. If allowed to accumulate, these
solids can cover the gas control (thermostat)
Housekeeping
Make sure the flammable vapor sensor is
not blocked or obstructed.
To ensure sufficient ventilation and
combustion air supply, proper clearances
must be maintained.
sensors, causing the sensors to operate
erratically. Because accumulated solids
can prevent the gas control (thermostat)
sensors from accurately reading the water
temperature, the water at the fixture can be
hotter than the gas control (thermostat) dial
setting. It is suggested that a few quarts of
water be drained from the water heater’s
tank every month to clean the tank of these
deposits.
Rapid closing of faucets or solenoid valves
in automatic water using appliances can
cause a banging noise heard in a water pipe.
Strategically located risers in the water pipe
system or water hammer arresting devices
can be used to minimize the problem.
The anode rod should be removed from the
water heater’s tank annually for inspection
and replaced when more than 6” of core
wire is exposed at either end of the rod.
Make sure the cold water supply is turned
off before removing anode rod.
This water heater incorporates a combustion
shut off device that shuts the operation
of the water heater down if undesirable
combustion conditions occur, such as the
presence of flammable vapors or blockage
of the combustion air inlet openings. Please
contact a qualified service technician if this
occurs.
When installed in a closet, DO NOT
block or obstruct any of the combustion
air inlet openings located around
the perimeter of the water heater. A
minimum of 1” is required between
these combustion air inlet openings and
any obstruction.
21
Care and cleaning of the water heater
Venting System Inspection
The water heater’s internal flue must be
inspected annually to be certain it is clean
by removing the damper and flue baffle.
When reinstalling the flue baffle make
certain it is hung securely by its hanger at
the top of the flue way.
Reinstall the flue damper and the draft
hood.
Inspect the gas venting system and the
chimney.
Make certain the vent connector from
the draft hood to the vent system and/
or chimney is properly positioned and
securely attached.
If after inspection of the vent system you
find soot or deterioration; call the local gas
utility to correct the problem and clean the
flue, or replace the flue, flue baffle, and
venting system before resuming operation
of the water heater.
Test for spillage at the draft hood relief
opening after 5 minutes of burner
operation. Use a flame of a match or
candle or smoke. The flame or smoke
should be pulled into the draft hood’s relief
opening(s). If the flame or smoke is not
pulled into the draft hood's relief opening,
shut off the water heater and make proper
adjustments/repairs to the venting system.
Burner Inspection
Gas flame
should be visible on entire
burner surface.
Visually inspect the pilot burner and main
burner annually.
Through the sight glass, inspect the pilot
burner flame with the main burner off and
inspect the main burner while firing.
If any unusual burner operation is noted,
the water heater should be shut off
until qualified service assistance can be
obtained.
Proper burner flame
pattern
The burner operates in radiant mode
and glows bright orange when burning
correctly. Allow approximately 30 seconds
after turning on for the burner to reach the
radiant mode
CAUTION: For your safety, cleaning of
the burner must be performed only by
qualified service personnel. The burner
chamber is a sealed area. If the burner inner
door, lower air box, or inner door burner
assembly are removed, the inner door
gaskets, burner access door gasket, and
transition pan gasket must be replaced.
For cleaning, remove the inner door and
inner door burner assembly from the water
heater. A vacuum cleaner can be used on
the burner and inside the water heater. The
burner can also be cleaned by blowing air
over the burner surface. Do not allow any
large debris to remain inside the burner.
Refer to page 23.
Vacation and Extended Shut-Down
NOTICE: Refer to the
Hydrogen Gas Caution in the
Operating Instructions.
If the water heater is to remain idle for an
extended period of time, the power and
water to the appliance should be turned off
to conserve energy and prevent a build-up
of dangerous hydrogen gas.
After a long shut-down period, the water
heater’s operation and controls should be
checked by qualified service personnel.
Make certain the water heater is completely
filled again before placing it in operation.
The water heater and piping should be
drained if they might be subjected to
freezing temperatures.
NOTICE: DO NOT remove
the anode rod from the water
heater’s tank, except for
inspection and/or replacement,
as operation with the anode rod
removed will greatly shorten the
life of the glass lined tank and
will exclude warranty coverage.
22
Anode Rod
This water heater is equipped with an
anode rod designed to prolong the life
of the glass lined tank. The anode rod is
slowly consumed, thereby eliminating or
minimizing corrosion of the glass lined
tank.
Water sometimes contains a high sulfate
and/or mineral content and together with
cathodic protection process can produce
a hydrogen sulfide, or rotten egg odor in
the heated water. Chlorination of the water
supply should minimize the problem.
Before You Call For Service
Troubleshooting Tips
Save time and money! Review the charts on the following pages first and you may not need to call for service.
This water heater incorporates a combustion shut off device that shuts the operation of the water heater down
if undesirable combustion conditions occur, such as the presence of flammable vapors or blockage of the
combustion air inlet openings. Please contact a Qualified Service Technician if this occurs.
Problem
Possible Causes
What To Do
Condensation
This usually happens when a
new heater is filled for the first
time
•
Moisture from the products of
combustion condensing on the
tank surface.
•
Yellow flame
or soot
An undersized water heater will •
cause condensation.
Scale on top of the burner.
•
Flue or combustion air inlet
•
openings are restricted.
Not enough combustion or ven- •
tilation air supplied to the water
heater location.
Unable to light
main burner
Air in gas line.
•
Pilot burner orifice clogged.
•
Pilot burner tube pinched or
clogged.
Damper unable to open.
•
•
•
Main burner does
not stay lit
Wire connection(s) not fully
secured.
Combustion shut-off device
tripped.
Gas control (thermostat) problem.
•
Combustion shut-off device
tripped.
Gas control (thermostat) shutoff device tripped.
•
•
•
•
•
This is normal. After the water in the tank warms up,
the condensation will disappear. If, however, the condition persists, examine the piping and fittings for possible leaks. Refer to the "Condensation" information in
the "Installing the Water Heater" section of this manual.
This is normal and will disappear in time. Excessive
condensation can cause main burner outage. Refer to
the "Condensation" information in the "Installing the
Water Heater" section of this manual.
Use a water heater size that meets the requirements of
your needs.
Contact a qualified service technician to clean the
burner.
Remove obstruction or debris from flue or combustion
air inlet openings on water heater jacket.
Proper operation of the water heater requires air for
combustion and ventilation. See the "Combustion and
Ventilation Air" information in the "Installing the Water
Heater" section of this manual.
Contact a qualified service technician to purge air from
the gas line.
Pilot should be cleaned or replaced by a qualified service technician.
The pilot burner should be cleaned, repaired, or replaced by a qualified service technician.
Contact a qualified service technician to evaluate
damper.
Refer to "Gas Valve Error Codes" in the "Gas Valve
LED Codes" section of this manual.
Contact a qualified service technician to confirm wire
connection(s).
Combustion shut-off device should be inspected by a
qualified service technician.
Contact a qualified service technician.
Refer to "Gas Valve Error Codes" in the "Gas Valve
LED Codes" section of this manual.
Combustion shut-off device should be inspected by a
qualified technician.
Contact a qualified service technician.
CAUTION: For your safety DO NOT attempt repair of gas piping, gas control (thermostat), burners, vent connectors or other
safety devices. Refer repairs to qualified service personnel.
23
Before You Call For Service
Troubleshooting Tips
Save time and money! Review the charts on the following pages first and you may not need to call for service.
This water heater incorporates a combustion shut off device that shuts the operation of the water heater down
if undesirable combustion conditions occur, such as the presence of flammable vapors or blockage of the
combustion air inlet openings. Please contact a Qualified Service Technician if this occurs.
Problem
Possible Causes
What To Do
Rumbling noise
Scale and sediment
Relief valve producing
popping noise or
draining
Not enough or no hot
water
Pressure build up caused by
thermal expansion to a closed
system.
Water usage may have
exceeded the capacity of the
water heater.
Low gas pressure.
Drain the water heater to remove scale and sediment from
the tank. Refer to the top of page 20.
This is an unacceptable condition and must be corrected.
Contact the water supplier or plumbing contractor on how to
correct this. Do not plug the relief valve outlet.
Wait for the water heater to recover after an abnormal
demand.
Water is too hot
Check gas supply pressure and manifold pressure.
The Gas Control (thermostat)
may be set too low.
See the “Water Temperature Setting” of The Water Heater
section of this manual.
Leaking or open hot water
faucets.
Make sure all faucets are closed.
Check valve error codes.
Refer to gas valve error code table on page 24.
“ON/OFF” switch turned off.
Gas Control (thermostat)
shutoff device has tripped.
Combustion Shutoff System
tripped
The Gas Control (thermostat) is
set too high.
Turn “ON”.
Contact a qualified service technician.
Gas Control (thermostat) is
Defective.
Contact a qualified service technician to replace the Gas
Control (thermostat).
Contact a qualified service technician.
See the “Water Temperature Setting” of The Water Heater
section of this manual.
CAUTION:
your
safety
NOT
attempt
repair
of garol
(thermostat),
vent burners,
connectors,
dampers,
or other
CAUTION:
ForFor
your
safety
DODO
NOT
attempt
repair
of gas
piping,
gas control burners,
(thermostat),
vent
connectors
or other
devices.
Refer repairs
to qualified
personnel.
safety safety
devices.
Refer repairs
to qualified
serviceservice
personnel.
24
Gas Valve LED Codes
GAS VALVE LED
STATUS/PROBLEM
PROBABLE CAUSE
SOLUTION
Short flash once every four seconds
Normal Operating
Condition/ No Fault
Condition
Water Temperature setpoint has been
achieved
“Heartbeat”, alternates bright/dim
Calling For Heat/No
Fault Conditions
Water temperature is below setpoint and
None required
burner is on
One Flash, three
second pause
• Pilot tube restricted or damaged
Control still operating/ • Carbon build-up on pilot's electrode
Low flame signal
• Pilot igniter wire damaged
• Gas supply problems
Two Flashes, three
second pause.
•
•
Sytem in Lockout/Flue
•
Damper Switch closed
•
•
•
•
Three Flashes, three System in Lockout/Flue
•
second pause
Damper Switch open
•
•
Four Flashes, three
second pause
Five Flashes, three
second pause
System in Lockout/No Pilot and/or Main Burner valve has
Flame Sense
failed to open
Six-One Flashes,
three second pause
Six-Two Flashes,
three second pause
Six-Three Flashes,
three second pause
System in Lockout/
Unit failed to light
• Replace Pilot assembly
• Correct gas supply
• Inspect Flue Damper wiring and conFlue Damper improperly sealed
nections
Flue Damper switch stuck closed
• Replace Flue Damper Assembly
Faulty Flue Damper motor
• Contact a qualified service techniObstruction or debris in damper opencian. See "IF YOU NEED SERing
VICE" on page 28
Flue Damper improperly installed
Flue Damper switch stuck open
• Inspect wiring and connections
Faulty Flue Damper switch
• Replace Flue Damper Assembly
Incorrect wiring and/or connections • Contact a qualified service techniFaulty Flue Damper motor
cian. See "IF YOU NEED SERObstruction or debris in damper open- VICE" on page 28
ing
•
System in Lockout/
Thermal Cutoff Device
•
tripped
•
•
•
•
•
•
None required
Thermal well fault in Gas Control
(Thermostat)
Gas Control (Thermostat) faulty
Tank not filled with water
Pilot flame unstable
Pilot tube restricted or damaged
Carbon build-up on pilot's electrode
Pilot igniter wire damaged
Gas supply problem(s)
• Reset Gas Control (Thermostat) and
check for proper cycling of control.
• Replace Gas Control (Thermostat)
• Ensure tank is completely filled with
water
Replace the Gas Control (Thermostat)
• Replace Pilot assembly
• Correct gas supply
System in Lockout/
Flue Damper Switch
opened
• Improper Flue Damper installation
• Faulty Flue Damper switch
• Incorrect wiring and/or connections
• Inspect Flue Damper wiring and connections
• Replace Flue Damper Assembly
• Contact a qualified service technician. See "IF YOU NEED SERVICE" on page 28
System in Lockout/
Flame Lost
• Combustion air supply restricted or
blocked
• Pilot tube restricted or damaged
• Carbon build-up on pilot's electrode
• Pilot igniter wire damaged
• Gas supply problem(s)
• Ensure combustion air supply is not
blocked or restricted
• Replace Pilot assembly
• Correct gas supply
CAUTION: Make certain power to water heater is “OFF” before removing protective cover FOR ANY REASON.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation. VERIFY PROPER OPERATION AFTER SERVICING.
CAUTION: For your safety DO NOT attempt repair of gas piping, remote control, burners, vent connectors or other
safety devices. Refer repairs to qualified service personnel.
25
Gas Valve LED Codes cont.
GAS VALVE LED
STATUS/PROBLEM
PROBABLE CAUSE
Six-Four Flashes, three System in Lockout/Flame Gas Control (Thermostat's) valve
second pause
sense out of sequence
stuck open
Seven Flashes, three
second pause
System in Lockout/Presence of Flammable Vapors detected
• Gasoline or other flammable
vapor(s) were detected
• Faulty Flammable Vapor Sensor
• Faulty Gas Control (Thermostat)
• Flammable vapor sensor values
System in Lockout/Flamout of range
Eight-One Flash, three
mable Vapor Sensor fault • Improper Flammable Vapor Sensecond pause
detected
sor wiring and/or connection(s)
• Faulty Flammable Vapor Sensor
System in Lockout/EnEight-Two Flashes,
• Thermal well fault in Gas Control
ergy cutoff device fault
three second pause
(Thermostat)
detected
System in Lockout/Fault • Thermal well fault in Gas Control
Eight-Three Flashes,
in the electronics circuit
(Thermostat)
three second pause
detected
• Faulty Gas Control (Thermostat)
• Gas Control (Thermostat) needs to
System in Lockout/Fault
Eight-Four Flashes,
be reset
with the Gas Control
three second pause
• Gas Control (Thermostat) has been
(Thermostat)
damaged
SOLUTION
Replace Gas Control (Thermostat)
• Ensure that no flammable vapor(s) are
present
• Reset the Gas Control (Thermostat)
using "ON/OFF" switch located on the
front of the control
• Replace Flammable Vapor Sensor
• Replace Gas Control (Thermostat)
• Inspect the Flammable Vapor Sensor
wiring and connection(s)
• Replace Flammable Vapor Sensor
• Replace Gas Control (Thermostat)
• Inspect the wiring connection(s) to the
thermal well
• Replace the thermal well
• Replace thermal well
• Replace Gas Control (Thermostat)
• Cycle the power to the Gas Control
(Thermostat)
• Replace the Gas Control (Thermostat)
CAUTION: Make certain power to water heater is “OFF” before removing protective cover FOR ANY REASON.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation. VERIFY PROPER OPERATION AFTER SERVICING.
CAUTION: For your safety DO NOT attempt repair of gas piping, remote control, burners, vent connectors or other safety
devices. Refer repairs to qualified service personnel.
26
Replacement Parts
For 38 and 48 gallon models using natural gas.
Instructions For Placing a Parts Order
All parts orders should include:
T
he model and serial number of the water
heater from the rating plate.
Draft Hood
pecify type of gas (natural or LP) as
S
marked on the rating plate.
Flue Damper Housing
* Heat
Trap
Nipple
Transformer
CAUTION: For your safety, DO NOT
attempt repair of gas piping, gas control
(thermostat), burners, vent connectors or
other safety devices. Refer repairs to
qualified service personnel.
Burner
Flue Damper
Anode rod
P
art description (as noted below) and
number of parts desired.
Baffle Assembly
Ignitor Wire
Heat Trap Nipple
Pilot Screw
Pilot
Bracket
Dip tube
Dip tube gasket
Temperature
and pressure
relief valve
Pilot Bracket
Screws
Burner Access
Door Gasket
Burner Access
Door Assembly
Pilot Tube
Burner
Hex Nuts
The kit provides extra speed clips and tamper resistant screws.
Gas Control Shank
Gas Control (Thermostat)
Drain valve
*Burner
Lower Air Box
Transition Pan
Gasket
Inner Door Gasket
Burner Access Door Gasket
Inner Door
Jacket Door
Inner Door Burner Assembly
Mounting Screws
Lower Air Box Screws
Inner Door Hex Nuts
27
IF YOU NEED SERVICE
1. Should you have any questions about your new water heater, or if it requires adjustment,
repair, or routine maintenance, it is suggested that you first contact your installer, plumbing
contractor or previously agreed upon service agency. In the event the firm has moved, or is
unavailable, refer to the telephone directory, commercial listings or local utility for qualified
service assistance.
2. Should your problem not be solved to your complete satisfaction, you should then contact
the Manufacturer’s National Service Department at the following address:
1241 Carwood Court
Montgomery, Alabama 36117
Phone: 1-866-279-4566.
When contacting the manufacturer, the following information will be requested:
a. Model and serial number of the water heater as shown on the rating plate attached to the
jacket of the heater.
b. Address where the water heater is located and physical location.
c. Name and address of installer and any service agency who performed service on the water
heater.
d. Date of original installation and dates any service work was performed.
e. Details of the problems as you can best describe them.
f. List of people, with dates, who have been contacted regarding your problem.
Important Instructions for the Commonwealth of Massachusetts
The Commonwealth of Massachusetts requires compliance with regulation 5.08: Modifications to NFPA-54, Chapter 10 : 248 CMR 4.00
and 5.00 for installation of through – the – wall vented gas appliances as
follows:
(1) Revise NFPA-54 section 10.5.4.2 by adding a second exception as follows:
Existing chimneys shall be permitted to have their use continued when a gas
conversion burner is installed, and shall be equipped with a manually reset
device that will automatically shut off the gas to the burner in the event of a
sustained back-draft.
(2) Revise 10.8.3 by adding the following additional requirements:
(a) For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the Commonwealth and
where the side wall exhaust vent termination is less than seven (7) feet above
finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time
of installation of the side wall horizontal vented gas fueled equipment, the
installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level
where the gas equipment is to be installed. In addition, the installing plumber
or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to secure the
services of qualified licensed professionals for the installation of hard wired
carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is
installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor
level.
b. In the event that the requirements of this subdivision can not be met at the
time of completion of installation, the owner shall have a period of thirty (30)
days to comply with the above requirements; provided, however, that during
said thirty (30) day period, a battery operated carbon monoxide detector with
an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon
monoxide detector as required in accordance with the above provisions shall
comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently
mounted to the exterior of the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent terminal for the horizon-
28
tally vented gas fueled heating appliance or equipment. The sign shall read,
in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless,
upon inspection, the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1
through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR
5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To
Be Vented" in the most current edition of NFPA 54 as adopted by the Board;
and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure
used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM PROVIDED. When the manufacturer of Product Approved side
wall horizontally vented gas equipment provides a venting system design or
venting system components with the equipment, the instructions provided
by the manufacturer for installation of the equipment and the venting system
shall include:
1. Detailed instructions for the installation of the venting system design or
the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING
SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved
side wall horizontally vented gas fueled equipment does not provide the parts
for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with
the appliance or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board,
and the instructions for that system shall include a parts list and detailed
installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall
horizontally vented gas fueled equipment, all venting instructions, all parts
lists for venting instructions, and/or all venting design instructions shall
remain with the appliance or equipment at the completion of the installation.
(3) After NFPA-54 section 10.10.4.2 add a new section 10.10.4.3 as follows:
When more than four gas appliances are to be vented through a common
gas vent or common horizontal vent manifold, a plan of the proposed vent
installation shall be submitted to the Inspector and the serving gas supplier
for review and approval.
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