Rheem Performance XG55T06EN45U0 Instructions / Assembly

! 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
Residential 28, 38, 40, 48 and 55 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.
— I mproper 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
®
AP17110-1 (01/15)
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
Gas Supply. . . . . . . . . . . . . . . 11
Pipe Insulation. . . . . . . . . . . . 14
#
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.
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
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
Water 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 18 & 19 for more details and
contact a licensed plumber or the local plumbing
authority for further information.
150°F 155°F
140°F
130°F
125°F
120°F
91°F
! DANGER: Hotter water increases the
potential for Hot Water SCALDS.
4
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.(See page 18 and 19 for more details.)
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 illustration at the left details the approximate
T
water temperature for each mark on the Gas Control
(Thermostat) Temperature Dial.
!
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
different from natural gas models. A
natural gas water heater will not function
safely on LP gas and vice versa.
●N
o attempt should ever be made to
convert the water heater from natural
gas to LP gas. To avoid possible
equipment damage, personal injury or
fire, do not connect the water heater to a
fuel type not in accordance with the unit
data plate. LP for LP units. Natural gas
for natural gas units. These units are not
certified for any other fuel type.
●L
P appliances should not be installed
below grade (for example, in a basement)
if such installation is prohibited by
federal, state and/or local laws, rules,
regulations or customs.
●L
P 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.
! DANGER: If a gas leak is present or
suspected:
● DO NOT attempt to find the cause
yourself.
● DO NOT try to light any appliance.
● DO NOT touch any electrical switch.
● DO NOT use any phone in your building.
● Leave the house immediately and make
sure your family and pets leave also.
● Leave the doors open for ventilation
and contact the gas supplier, a qualified
service agency or the fire department.
● Stay away from the house (or building)
until the service call has been made, the
leak is corrected and a qualified agency
has determined the area to be safe.
●B
efore 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.
●G
as 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.
● I t 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.
● Use this appliance only for its intended
purpose as described in this Use and Care
Manual.
● DO 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.
The auxiliary drain pan
installation MUST conform
to local codes.
Location
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 drain pan,
adequately drained, must be installed
under the water heater.
The drain pan must not restrict air
flow to the combustion air inlet openings
(perforation openings) located around the
lower perimeter of the water heater.
● The water heater should be installed
as close as practical to the gas vent or
chimney.
● Long hot water lines should be insulated
to conserve water and energy.
Drain pan kits are available from the store
where the water heater was purchased, or
any water heater distributor.
● The water heater and water lines should
be protected from exposure to freezing
temperatures.
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.
● DO NOT install the water heater in
bathrooms, bedrooms, any occupied
rooms normally kept closed, or in
unprotected outdoor areas.
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.
● Minimum clearance from combustible
construction:
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.
! 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.
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
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
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.
● I f 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
Inspect the water heater for possible
damage. Check the markings on the rating
plate of the water heater to be certain the
type of gas supplied corresponds to the
water heater requirements.
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.
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.
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
NOTICE: The water heater
should not be installed near
an air supply containing
halogenated hydrocarbons.
Buildings of unusually tight construction
shall have the combustion and ventilation
air supplied from outdoors, or a freely
ventilated attic or crawl space.
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
(but not less than 100 square inches), if
each opening communicates with other
unconfined areas inside the building.
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 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
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.
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
Heat trap
6” minimum
Pitch up 1/4”
per foot
Union
Draft hood
Hot water outlet to
fixtures
Anode
Union
Water Heater Jacket
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.
Temperature and
pressure relief valve
Manual gas shut-off
To gas supply
Ground joint union
Sediment trap
Cap
Thermostatic gas valve
Jacket door
Shut-off
valve
Heat trap
6” minimum
To cold water
supply
Shut-off valve
Thermal expansion
tank (if required)
Relief valve discharge
Drain
line to suitable open
valve
drain.
Combustion Air
Inlet Openings
Auxiliary drain 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.
To Fill the Water Heater
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.
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.
A steady flow of water from the hot water
faucet(s) indicates a full water heater.
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.
Drops of water falling on the burner can
produce a sizzling or pinging sound.
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.
10
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.
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 1/2” black steel
pipe or other approved gas piping
material.
A ground joint union or ANSI design
certified semi-rigid 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.
If flexible connectors are used, the
maximum length shall not exceed 36”.
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
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. 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. DO NOT use excessive
force (over 31.5 ft lbs.) in tightening the
pipe joint at the gas control (thermostat)
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 10.5” w.c. for natural gas,
or 14” w.c. for LP 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 appliance and its individual shutoff
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).
High Altitude
WARNING: Failure to
install a water heater
This water heater is certified for
suitable for the altitude at
installations up to 10,200 feet above sea
the location it is intended to
serve, can result in improper level.
operation of the appliance
resulting in property
damage and/or, producing
carbon monoxide gas, which
could result in personal
injury, or death.
The appliance must be isolated from the
gas supply piping system by closing its
individual manual shutoff 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).
! WARNING: Installations above
10,200 feet 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.
Insulation Blankets
WARNING: If local codes
require external application
of insulation blanket kits
the manufacturer’s
instructions included with
the kit must be carefully
followed.
Insulation blankets, available to the
general public, for external use on gas
water heaters are not necessary. The
purpose of an insulation blanket is to
reduce the standby heat loss encountered
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.
D
O NOT cover the burner access door,
jacket door, gas control (thermostat)/gas
valve or pressure and temperature relief
valve.
D
O 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.
 I nspect 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.
Venting
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.
12
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.
For proper venting in certain installations
a larger vent connector size may be
needed. Consult the Vent Tables in
Appendix G of the latest version of the
National Fuel Gas Code (ANSI standard
Z223.1 or NFPA 54.)
Horizontal vent connectors must be
pitched upward to the chimney at least
1/4” per 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.
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).
Hot and Cold Pipe Insulation Installation
Typical vertical piping arrangement
Typical horizontal piping arrangement
For increased energy efficiency, some
water heaters have been supplied with
two 24” sections of pipe insulation.
Please install the insulation, according
to the illustrations above, that best meets
your requirements.
T&P Insulation Installation
For increased energy efficiency, this
water heater has been supplied with a
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.
2 3/8” section of T&P insulation. Please
install the insulation as shown below.
Typical Top Connect T & P Arrangement.
Ensure the T&P Valve opening is not
obstructed by the insulation.
Heat Trap
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 23.
13
Installing the water heater.
During Installation of this water heater...........
DO
DON’T
❑ DO check inlet gas pressure to ensure
that it is within the range specified on the
rating plate.
❑ DON’T block or restrict Combustion
❑ DO provide adequate air for combustion
❑ DON’T remove the Burner Access
❑ DON’T install this water heater where
and ventilation as discussed in the Use and
Care Manual and the National Fuel Gas
Code.
❑ DO maintain proper clearances to
❑ DO ensure that the venting system
❑ DO contact a qualified service
combustibles as specified on the rating
plate.
complies with the guidelines found in the
Use and Care Manual and National Fuel
Gas Code.
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.
Sight Glass
Burner
Access Door
Grommet
14
Air Inlet Openings located around the lower
portion of the water heater jacket.
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.
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.
Installation Checklist
A. Water Heater Location
❑ Close to area of vent.
❑ Indoors and protected from freezing temperatures.
❑ Proper clearance from combustible surfaces observed and water heater not installed on carpeted floor.
❑ Sufficient fresh air supply for proper ❑ Air supply free of corrosive elements and operation of water heater.
❑ Provisions made to protect area from water ❑ Sufficient room to service heater.
❑ Combustible materials, such as clothing, damage.
cleaning materials, rags, etc. clear of the base of the heater.
❑Clearances from combustion air inlet
openings observed (see page 7).
flammable vapors.
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 ❑ Soap and water solution used to check all ❑ Gas Company inspected installation (if ❑ Vent connector(s) securely fastened together ❑ Single wall vent connector(s) at least 6” and sediment trap.
❑ Approved pipe joint compound used.
connections and fittings for possible gas leak.
required).
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 top of heater’s flue.
❑ Draft hood properly installed.
❑ Vent connector(s) pitched upward to chimney
(¼" per foot of length minimum) .
with screws.
from combustible material.
15
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.
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.
Combination Potable and Space Heating Application
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.
NOTICE: Suitable for combination
water (potable) heating and space
heating and not suitable for space
heating applications only.
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: 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.
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.
Typical Piping Diagram for Combination Potable/Space Heating Installation
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" pipe.
Air vent
Spring loaded check valve in heating unit
hot water supply line and cold water return
line (not supplied with water heater)
3/4" Tempered
domestic hot water
supply to house.
Heat Trap
6” Min.
2 Gallon Thermal
Expansion Tank (if
required-not supplied
with water heater)
3/4" Shut-Off
Valve (Typ.)
Isolation valve in hot water supply line
to heating unit (not supplied with water
heater)
See diagrams above for proper
pipe application for vertical
or horizontal supply lines.
°F
120
16
to
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
All water piping shall be insulated in
accordance with Local and State Energy
Code.
All bronze pump.
°F
140
Gas line to water heater
Water Heater to be in accordance with
the Local and State Energy Code
Hot water
to space heater
Hot water coil
Temperature and Pressure Relief
Valve, tie to location approved by
local code
Water Heater drain pan installed in
accordance with the Local and State
Code
3/4" cold water supply
3/4" Shut-Off Valve (Typ.)
NOTICE: 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 jacket
Pressure Gauge
3/4" Check Valve with 1/8" Hole
3/4" Shut-Off Valve (Typ.)
Gas Fired
Water Heater
Isolation valve in
cold water return line
from heating unit (not
supplied with water
heater)
Air Handler
Gas Direct Vent discharge
must comply with Local
and State Code
Combustion Air Inlet
Openings
6” Air Gap
Vacuum Relief Valve
(Not Supplied)
If required, install per local codes
and valve manufacturer’s
instructions.
Electronically controlled pump timer.
Activates every 6 hours for 60 seconds.
Wire to bronze pump.
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 OPER ATING
WARNING: If you do not follow these instructions and the Use & Care
Manual instructions exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance has a pilot which is lit by a
piezo-electric spark gas ignition system.
Do NOT open the inner door of this
appliance and try to light the pilot by
hand!
•
If you cannot reach your gas supplier,
call the fire department.
C. Use only your hand to turn the gas control
knob. Never use tools. If the knob will not
turn by hand, don’t try to repair it, call a
B. BEFORE LIGHTING smell all around the
qualified service technician. Force or
appliance area for gas. Be sure to smell
attempted repair may result in a fire or
next to the floor because some gas is
explosion.
heavier than air and will settle on the floor.
D. Do not use this appliance if any part has
WHAT TO DO IF YOU SMELL GAS:
been under water. Immediately call a
Do not try to light any appliance.
qualified installer or service agency to
Do not touch any electric switch; do not
replace a flooded water heater. Do not
use any phone in your building.
Immediately call your gas supplier from
attempt to repair the unit! It must be
a neighbor’s phone. Follow the gas
replaced!
supplier’s instructions.
••
•
LIGHTING INSTRUCTIONS
1. STOP! Read safety information above on this label.
2. Rotate the combination gas control/thermostat knob counter-clockwise  to the “OFF”
position.
3. 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 don’t smell gas, go to the next step.
4. Remove the outer door from the water heater. Do not attempt to remove the inner door
assembly. Locate the piezo-electric spark generator button which is just below the combination gas control/thermostat knob.
5. Rotate the combination gas control/thermostat knob clockwise  to the “PILOT” position.
6. Depress and hold the combination gas control/thermostat knob all the way in while immediately depressing the piezo-electric spark generator button several times until the “STATUS”
indicator light begins to blink. Once the “STATUS” indicator light begins to blink, verify the
pilot is lit by viewing the pilot flame through the sight glass window located on the inner
door.
• If the “STATUS” indicator light does not start blinking after 90 seconds and the pilot is not
lit, repeat steps 2 through 6.
• If the pilot will not stay lit after several lighting sequence attempts, turn the combination
gas control/thermostat knob counter-clockwise  to the “OFF” position and call your service
technician or gas supplier.
7. Replace the outer door.
8. Release the combination gas control/thermostat knob. The knob should
pop back out.
• If the combination gas control/thermostat knob does not pop back
out when released, stop and immediately call your service technician or
gas supplier.
9. Set the combination gas control/thermostat knob to the desired setting.
TO TURN GAS OFF TO THE APPLIANCE
Rotate the combination gas control/thermostat knob counter-clockwise  to the “OFF”
position. Note: The “STATUS” indicator light will briefly stay lit, then go off after a short
period of time.
17
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
o turn off manual gas shut-off valve if water heater
D
has been subjected to over heating, fire, flood,
physical damage or if the gas supply fails to shut off.
DO NOT store or use gasoline or other flammable
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.
O NOT turn on water heater unless it is completely
D
filled with water.
O NOT turn on water heater if cold water supply
D
shut-off valve is closed.
O NOT allow combustible materials such as
D
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.
I f 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.
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.
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).
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.
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 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.
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.
The chart below may be used as a guide in
determining the proper water temperature
for your home.
Time/Temperature Relationship in Scalds
Water 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
18
Operating the water heater.
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.
The reference mark "Low" represents an
approximate water temperature of 91°F.
The reference mark "Hot" represents an
approximate water temperature of 125°F.
The reference mark "A" represents an
approximate water temperature of 130°F
The reference mark "B" represents an
approximate water temperature of 140°F
The reference mark "C" represents an
approximate water temperature of 150°F
The reference mark "Very Hot" represents
an approximate water temperature of 155°F
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 Combination
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 Combination Gas Control
(Thermostat) is constructed with a built
in safety shut-off device designed to shut
off the gas supply to the burner if the pilot
flame is extinguished for any reason.
The Combination Gas Control
(Thermostat) is also equipped with a single
use gas shut off 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.
If the water heater has been subjected to
fire, flood or physical damage, turn off
the manual gas (shut-off) valve, and do
not operate the water heater again until is
has been checked by a qualified service
technician.
NOTICE: DO NOT use this appliance
if any part has been under water.
Immediately call a qualified installer or
service agency to replace a flooded water
heater. DO NOT attempt to repair the
unit! It must be replaced.
Temperatures are approximate
155°F APPROX.
150°F APROX.
140°F APPROX.
130°F APPROX.
125°F APPROX.
120°F APPROX.
90°F APPROX.
19
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.
In order to drain the water heater, turn off
the cold water supply. 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
! 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.
Properly maintained, your water heater
will provide years of dependable troublefree service.
! DANGER: Hotter water
increases the potential for
Hot Water Scalds.
At least once a year, 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.
! 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.
20
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.
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)
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.
Housekeeping
Visually inspect pilot burner and relight if
necessary.
To ensure sufficient ventilation and
combustion air supply, proper clearances
must be maintained.
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.
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 draft hood 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 draft hood.
Inspect the gas venting system and the
chimney.
Make certain the vent connector from
the draft hood to the chimney is properly
positioned and securely attached.
If after inspection of the vent system you
found 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.
Burner Inspection
Gas flame
Visually inspect the pilot burner and main
should be visible burner annually.
on entire burner
Through the sight glass, inspect the pilot
surface.
burner flame with the main burner off and
Pilot
inspect the main burner while firing.
Flame
If any unusual burner operation is noted,
the water heater should be shut off
until qualified service assistance can be
obtained.
Proper burner and pilot burner
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.
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.
The water heater and piping should be
drained if they might be subjected to
freezing temperatures.
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.
Anode Rod
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.
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.
21
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  This is normal. After the water in the tank warms
a new water heater is up, the condensation will disappear. If, however, the
filled for the first time. condition persists, examine the piping and fittings
for possible leaks.
Moisture from the products
 This is normal and will disappear in time. Excessive
of combustion condensing condensation can cause pilot burner outage.
on the tank surface.
An undersized water  Use a water heater size that meets the requirements
heater will cause of your needs.
condensation.
Yellow flame or soot
Scale on top of the burner.
 Contact a qualified service technician to remove scale.
Flue or Combustion air inlet  Remove obstruction or debris from flue or
openings are restricted. combustion air inlet openings on water heater jacket.
Not enough combustion or
 Proper operation of the water heater requires air for
ventilation air supplied to combustion and ventilation. See the Combustion and
the water heater location. Ventilation Air information in the “Installing The Water Heater” section of this manual.
Unable to light Air in gas line.
 Contact a qualified service technician to purge the air
the pilot burner from the gas line.
Pilot burner orifice clogged.
 The pilot burner should be cleaned or replaced by a qualified service technician.
Pilot burner tube pinched or  The pilot burner should be cleaned, repaired or clogged. replaced by a qualified service technician.
Gas Cock Knob not
 See the “Lighting The Water Heater” section of this
correctly positioned. manual.
Pilot burner does not stay Loose thermocouple.
 The connection at the gas control (thermostat) should
when the BLACK be tightened by a qualified service technician.
button is released
Thermocouple defective.
 The thermocouple should be replaced by a qualified
service technician.
Safety magnet defective.
 The gas control (thermostat) should be replaced by a qualified service technician.
Gas Controls (Thermostat’s)  The gas control (thermostat) should be replaced by a single use gas shut-off device qualified service technician.
has opened.
Combustion Shutoff Device
 The combustion shutoff device should be inspected
Tripped. by 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.
22
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
in tank.
Relief valve producing popping noise or draining Pressure build up  This is an unacceptable condition and must be
caused by thermal corrected. Contact the water supplier or plumbing
expansion to a contractor on how to correct this. Do not plug the
closed system. relief valve outlet.
Not enough or no hot water Water usage may have  Wait for the water heater to recover after an exceeded the capacity abnormal demand.
of the water heater.
Low gas pressure.
 Clean tank.
 Check gas supply pressure and manifold pressure.
The pilot burner may be out.
 Check the pilot burner. If necessary, relight using the
instructions in the “Lighting The Water Heater” section of this manual.
The gas control (thermostat)  See the “Water Temperature Setting” of The Water may be set too low. Heater section of this manual.
Leaking or open hot water faucets.
 Make sure all faucets are closed.
Combustion Shutoff System  Contact a qualified service technician.
tripped.
Water is too hot
The gas control (thermostat) ●See the “Water Temperature Setting” of The Water is set too high. Heater section of this manual.
Gas Control (Thermostat)
●Contact a qualified service technician to replace the
Defective. gas control (thermostat).
Pilot Burner Lights, but
Main Burner will not
stay lit.
Combustion Shutoff System
●Contact a qualified service technician.
tripped.
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
Combination Gas Control, Status Light Troubleshooting
STATUS LIGHT CODE
FLASHES STATUS
0
1
2
4
5
7
8
Control Off/Pilot Out
Normal Operation
Thermopile Voltage Low
High Temperature Shutdown
Temperature Sensor Failure
Gas Control or Valve Failure
Flame Sense Error
If the Status Light is not blinking, relight the
Pilot. To light Pilot, see Lighting Instructions
on water heater. If Status Light blinks more
than one flash every three seconds, see
Installation Instructions.
Example:
3 sec. pause
If Pilot is lit, Status Light will briefly stay lit when Knob is turned to OFF.
STATUS LIGHT
CODE
OFF
Constantly lit
One (1) blink every three
(3) seconds
Two (2) blinks every three
(3) seconds
Four (4) blinks every
three (3) seconds
CONDITION
Combination Gas Control turned
off
Follow the operating instructions in the Use & Care
Manual to turn on the Combination Gas Control
Pilot not lit
Follow the lighting instructions as detailed on this water
heater and it's Use & Care manual to light the pilot
Check thermopile connector to the Combination Gas
Control to ensure it is properly connected
Check thermopile wires for damage and replace if
needed
Inspect pilot assembly
Follow the lighting instructions as detailed on the water
heater and it's Use & Care manual to light the pilot
Insufficient power supply (millivoltage)
Pilot recently extinguished and
Thermopile is cooling down
Temperature knob recently turned
to OFF position
Normal Operation
Temperature knob in pilot position
and pilot is lit
Low thermopile voltage however
pilot is lit
High water temperature limit
tripped
Five (5) blinks every three Water temperature sensor failure
(3) seconds
Seven (7) blinks every
Combination Gas Control failure
three (3) seconds
Eight (8) blinks every
False pilot flame signal
three (3) seconds
24
POTENTIAL SOLUTION(S)
Set temperature knob on Combination Gas Control to
desire setting
Check thermopile connector to the Combination Gas
Control to enssure it is properly connected
Check thermopile wires for damage and replace it
needed
Inspect pilot assembly
Contact a qualified service technician.
See "IF YOU NEED SERVICE" on page 28
Contact a qualified service technician.
See "IF YOU NEED SERVICE" on page 28
Contact a qualified service technician.
See "IF YOU NEED SERVICE" on page 28
Contact a qualified service technician.
See "IF YOU NEED SERVICE" on page 28
Replacement Parts.
For 28, 38, 40, 48 and 55 gallon models using natural or LP gas.
Instructions For Placing a Parts Order
All parts orders should include:
art description (as noted below) and
P
number of parts desired.
he model and serial number of the
T
water heater from the rating plate.
pecify type of gas (natural or LP) as
S
marked on the rating plate.
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
Piezo Wire
Baffle
Assembly
Draft Hood
Heat Trap Nipple
Heat Trap Nipple
Burner Access
Door Gasket
Burner Access
Door Assembly
Pilot
Bracket
Dip tube
gasket
Anode rod
Thermocouple
Tube
Pilot
Assembly
Screw
Dip tube
Pilot Bracket
Screws
Pilot Tube
Burner
Hex Nuts
Temperature and
pressure relief valve
Drain valve
Gas Control (Thermostat)
*Burner
Lower Air Box
Transition Pan
Gasket
Inner Door Gasket
Inner Door
Burner Access Door Gasket
Jacket Door
Inner Door Burner Assembly
Mounting Screws
*Combustion Shut-off Device (enlarged view)
Located inside the combustion chamber.
Lower Air
Box Screws
Inner Door Hex Nuts
25
Notes:
26
Notes:
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.
28