Use & Care Manual
With Installation Instructions for the Installer
Direct Vent Gas - FVIR Certified
Water Heaters
40 and 50 Gallon Vertical Co-Axial Vent System
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 very important 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 assistance.
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 injury,
property damage or death. Refer to this
manual. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.
DESIGN
CER
TIFIED
Printed in USA
®
AP14381-6 (02/14)
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. 10
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.
Gas Supply. . . . . . . . . . . . . . 12
Pipe Installation. . . . . . . . . . . 12
Heat Traps . . . . . . . . . . . . . . . 13
Installation Checklist. . . . . . . 14
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.
Operating Instructions
Lighting Instructions. . . . . . 15
Water Temperature . . . . . 16, 17
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
Care and Cleaning
Draining. . . . . . . . . . . . . . . . 18
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.
Burner Inspection . . . . . . . . 19
!
Extended Shut-Down. . . . . 19
Troubleshooting Tips
Before You Call
For Service. . . . . . . . . . . 20, 21
Customer Service
Parts List. . . . . . . . . . . . . . . . 22
Conversion Instructions. 23-26
If You Need Service . . . . . . 28
2
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:
!
CAUTION:
A potentially hazardous situation that could result in death or serious injury and/or damage to property.
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.
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 VENTING SYSTEM AND PROPERLY VENT
THE WATER HEATER…
Failure to install the venting system 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 the 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.
! WARNING
FLAMMABLES
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 water heater’s thermostat. 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
!
DANGER
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
HOT
BURN
Water temperature over 125° F
can cause severe burns
instantly or death from scalds.
Children, disabled and elderly are
at highest risk of being scalded.
See instruction manual before
setting temperature at water
heater.
Feel water before bathing or
showering.
Temperature limiting valves are
available, see manual.
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.
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 thermostat setting to prevent
contact with “HOT” water.
Maximum water temperatures occur just after
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 16 and 17 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 thermostat was set at its lowest
setting before the water heater was shipped from the
factory.
The illustration at
the left details the
110°F
approximate water
temperature for each
120°F
100°F
mark on the Gas
130°F
90°F
Control (Thermostat)
140°F
80°F
Temperature Dial.
150°F
155°F
45°F
Temperatures are approximate
DANGER: Hotter water increases the potential for
Hot Water SCALDS.
DANGER!
LIQUEFIED PETROLEUM (LP - PROPANE OR BUTANE)
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.
● This water heater is supplied with a
! DANGER: If a gas leak is present or
thermostatic gas valve that is convertible
suspected:
from LP to natural gas. Be sure to read
● DO NOT attempt to find the cause
and carefully follow the Conversion
yourself.
Instructions included in this manual
when converting the valve from one type
● DO NOT try to light any appliance.
of gas to another.
● DO NOT touch any electrical switch.
● After conversion, be certain that the gas
● DO NOT use any phone in your building.
supplied to the heater is the type that
the valve has been converted for (LP for
● Leave the house immediately and make
heaters converted to LP use, and natural
sure your family and pets leave also.
gas for heaters converted to natural gas
● Leave the doors open for ventilation
use). This water heater will not operate
and contact the gas supplier, a qualified
safely if connected to a fuel type other
service agency or the fire department.
than the one the gas valve is converted
for.
● Stay away from the house (or building)
until the service call has been made, the
● LP gas must be used with great caution.
leak is corrected and a qualified agency
It is heavier than air and will collect first
has determined the area to be safe.
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 an
LP leak, be sure to sniff near the floor
also.
● Gas detectors are recommended in LP
and natural gas applications and their
installation should be in accordance with
the 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
LP 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
by a qualified technician in accordance
with the provided installation instructions.
READ AND FOLLOW THIS SAFETY INFORMATION CAREFULLY.
SAVE THESE INSTRUCTIONS
6
Installing the water heater.
This water heater is suitable for Direct Vent Installation in a Manufactured Home (Mobile Home) and
other non-Manufactured Home (non-Mobile Home) Installations. This water heater must be installed
in accordance with these instructions, provided with the Co-Axial Roof Jack assembly, 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. Capital 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. This product also
meets the requirements of Title 24 CFR Part 3280.
Location
The water heater should not be located
in an area where leakage from the tank
or connections will result in damage
2”
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
Diameter of
under the water heater.
water heater
plus 2” min.
Catch pan kits are available from the store
The auxiliary catch pan
where the water heater was purchased, or
installation MUST conform any water heater distributor.
to local codes.
This water heater must be installed
within an enclosure so as to separate the
water heater’s combustion and venting
system from the interior atmosphere
of the home. The enclosure must be
large enough to allow for bracing. Front
clearance must also be provided for
inspection and servicing of the water
heater.
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.
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.
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.
The water heater must be located so
it is not subject to physical damage, for
example, by moving vehicles, area
flooding, etc.
All air for combustion must be obtained
from the outside atmosphere, and the
products of combustion (flue gases)
must be discharged directly to the
outside atmosphere through the gas
vent Co-Axial Roof Jack assembly.
Because the water heater is of the sealed
combustion type, a vent hood is not
Max.
required between the water heater and
the Co-Axial Roof Jack.
Refer to installation illustration as shown
in this manual.
Install the water heater with minimum
clearance from combustible construction
of 0 inch sides and rear; 2 inches from
front of control; 12 inches from ceiling.
If clearances stated on the Instruction/
Warning label, located on the front
of the water heater, differ from the
aforementioned clearances, install heater
according to the clearances stated on the
Instruction/Warning label.
The water heater may be installed on
combustible flooring, but not directly on
carpeting.
If the water heater must be installed on
carpeting, place a wood or metal panel
beneath the water heater extending
beyond its full width and depth at least
3 inches in all directions. If the water
heater is installed in an alcove or closet,
the entire floor must be covered by the
wood or metal panel. A minimum of 24”
clearance from the front and top should
be available for adequate inspection and
servicing.
CAUTION: Provisions should be made so
that in the event the water heater or one of its
fittings were to leak, the resulting flow of water
will not cause damage to the home. It is
recommended that a suitable catch pan,
adequately drained, be installed under the
water heater.
CAUTION: DO NOT subject the water
heater to any water distribution system air
pressure test. The water heater should either
be isolated with valves at the inlet and outlet
water connections or disconnected during the
test. Failure to properly isolate the water
heater during an air pressure test presents a
hazard to life and property. With a water
pressure test the water heater need not be
isolated.
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.
7
Installing the water heater.
Installation Methods
NOTICE: The water
heater should not be
installed near an air supply
containing halogenated
hydrocarbons.
NOTICE: The old roof
jack must be replaced with
the new co-axial roof jack.
8
Inspect shipment. Inspect the water
heater for possible shipping damage.
P
lacement of water heater. Locate
the water heater as desired, make
certain the minimum clearances
outlined in this manual are
observed.
C
ombustion and ventilation air.
Air for combustion and ventilation
must not be supplied from occupied
spaces of the home. The air inlet
must not be obstructed under any
circumstances. Outside air is
necessary for proper and safe
operation of the water heater.
O
penings for gas vent Co-Axial
Roof Jack assembly. Cut a 7 1/4 in.
diameter hole in the ceiling and roof
directly above the flue of the water
heater.
Securing the water heater. Secure
the water heater using the provided
metal straps. Attach them to the top pan
and bottom pan of the water heater
then fasten the straps to the adjacent
wall on each side.
Gas
vent Co-Axial Roof Jack.
The roof jack must be one of the
models listed in this manual, and
marked as approved by
Underwriters Laboratories, Inc.
The installation instructions
supplied with each Co-Axial Roof
Jack must be observed to obtain the
proper roof jack installation.
The Gas Vent Roof Jack Assembly
has a multi piece telescopic vent
connector pipe consisting of an
upper, center and lower section that
must be pre-adjusted according to
the following directions prior to final
installation of the roof jack.
From the water heater location, measure
the distance from the highest point on roof
opening to the top of the water heater.
Select correct size Co-Axial Roof Jack
from Co-Axial Roof Jack Sizing Guide
on Page 9, Dimension X. Remove the
Co-Axial Roof Jack from its carton, and
extend the center section of the inner
most pipe to its maximum length by
grasping the pipe and sliding the center
section of pipe downward. Then extend
the lower section of the inner pipe in
the same manner to its full extension.
Silicone rubber sealing bands are provided
and must be pulled down over the joints
between the tubes to ensure a leak proof
seal.
pply a non-hardening mastic on the roof
A
around the previously cut hole to form a
weather tight seal with the roof flange of the
Co-Axial Roof Jack Assembly. Insert the
Co-Axial Roof Jack through the opening
in roof from above, and fasten the flashing
to the roof using the pre-punched holes
in the flashing. The roof flange adjusts to
accommodate installation on a pitched roof,
(maximum allowable pitch is 8-12). For roof
pitches greater that 8-12 an alternate roof
jack can be purchased. Apply additional nonhardening mastic as required to complete the
weather seal.
To complete the assembly of the Co-Axial
Roof Jack Inner Pipe installation: Apply
silicone sealant around the outside of the
water heater flue pipe, then extend the
lower section of the vent connector pipe
by grasping the center section of pipe,
ensuring that the silicone rubber seal
remains in position over the joint, press it
firmly downward until seated over the flue
pipe protruding inside the water heater’s
top plenum. An improper seal can cause
nuisance pilot outages. Secure the inner
pipe to the top pan of the water heater
by inserting the two screws through the
brackets on each side.
To complete the assembly of the Co-Axial
Roof Jack Outer Pipe installation: Extend
the upper section down and over the
lower section of the vent connector pipe
by grasping the center section of pipe and
pull downward, ensuring that the silicone
rubber seal remains in position over the
joint, press it firmly downward until
seated outside the lip of the top plenum.
Secure on each side with the two screws
provided. Apply silicone sealant around
the edge of the top plenum and outer pipe
connection to ensure a good seal.
An improper seal can cause nuisance pilot
outages.
This water heater is suitable for Direct Vent Installation
in a Manufactured Home (Mobile Home) and other nonManufactured Home (non-Mobile Home) Installations. This
water heater must be installed in accordance with these
instructions, provided with the Co-Axial Roof Jack assembly,
local codes, utility company requirements, and/or in the absence
of local codes, use the latest addition of the American National
Standard/National Fuel Gas Code. A copy can be purchased
from either the American Gas Association, 400 N. Capital
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. This product also meets
the requirements of Title 24 CFR Part 3280.
NOTICE - All sizes of Co-Axial Roof Jack Assembly have an
adjustable tilt Roof Flange to accommodate installation on a pitched
roof. Maximum roof pitch is 8-12. For roof pitches greater than 8-12
an alternate roof jack can be purchased.
NOTICE: 12” Minimum recommended distance from the top of
the water heater to the ceiling for servicing the water heater.
Adjustable Tilt
Roof Flange
Roof Jack
(Purchased Separately)
34° Max.
(8 -12 Pitch)
Roof Flange
X
Roof Jack
Adjustment Range
Roof
Ceiling
2"
See Dimension Table Below
12"
Min
Telescopic Vent Connection Pipe
(Supplied with Roof Jack)
42° Max. Tilt is
available with
optional kit.
(10 3/4 -12 Pitch)
Silicone Rubber Seal
(Supplied with Roof Jack)
Apply silicone sealant to lip of top plenum
for a tight seal with outer pipe.
Secure Strapping provided with
the Water Heater around the
edge of the top pan, above the
drain pan, and into the walls studs
with the S.M. screws provided.
Access Door (Right or Left)
No Openings Required
Drain Pan
Floor
Bottom Sheathing
Co-Axial Roof Jack Sizing Table
Figure A - Top View of closet.
34° Max. (8-12
Pitch) Roof Jack
Kit Part Number
42° Max. (10 3/4-12
Pitch) Roof Jack Kit
Part Number
Roof Jack Adjustment
Range (See Dimension X)
AP14363A
AP14334A
24 - 37 Inches
AP14363B
AP14334B
33 - 68 Inches
AP14363C
AP14334C
45 - 97 Inches
AP14363D
AP14334D
60 - 130 Inches
AP14363E
AP14334E
72 - 160 Inches
Please note that the roof jack shown above is for illustration
purposes only and may not resemble the actual unit in your kit.
Water Heater
Water
Connections
Strap
Drain Pan
Water
Connections
Screws
Gas Control
(Thermostat)
Relief Valve
9
Installing the water heater.
G
v
H
A
D
E
V
B
B
B
C
V
L
v
ED
FIX ED
S
CLO
v
LE
RAB
OPE
F
RA
OPE
v
BLE
B
A
M
I
X
K
X
v
B
v
v
ED
FIX D
SE
CLO
J
B
V Vent Terminal
X Air Supply Inlet
Αrea Where Terminal Is Not Permitted
US Installations
12 in. (30 cm)
1
A = Clearance above grade, veranda, porch,
deck or balcony
B = Clearance to window or door that may be
opened
C = Clearance to permanately closed window
D =
ed above the terminal within a horizontal
distance of 2 feet (61 cm) from the center
line of the terminal
E F - Clearance to outside corner
G - Clearance to inside corner
H - Clearance to each side of centerline extended above meter/regulator assembly
I - Clearance to service regulator vent outlet
J - Clearance to nonmechanical air supply inlet
to building or the combustion air inlet to any
other appliance
K - Clearance to a mechanical air supply inlet
L - Clearance above paved sidewalk or paved
driveway located on public property
M - Clearance under veranda, porch, deck, or
balcony
6 ft. (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 9 in. (23
cm) for appliances > 10,000 Btuh (3 kW) and ≤ 50,000 Btuh
(15 kW), 12 in. (30 cm) for appliances > 50,000 Btuh (15 kW)
*
*
*
*
*
*
*
4 ft. (1.2 m) below or to side of opening; 1 ft (30 cm) above
opening
3 ft. (91 cm) above if within 10 ft. (3 m) horizontally
*
*
1 In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
*
"Clearance in accordance with local installation codes and the requirements of the gas supplier and the manfacture's installation
instructions"
10
Installing the water heater.
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.
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!
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.
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. 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.
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
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/or heat traps.
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
Hot water outlet to fixtures
Anode Rod (Located under top pan) Not accessible. Refer
to Protection Plus Kit for additional protection.
Flue baffle
(underneath)
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.
Drain valve
Piezo Igniter Striker
Manual gas shut-off
To gas supply
Sediment trap
Ground joint union or ANSI design certified semirigid or flexible gas appliance connector
Heat Trap
6" minimum
To cold water supply
Temperature and
pressure relief valve
Relief valve discharge line to suitable
drain
Vacuum Relief Valve
(Not Supplied)
Thermostat
Jacket door
If required, install per local codes
and valve manufacturer’s
instructions.
11
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 drain valve is closed,
then open the shut-off valve in the cold
water supply line.
A steady flow of water from the hot water
faucet(s) indicates a full water heater.
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.
Drops of water falling on the burner can
produce a sizzling or pinging sound.
! WARNING:
Never use an open
flame to test for gas
leaks, as bodily
injury, property
damage or death
could result.
Leak Testing
The water heater and its gas connections
must be leak tested at normal operating
pressures before it is placed in operation.
Turn on the manual gas shut-off
valve near the water heater.
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.
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 manual gas
shut-off valve must be disconnected from
the gas supply piping system during any
high pressure testing of that system at
pressures in excess of 1/2 psi (14” w.c.).
12
The water heater must be isolated from
the gas piping system by closing the
manual gas shut-off valve during any
pressure testing of the gas supply piping at
pressures equal to or less than
1/2 psi (14” w.c).
Gas Supply
Check the markings on the water heater’s rating plate to be
certain the type of gas being furnished corresponds to that
for which the water heater is built. The water heater can
be converted from natural gas to LP or vice versa. See the
Conversion Instructions section of this manual.
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 HUD code should be
followed for installation and location of a manual shutoff
valve. If lever type gas shut-offs are used, they shall be
T-Handle type.
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 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
14” w.c. for natural or 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.
If flexible connectors are used, the maximum length shall
not exceed 36” (91 cm).
High Altitude
Ratings of gas appliances are based on sea level
operation and need not be changed for installations at
elevations up to 7,700 feet.
For installations above 7,700 feet, Please contact your
local distributor or place of purchase for a high altitude
model.
WARNING: Failure to install a water heater suitable
for the altitude at the location it is intended to serve,
can result in improper operation of the appliance
resulting in property damage and/or, producing carbon
monoxide gas, which could result in personal injury, or
death.
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.
Typical horizontal piping arrangement
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 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.
13
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 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:
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.
 DO NOT apply insulation to the
top of the water heater. This will
interfere with the safe operation of
the vent.
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.
● 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 cover the burner access
door, jacket door, gas control
(thermostat)/gas valve or pressure
and temperature relief valve.
NOTICE: 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 water
connections on heater. Any heat
applied to the water supply fittings
will permanently damage the dip
tube and/or heat traps.
During Installation of this water heater...........
14
DO
DON’T
❑ 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
instruction/warning label.
❑ 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.
❑ DON’T block or restrict the vent
terminal.
❑ 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.
Installation Checklist
A. Water Heater Location
❑Water heater securely anchored.
❑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
operation of water heater.
❑Air supply free of corrosive elements
and flammable vapors.
❑Provisions made to protect area from
water damage.
❑ Sufficient room to service heater.
❑Combustible materials, such as clothing,
cleaning materials, rags, etc. clear of the
base of the heater.
B. Water Supply
❑Water heater completely filled with
water.
❑ Water connections tight and free of
leaks.
❑ Air purged from water heater and piping.
C. Gas Supply
❑Gas line equipped with shut-off valve,
union and sediment trap.
❑ Approved pipe joint compound used.
❑Soap and water solution used to check
all connections and fittings for possible
gas leak.
❑Gas Company inspected installation
(if required).
❑After conversion, be certain the gas
supplied to the heater is the type the
valve has been converted for (LP
for heaters converted to LP use, and
natural gas for heaters converted to
natural gas use).
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
❑ Vent terminal, air tube sealed with
silicone bands and sealants.
❑Vent connector(s) securely fastened
together with screws.
❑ Air tube securely fastened with screws.
heater’s flue.
❑ Air tube and vent tube properly installed.
15
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, bodily 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 the Use & Manual instructions
exactly, a fire or explosion may result causing property damage, personal injury or
loss of life.
instructions.
A. This appliance has a pilot which is lit by a piezoelectric spark gas ignition system. Do NOT open
If you cannot reach your gas supplier, call
the inner door of this appliance and try to light
the fire department.
the pilot by hand!
C. Use only your hand to turn the gas control knob.
Never use tools. If the knob will not turn by hand,
B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the
don't try to repair it, call a qualified service
floor because some gas is heavier than air and
technician. Force or attempted repair may result
will settle on the floor.
in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
D.
Do not use this appliance if any part has been
Do not try to light any appliance.
under water. Immediately call a qualified installer
Do not touch any electric switch; do not use
or service agency to replace a flooded water
any phone in your building.
heater. Do not attempt to repair the unit! It must
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
be replaced!
LIGHTING INSTRUCTION
1. STOP! Read safety information above on this 8. Depress and hold the gas control knob all the way
label.
down. Immediately depress the piezo-electric
spark generator button several times until the
2. Set the thermostat dial to the lowest
PIEZOGAS
setting by turning the thermostat
ELECTRIC pilot is lit. The pilot flame can only be seen through
CONTROL
SPARK
the sight glass window located on the inner door.
KNOB
dial clockwise
until it stops.
GENERATOR
DO NOT FORCE.
9. Continue to hold down the gas control knob for
about one (1) minute after the pilot is lit. If it goes
3. Slightly depress the gas control knob
out repeat steps 3 to 9.
and turn clockwise
to “OFF”
If the gas control knob does not pop up when
position. Note: Knob cannot be turned
released, stop and immediately call your service
from “PILOT” position unless pushed
technician or gas supplier.
down slightly. Do not use force.
4. Wait five (5) minutes to clear out any
If the pilot will not stay lit after several tries, turn the
THERMOSTAT
gas. If you smell any gas, STOP! follow
gas control knob clockwise to “OFF” and call
DIAL
“B” in the safety information above on
your service technician or gas supplier.
this label. If you do not smell gas,
10. Once the pilot flame is established replace the outer
go to the next step.
door.
5. Remove the outer door from the water
to
11. Turn the gas control knob counter-clockwise
heater. Do not attempt to remove the
the “ON” position. Warning do not use gas control
inner door.
knob to regulate gas flow to burner.
6. Locate the piezo-electric spark generator
12. Set the thermostat dial to desired setting by turning
which is located on top of the combidial counter-clockwise. The preferred starting point
nation gas control.
PILOT
for temperature setting is to align the two triangular
ASSEMBLY
7. Turn the gas control knob counterpointers on the dial and control face.
clockwise
to the “PILOT” position.
TO TURN GAS OFF TO THE APPLIANCE
1. Set the thermostat dial to the lowest setting
by turning the thermostat dial clockwise
until it stops. DO NOT FORCE.
16
2. Slightly depress the gas control knob and turn
clockwise to “OFF POSITION”. Note: Knob cannot
be turned from ”PILOT” position unless pushed down
slightly. Do not use force.
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
Do turn off manual gas shut-off valve if
water heater has been subjected to
overheating, 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 lights, to avoid vapors lighting.
DO NOT turn on water heater unless it is
filled with water.
DO NOT turn on water heater if cold water
supply shut-off valve is closed.
O NOT allow combustible materials such as
D
newspaper, rags or mops to accumulate near
water heater.
! DANGER: There is
a hot water scald
potential if the gas
control (thermostat) is
set too high. Households
with small children,
disabled, or elderly
persons may require a
120°F or lower
thermostat setting to
prevent contact with
HOT water.
NOTICE: Flammable vapors may 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.
Water Temperature Setting
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).
The lower the temperature setting,
the greater the savings in energy and
operating costs.
To comply with safety regulations the
gas control (thermostat) was factory set
at it's lowest setting before the water
heater is shipped from the factory. This
is the recommended starting point.
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 on the water
heater. This label is 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 pages 15
& 17 for more details and contact a
licensed plumber or the local plumbing
authority for further information.
The chart on the next page may be
used as a guide in determining the
proper water temperature for your
home.
17
Operating 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
1½ to 2 minutes
About 30 seconds
About 10 seconds
Less than 5 seconds
Less than 3 seconds
About 1½ seconds
About 1 second
Table courtesy of Shriners Burn Institute
Water Temperature Setting…
110°F
120°F
100°F
130°F
90°F
140°F
80°F
150°F
155°F
45°F
Temperatures are approximate
Maximum water temperatures occur
just after the burner has shut off. To
determine the hot water temperature
turn on a hot water faucet and place a
thermometer in the hot water stream.
The reference mark p on the rim of
the temperature dial, represents an
approximate water temperature of
120°F.
The reference A or ① mark
represents an approximate water
temperature of 130°F.
Each reference mark above or below
these points indicates an approximate
change of 10°F.
To adjust the temperature, turn the
temperature dial to an initial setting of
120°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
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.
18
Also, always supervise young children
or others who are incapacitated.
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 pilot flame
is extinguished for any reason.
The 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 power to water heater, and do not
operate the water heater again until
it 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
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 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 coming in
contact with 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.
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.
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.
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 (litres)
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 inspected
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.
Housekeeping
Vacuum around the base of the
water heater for dust, dirt and lint on
a regular basis.
To insure sufficient ventilation
and combustion air supply, proper
clearances must be maintained.
! DANGER: Combustible
materials, such as clothing,
cleaning materials, or flammable
liquids, etc., must not be placed
against or next to the water
heater.
19
Venting System Inspection
The water heater’s internal flue must
be inspected annually to be certain it is
clean by removing the venting system
and flue baffle.
Inspect the gas venting system and the
chimney.
If after inspection of the vent system
you found sooting or deterioration
call the local gas utility to correct the
problem and clean or replace the flue
and venting before resuming operation
of the water heater.
Make certain the vent system, vent,
and air pipes is properly sealed and
securely attached.
Burner Inspection
Visually inspect the pilot and main
burners annually.
Cone
Proper burner and pilot flame
pattern.
! CAUTION: Cone is used
only on natural gas burner
assemblies.
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.
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 access
door is removed, the burner access
door gasket must be replaced.
!
For cleaning, remove the burner
from the water heater. A vacuum
cleaner can be used on the burner
and floor shield inside the water
heater. The burner can also be
cleaned by scrubbing with mild
detergent.
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.
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.
20
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.
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 outage.
on the tank surface.
An undersized water ●Use a water heater size that meets the requirements
heater will cause of your needs.
condensation. ●Contact a qualified service technician for service.
Yellow flame or sooting
Scale on top of the burner.
●Contact a qualified service technician for service.
Combustion air inlets or
●Remove lint or debris and inspect air inlet opening
flue-way restricted. for restriction.
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 Locating the water
heater section of this manual.
Improper fuel or
●Check fuel type and Contact a qualified service fuel conversion technician to specify fuel type.
Wrong main burner assembly
●Contact a qualified service technician for service.
Unable to light Air in gas line. ●Contact a qualified service technician to purge the the pilot air from the gas line.
Pilot burner/orifice clogged.
●The pilot should be cleaned or replaced by a qualified
service technician.
Pilot tube pinched or ●The pilot should be cleaned, repaired or replaced by a
clogged. qualified service technician.
Gas Cock Knob not
●See the "Lighting the Water Heater" section of this positioned correctly. manual.
Pilot does not stay Loose thermocouple.
●The connection at the gas control (thermostat) should be lit when the RED 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 Control (thermostat's) ●The gas control (thermostat) should be replaced by a single use gas shut-off device service technician.
has opened.
! 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.
21
Troubleshooting Tips
Save time and money! Review the charts on the following pages first and you may not need to call for service.
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.
●Clean tank.
Rattling noise Internal heat trap ●This is normal for heat trap fittings when in operation
during periods of fittings in operation. and does not indicate a need for service.
water usage
Not enough or no hot water Water usage may have ●Wait for the water heater to recover after an abnormal
exceeded the capacity demand.
of the water heater.
Low gas pressure.
●Check gas supply pressure and manifold pressure.
The pilot burner may be out.
●Check the pilot. If necessary, relight using the
instructions in the "Lighting the Water Heater" section
of this manual.
The gas control (thermostat) may ●See the "Water Temperature Setting" of the water heater
be set too low. section of this manual.
Leaking or open hot water faucets.
Cold water inlet ●This is normal. The colder inlet water takes longer
temperature may be to heat.
colder during the
winter months.
Water is too hot
The gas control (thermostat) ●See the "Temperature Setting of the Water Heater"
is set too high. section of this manual.
Gas control (thermostat)
●Contact a qualified service technician to replace the gas defective control (thermostat).
●Make sure all faucets are closed.
! CAUTION: For your safety DO NOT attempt repair of gas piping, thermostat, burners, vent connectors or other safety
devices. Refer repairs to qualified service personnel.
22
Replacement Parts.
Instructions For Placing a Parts Order
All parts orders should include:
Part description (as noted below)
and number of parts desired.
he model and serial number of
T
the water heater from 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.
pecify type of gas (natural or
S
LP) as marked on the rating
plate.
LP Burner Assembly Kit
Roof Jack
(Purchased Seperately)
The kit provides extra speed clips
and tamper resistant screws.
Heat Traps
Flue Baffle and Hanger
Dip Tube
Dip Tube Gasket
T&P Relief Valve
Drain Valve Shroud
Drain Valve
Gas Control
(Thermostat)
Natural Gas
Burner Assembly
Thermocouple
Pilot Supply
Tube
Burner Cone
Inner Door
Gasket
Inner Door
Jacket Door
Burner Orifice
Burner Supply
Tube
Piezo Ignitor
Wire
Grommet
23
Conversion instructions—Natural Gas to LP Gas
If your gas supply is LP gas, your water heater can be converted to burn LP gas as follows:
Natural Gas to Liquefied Petroleum (LP or Propane) Gas
WARNING: This conversion kit must be installed by a qualified
installer or service technician in accordance with these instructions.
Installation must conform with local codes, or in their absence, with
the latest edition of the National Fuel Gas Code, ANSI Z223.1.
Failure to follow instructions could result in serious injury or
property damage. The qualified agency performing this work
assumes responsibility for this conversion.
CAUTION: The water heater is factory set to burn natural gas,
but can be converted to burn LP gas. Before placing the water
heater into operation, verify that the type of gas supplied to your
water heater and the type of gas your water heater is set to burn
are the same. If they are not, refer to these instructions.
NOTICE: The parts required to make this conversion are supplied
in a bag attached to the water heater. Should your heater not
have this bag attached to the water heater, a replacement can be
obtained. Simply contact the manufacturer at the address below
and request a replacement conversion kit.
Customer Service Department
1241 Carwood Court
Montgomery, AL 36117
Phone: 1-800-432-8373
Front View of Gas Thermostat
Piezo Igniter Striker
Gas Selector Screw
(Without cover.)
Piezo Wire
Connection
Thermostat Dial
Pilot Tube
(1/8" Aluminum
Tube)
Gas
Thermostat
Burner Supply
Tube
Thermocouple
(Copper Tube)
Remove outer jacket door.
Inner Door
Speed Clips
Inner Door
Gasket
Inner Door
Assembly
Jacket Door
Remove the four screws on the inner door using a
#20 TORX wrench supplied with the conversion
kit. Disconnect burner supply tube using the 3/4"
wrench, pilot tube using the 7/16" wrench, and
the thermocouple using the 3/8" wrench from the
thermostat. Disconnect the piezo wire from piezo
ignitor striker connection. Remove the entire burner
assembly along with the inner door.
Tools Required:
#20 Torx Wrench (Included)
#2 Phillips Screwdriver
3/4" Wrench
7/16" Wrench
3/8" Wrench
5/16" Wrench
urn manual gas shut off valve to the OFF position to
T
shutoff gas to the thermostat.
et the thermostat dial to the lowest setting by turning
S
the thermostat dial clockwise
until it stops. DO NOT
FORCE.
Slightly depress the gas control knob and turn clockwise
to "OFF" position. NOTICE: Knob cannot be turned
from "PILOT" position unless
pushed down slightly. DO NOT USE
FORCE.
hange gas regulators setting by
C
removing cover from the gas selector
screw; then remove and reinstall the
selector screw with the red washer and LP arrow mark
pointing inward toward the heater. Tighten to 4-8 in-lb.
Replace cover.
Thermocouple
Supply Tube
Pilot
Pilot Burner
Burner Supply
Tube
Remove the Philips head screw that holds the pilot
burner assembly in place. Remove the pilot burner
assembly from the burner bracket. Remove the two
#6 x 3/8" long Phillips head screws from the burner
bracket and remove the burner from inner door
assembly to expose main burner orifice.
Pilot
#6 x 3/8"
long screws
Blue Washer
Natural Gas Position
24
Red Washer
LP Gas Position
Gas Selector Screw Settings
Bottom View of Inner Door Assembly
Conversion Instructions—Natural Gas to LP Gas
S
lide the cone to the end of the burner tube to
remove the flat end from the closed slot, turn the
burner supply tube so the narrow side slides out
of the cone.
Cone
Replace main burner (Natural gas) with the
(Red) colored (LP) main burner supplied in the
package. Reinstall the two #6 x 3/8" long Phillips
head screws. Screw the pilot burner assembly to
the burner bracket using the Phillips head screw
removed on step 7.
Red
marked
color
Burner supply tube
R
emove main burner orifice. Replace main
burner natural gas orifice with the Red colored
main burner orifice (stamped LP) supplied in
the bag.
Red color indicates
LP gas orifice
Burner
Burner
orifice
Main burner orifice
(stamped LP)
Burner supply
tube
R
emove the compression nut from the pilot
burner assembly using the 3/8" and 5/16" wrench
to expose pilot burner orifice. Remove natural
gas pilot burner orifice and replace with Yellow
marked LP pilot burner orifice supplied in the
package. Replace the compression nut on pilot
burner assembly and tighten the nut.
Pilot supply tube
Thermocouple
Burner supply
Natural/ LowNox Gas Burner
LP Burner
Reinstall entire inner door assembly to the heater.
Ensure the speed clips are in place and the
gasket is fully sealed. Attach inner door loosely
to the heater using four #20 TORX screws.
Reconnect and tighten burner supply, pilot tube
and thermocouple at the thermostat. Handle tubes
carefully to avoid damaging them. DO NOT
over-tighten or cross-thread the connections.
Now tighten the four #20 TORX screws to secure
the inner door firmly to the heater. Reconnect the
piezo wire to the piezo ignitor striker connection.
Attach green CAUTION label from the bag
to the outside of the water heater near the gas
control. Label should be signed by qualified
installer or service organization
Return the unused parts to the bag for possible
future conversions. Return the bag and this Use
and Care manual to the plastic bag attached to
the water heater.
Install outer jacket door to heater.
Yellow mark
indicates LP gas
orifice
Pilot burner orifice
R
emove the gasket from inner door. Clean the
metal surfaces to assure good adhesion of new
gasket (supplied in bag) to the inner door. Align
screw holes of new gasket with holes on inner
door and press gasket firmly in place.
Jacket door
Turn manual gas shut off valve to the ON
position to start gas flow to the thermostat. Leak
test all gas connections and caps with soap/water
solution. Bubbles indicate a leak. Make certain
all leaks have been repaired, and the outer jacket
door has been replaced.
8 Follow lighting instructions on page 15 of the
manual to start the water heater.
25
Conversion instructions—LP Gas to Natural Gas
Your water heater was factory pre-set to burn natural gas but may have been converted to burn LP gas. If your water
heater has been converted to burn LP Gas, and your gas supply is now natural gas, your water heater can be converted to
burn natural gas as follows:
Liquefied Petroleum (LP or Propane) to Gas Natural Gas
Front View of Gas Thermostat
WARNING: This conversion kit must be installed by a
qualified installer or service technician in accordance with
these instructions. Installation must conform with local
codes, or in their absence, with the latest edition of the
National Fuel Gas Code, ANSI Z223.1. Failure to follow
instructions could result in serious injury or property
damage. The qualified agency performing this work assumes
responsibility for this conversion.
CAUTION: The water heater is factory set to burn
natural gas, but can be converted to burn LP gas. Before
placing the water heater into operation, verify that the type
of gas supplied to your water heater and the type of gas your
water heater is set to burn are the same. If they are not,
refer to these instructions.
NOTICE: The parts required to make this conversion are
supplied in a bag attached to the water heater. Should
your heater not have this bag attached to the water
heater, a replacement can be obtained. Simply contact
the manufacturer at the address below and request a
replacement conversion kit.
Customer Service Department
1241 Carwood Court
Montgomery, AL 36117
Phone: 1-800-432-8373
Piezo Igniter Striker
Gas Selector Screw
(Without cover.)
Piezo Wire
Connection
Thermostat Dial
Pilot Tube
(1/8" Aluminum
Tube)
Gas
Thermostat
Burner Supply
Tube
Thermocouple
(Copper Tube)
Remove outer jacket door.
Remove the four screws on the inner door using a
#20 TORX wrench supplied with the conversion
kit. Disconnect burner supply tube using the 3/4"
wrench, pilot tube using the 7/16" wrench, and
the thermocouple using the 3/8" wrench from the
thermostat Disconnect the piezo wire from the piezo
ignitor striker connection. Remove the entire burner
assembly along with the inner door.
Inner Door
Speed Clips
Tools Required:
#20 Torx Wrench (Included)
#2 Phillips Screwdriver
3/4" Wrench
7/16" Wrench
3/8" Wrench
5/16" Wrench
Inner Door
Gasket
Inner Door
Assembly
Jacket Door
Turn manual gas shut off valve to the OFF position to
shutoff gas to the thermostat.
et the thermostat dial to the lowest
S
setting by turning the thermostat dial
clockwise
until it stops. DO NOT
FORCE.
lightly depress the gas control knob
S
and turn clockwise
to "OFF"
position. NOTICE: Knob cannot be turned from
"PILOT" position unless pushed down slightly. DO
NOT USE FORCE.
Change gas regulator setting by removing cover from
the gas selector screw; then remove and reinstall the
selector screw with the blue washer and NAT arrow
mark pointing inward toward the heater. Tighten to
4-8 in lb. Replace cover.
Remove the Phillips head screw that holds the pilot
burner assembly in place. Remove the pilot burner
assembly from the burner bracket. Remove the two
#6 x 3/8" long Phillips head screws from the burner
bracket and remove the burner from inner door
assembly to expose main burner orifice.
Pilot
Burner Supply Tube
Pilot Burner
Thermocouple
Supply Tube
Pilot
#6 x 3/8"
long screws
Blue Washer
Natural Gas Position
26
Red Washer
LP Gas Position
Gas Selector Screw Settings
Bottom View of Inner Door Assembly
Conversion instructions—LP Gas to Natural Gas
R
emove LP burner orifice. Replace Red marked
LP gas burner orifice with the main burner orifice
stamped NG supplied in the bag.
Burner
Burner
orifice
Replace Red marked LP main burner with
main burner (Natural gas) supplied in the package.
Reinstall the two #6 x 3/8" long Phillips head
screws. Screw the pilot burner assembly to the
burner bracket using the Phillips head screw
removed on step 7.
Red
marked
color
Main burner orifice
(stamped NG)
Burner supply
tube
Natural/ LowNox Gas Burner
Remove
the gasket from inner door. Clean the
metal surfaces to assure good adhesion of new
gasket (supplied in bag) to the inner door. Align
screw holes of new gasket with holes on inner
door and press gasket firmly in place.
S
lide the notch on the cone onto the flat part of
the burner tube, then turn the cone upright and
slide the flat end of the burner supply tube into
the closed slot.
Cone
LP Burner
Reinstall entire inner door assembly to the heater.
Ensure the speed clips are in place and the
gasket is fully sealed. Attach inner door loosely
to the heater using four #20 TORX screws.
Reconnect and tighten burner supply, pilot tube
and thermocouple at the thermostat. Handle tubes
carefully to avoid damaging them. DO NOT
over-tighten or cross-thread the connections. Now
tighten the four #20 TORX screws to secure the
inner door firmly to the heater. Reconnect the
piezo wire to the piezo ignitor striker connection.
Attach green CAUTION label from the bag to the
outside of the water heater near the gas control.
Label should be signed by qualified installer or
service organization
Burner supply tube
emove the compression nut from the pilot
R
burner assembly using the 3/8" and 5/16" wrench
to expose pilot burner orifice. Remove yellow
marked LP gas pilot burner orifice and replace
with Natural pilot burner orifice in the bag.
Replace the compression nut on pilot burner
Return the unused parts to the bag for possible
future conversions. Return the bag and this Use
and Care manual to the plastic bag attached to the
water heater.
Install outer jacket door to heater.
Pilot supply tube
Thermocouple
Burner supply
Natural Gas Pilot burner
orifice
Jacket door
Turn manual gas shut off valve to the ON
position to start gas flow to the thermostat. Leak
test all gas connections and caps with soap/water
solution. Bubbles indicate a leak. Make certain
all leaks have been repaired and the outer jacket
door has been replaced.
8 Follow lighting instructions on page 15 of the
manual to start the water heater.
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: 1-800-432-8373.
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