A.O. Smith G6-UT10076NV Signature 98-Gallon Tall 6-Year Limited Natural Gas Water Heater Operating Guide

A.O. Smith G6-UT10076NV Signature 98-Gallon Tall 6-Year Limited Natural Gas Water Heater Operating Guide
Installation Instructions and Use & Care Guide
ULTRA LOW NOX RESIDENTIAL GAS WATER HEATERS
NOT FOR USE IN MANUFACTURED (MOBILE) HOMES
LOW LEAD
CONTENT
• For Your Safety •
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
DO NOT RETURN THIS UNIT TO THE STORE. To obtain technical, warranty, or service assistance during or after the installation
of this water heater, visit our website at: http:// www.AOSmithAtLowes.com or call toll free 1-877-817-6750.
PRINTED 1116
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
1
2000538356 (VER 00) 100279884 (REV A)
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE............................ 3
Fresh Air Openings For Confined Spaces ............................ 13
GENERAL SAFETY INFORMATION........................................ 4
Outdoor Air Through Two Openings ..................................... 13
Abbreviations Used................................................................. 5
Outdoor Air Through Two Horizontal Ducts .......................... 14
Qualified Installer or Service Agency ...................................... 5
Outdoor Air Through Two Vertical Ducts ............................... 14
Preparing For The Installation ................................................ 5
Air From Other Indoor Spaces .............................................. 14
INTRODUCTION ...................................................................... 5
Venting .................................................................................. 14
INSTALLATION CONSIDERATIONS ....................................... 6
Gas Piping ............................................................................ 16
Thermometers (Not Supplied) ................................................ 7
Sediment Traps..................................................................... 17
Facts to Consider About the Location ..................................... 7
TEMPERATURE REGULATION ............................................ 19
High Altitude............................................................................ 8
Start Up Conditions............................................................... 19
Clearances.............................................................................. 8
Operational Conditions ......................................................... 20
Insulation Blankets.................................................................. 9
Venting System Inspection ................................................... 21
Hard Water ............................................................................. 9
Burner Inspection.................................................................. 21
Circulation Pumps................................................................... 9
Burner Cleaning .................................................................... 21
Gas Supply Systems ............................................................ 10
Housekeeping ....................................................................... 21
Gas Pressure Requirements ................................................ 10
PERIODIC MAINTENANCE ................................................... 21
Supply Gas Regulator........................................................... 10
Anode Rod Inspection .......................................................... 22
Mixing Valves ........................................................................ 10
Temperature-Pressure Relief Valve Test .............................. 22
INSTALLATION REQUIREMENTS ........................................ 10
Draining And Flushing........................................................... 23
Water Piping ......................................................................... 11
Closed Water Systems ......................................................... 11
Service .................................................................................. 23
Thermal Expansion ............................................................... 11
REPLACING PARTS .............................................................. 24
Temperature-Pressure Relief Valve ...................................... 11
Replacement Parts ............................................................... 24
Filling the Water Heater ........................................................ 12
LEAKAGE CHECKPOINTS .................................................... 27
Air Requirements .................................................................. 12
REPAIR PARTS ...................................................................... 28
Unconfined Space ................................................................ 13
TROUBLESHOOTING GUIDELINES..................................... 29
Confined Space .................................................................... 13
NOTES ................................................................................... 30
2
SAFE INSTALLATION, USE AND SERVICE
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
APPROVALS
Low Lead Content
3
GENERAL SAFETY INFORMATION
4
INTRODUCTION
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
properly. It could cause DEATH, SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE.
ABBREVIATIONS USED
This manual contains instructions for the installation,
operation, and maintenance of the gas-fired water heater.
It also contains warnings throughout the manual that you
must read and be aware of. All warnings and all instructions
are essential to the proper operation of the water heater
and your safety. Since we cannot put everything on the
first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
Abbreviations Found In This Instruction Manual:
•
•
•
•
•
•
•
UL - Underwriters Laboratories Inc.
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
ASME - American Society of Mechanical Engineers
AHRI - Air-Conditioning, Heating and Refrigeration Institute
EPACT - Energy Policy Act
CSA - Canadian Standards Association
2. The installation must conform with these instructions and
the local code authority having jurisdiction. In the absence
of local codes, the installation must comply with the current
edition of the National Fuel Gas Code, ANSI Z223.1/NFPA
54. All documents are available from the Canadian Standards
Association, 8501 East Pleasant Valley Road, Cleveland, OH
44131. NFPA documents are also available from the National
Fire Protection Association, 1 Batterymarch Park, Quincy,
MA 02269.
This gas-fired water heater is design certified by Underwriters
Laboratories Inc. under American National Standard/CSA Standard
for Gas Water Heaters ANSI Z21.10.3 • CSA 4.3 (current edition).
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability equivalent
to that of a Qualified Agency (as defined by ANSI below) in the field
involved. Installation skills such as plumbing, air supply, venting,
gas supply and electrical supply are required in addition to electrical
testing skills when performing service.
3. If after reading this manual you have any questions or do
not understand any portion of the instructions, call the local
gas utility or the manufacturer whose name appears on the
rating plate.
4. Carefully plan the place where you are going to put the
water heater. Correct combustion, vent action, and vent
pipe installation are very important in preventing death from
possible carbon monoxide poisoning and fires, see Figures
3 and 7.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualified Agency” - “Any individual,
firm, corporation or company that either in person or through a
representative is engaged in and is responsible for (a) the installation,
testing or replacement of gas piping or (b) the connection, installation,
testing, repair or servicing of appliances and equipment; that is
experienced in such work; that is familiar with all precautions required;
and that has complied with all the requirements of the authority
having jurisdiction.”
Examine the location to ensure the water heater complies with
the Fact to Consider About The Location section in this manual.
5. For California installation this water heater must be braced,
anchored, or strapped to avoid falling or moving during
an earthquake. See instructions for correct installation
procedures. Instructions may be obtained from California
Office of the State Architect, 400 P Street, Sacramento,
CA 95814.
If you are not qualified (as defined by ANSI above) and licensed or
certified as required by the authority having jurisdiction to perform a
given task do not attempt to perform any of the procedures described
in this manual. If you do not understand the instructions given in
this manual do not attempt to perform any procedures outlined in
this manual.
6. Massachusetts Code requires this water heater to be installed
in accordance with Massachusetts 248-CMR 2.00: State
Plumbing Code and 248-CMR 5.00.
PREPARING FOR THE INSTALLATION
1. Read the General Safety Information section, page 4 of this
manual first and then the entire manual carefully. If you
don’t follow the safety rules, the water heater will not operate
7. Complies with SCAQMD rule #1146.2 and districts having
equivalent NOx requirements.
5
INSTALLATION CONSIDERATIONS
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
G
H
Vent Pipe
Drafthood
Anode
Hot Water Outlet
Outlet
Insulation
Gas Supply
Manual Gas Shut-off Valve
I
J
K
L
M
N
O
P
Ground Joint Union
Sediment Trap
Inner Door
Outer door
Union
Inlet Water Shut-off Valve
Cold Water Inlet
Inlet Dip Tube
Q
R
S
T
U
V
W
X
Temperature-Pressure Relief Valve
Rating Plate
Flue Baffle(s)
Gas Control Valve/Thermostat
Drain Valve
Pilot and Main Burner
Flue
Metal Drain Pan
(T) GAS CONTROL VALVE/THERMOSTAT
GAS CONTROL KNOB
* INSTALL IN ACCORDANCE WITH
LOCAL CODES.
* SEDIMENT TRAP AS REQUIRED
BY LOCAL CODES.
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
A
**INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER
HEATER IS INSTALLED IN A
CLOSED WATER SYSTEM
B
S
D E
M
N
O
C
WATER TEMPERATURE
(ADJUSTING DIAL)
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
Q
P
F
G
H
R
I
T
U
J
6” MAXIMUM
AIR GAP
K
FLAME CHARACTERISTICS
X
W
**CLOSED WATER SYSTEMS ARE THOSE
WITH BACK FLOW PREVENTION DEVICES
INSTALLED IN THE WATER SERVICE LINE.
V
L
FIGURE 1.
6
CORRECT FLAME
SOFT BLUE
THERMOMETERS (NOT SUPPLIED)
the structure. For this reason, it is not advisable to install water heater
in an attic or upper floor. When such locations cannot be avoided, a
suitable metal drain pan should be installed under the water heater.
Metal Drain pans are available at your local hardware store. Such a
metal drain pan must have a minimum length and width of at least
2” (51 mm) greater than water heater dimensions and must be piped
to an adequate drain. The pan must not restrict combustion air flow.
Thermometers should be obtained and field installed.
Thermometers are installed in the system as a means of detecting
the temperature of the outlet water supply.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector
or water shut-off device used in conjunction with a piped drain pan.
These devices are available from some plumbing supply wholesalers
and retailers, and detect and react to leakage in various ways:
•
•
•
•
This Water Heater has been design certified as complying with
ANSI Z21.10.3-CSA 4.3 current edition for water heaters and is
considered suitable for:
Sensors mounted in the drain pan that trigger an alarm or turn off
the incoming water to the water heater when leakage is detected.
Sensors mounted in the drain pan that turn off the water supply
to the entire home when water is detected in the drain pan.
Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
Devices that will turn off the gas supply to a gas water heater
while at the same time shutting off its water supply.
Water (Potable) Heating and Space Heating: All models are
considered suitable for water (potable) heating and space heating.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing, and other sanitizing needs can scald and permanently injure
you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly, children,
the infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is a local
code requiring a certain temperature water at the hot water tap, then
you must take special precautions. In addition to using the lowest
possible temperature setting that satisfies your hot water needs,
a means such as a *Mixing Valve should be used at the hot water
taps used by these people or at the water heater. Mixing valves are
available at plumbing supply or hardware stores. Consult a qualified
installer or service technician. Follow mixing valve manufacturer’s
instructions for installation of valves. Before changing the factory
setting on the thermostat, read the “Temperature Regulation” section
in this manual, see Figures 17 and 18.
FACTS TO CONSIDER ABOUT THE LOCATION
Carefully choose an indoor location for the new water heater,
because the placement is a very important consideration for
the safety of the occupants in the building and for the most
economical use of the water heater. This water heater is not
for use in manufactured (mobile) homes or outdoor installation.
Whether replacing an old water heater or putting the water heater
in a new location, the following critical points must be observed:
1. Select a location indoors as close as practical to the gas vent or
chimney to which the water heater vent is going to be connected,
and as centralized with the water piping system as possible.
2. Selected location must provide adequate clearances for
servicing and proper operation of the water heater.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES,
STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as
gasoline, solvents, propane [LP or butane, etc.] and other substances
such as adhesives, etc.) emit flammable vapors which can be ignited by
a gas water heater’s pilot light or main burner. The resulting flashback
and fire can cause death or serious burns to anyone in the area, as well
as property damage. If installation in such areas is your only option, then
installation must be accomplished in a way that the pilot flame and main
burner flame are elevated from floor at least 18 inches. While this may
reduce chances of flammable vapors, from a floor spill being ignited,
gasoline and other flammable substances should never be stored or
Installation of water heater must be accomplished in such a manner that
if the tank or any connections should leak, flow will not cause damage to
7
CLEARANCES
used in the same room or area containing a gas water heater or other
open flame or spark producing appliance. NOTE: Flammable vapors may
be drawn by air currents from other areas of the structure to the appliance.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 4” (102 mm) for 100
gallon unit and 5” (127 mm) for 75 gallon unit at the front, and 6”
(153 mm) from the vent pipe. Clearance from the top of the jacket
is 12” (305 mm).
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
FIGURE 2.
This water heater must not be installed directly on carpeting. Carpeting
must be protected by metal or wood panel beneath the water heater
extending beyond the full width and depth of the water heater by at least
3” (76.2 mm) in any direction, or if the water heater is installed in an
alcove or closet, the entire floor must be covered by the panel. Failure
to heed this warning may result in a fire hazard.
High Altitude
A gas water heater cannot operate properly without the correct
amount of air for combustion. Do not install in a confined area
such as a closet, unless you provide air as shown in the Facts to
Consider About The Location section. Never obstruct the flow of
ventilation air. If you have any doubts or questions at all, call your
gas supplier. Failure to provide the proper amount of combustion
air can result in a fire or explosion and cause death, serious bodily
injury, or property damage.
Water heaters covered in this manual have been tested and approved
for installation at elevations up to 7,700 feet (2,347 m) above sea level.
For installation above 7,700 feet (2,347 m), the water heater’s Btu input
should be reduced at the rate of 4 percent for each 1,000 feet (305
m) above sea level which requires replacement of the burner orifice
in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA
54. Contact your local gas supplier for further information.
Failure to replace the standard orifice with the proper high altitude
orifice when installed at elevations above 7,700 feet (2,347 m)
could result in improper and inefficient operation of the water heater,
producing carbon monoxide gas in excess of the safe limits. This
could result in serious injury or death. Contact your local gas supplier
for any specific changes that may be required in your area.
FIGURE 3.
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry
cleaning equipment, it is imperative that the water heater or
water heaters be installed so that combustion and ventilation
air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly fl ammable in many cases, will also change to corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
8
INSULATION BLANKETS
CIRCULATION PUMPS
A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the
water heater. See Water Piping Diagrams in this manual for
installation location of circulating pumps.
Breathing Hazard - Carbon Monoxide Gas
See the Circulation Pump Wiring Diagrams below for electrical
hookup information. Install in accordance with the current
edition of the National Electrical Code, NFPA 70.
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
All bronze or stainless steel circulating pumps are recommended
for used with commercial water heaters.
Install water heater in accordance with
the instruction manual.
Some circulating pumps are manufactured with sealed bearings
and do not require further lubrication. Some circulating pumps
must be periodically oiled. Refer to the pump manufacturer’s
instructions for lubrication requirements.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Insulation blankets are available to the general public for
external use on gas water heaters but are not necessary
with these products. The purpose of an insulation blanket is
to reduce the standby heat loss encountered with storage
tank heaters. The water heaters covered by this manual meet
or exceed the Energy Policy Act standards with respect to
insulation and standby heat loss requirements, making an
insulation blanket unnecessary.
CIRCULATING PUMP WIRING DIAGRAM
STORAGE TANK OR BUILDING RECIRCULATION
FIELD SUPPLIED TEMPERATURE CONTROL
INSTALLED IN THE STORAGE TANK
OR CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS THIS
MAY CAUSE ELECTRICAL LINE NOISE AND
LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions. See the Installation
Considerations section of this manual for identification
of components mentioned below. Failure to follow these
instructions can restrict the air flow required for proper
combustion, potentially resulting in fire, asphyxiation, serious
personal injury or death.
L1 HOT
120 VAC
POWER
• DO NOT apply insulation to the top of the water heater, as
this will interfere with safe operation of the draft hood.
CIRC
PUMP
MOTOR
L2 NEUTRAL
FIGURE 4.
• DO NOT cover the thermostat or the TemperaturePressure Relief Valve.
• DO NOT allow the insulation to come within 2 inches (5
cm) of the floor to prevent blockage of combustion air flow
to the burner.
CIRCULATING PUMP WIRING DIAGRAM
DISHWASHER LOOP WITH TOGGLE SWITCH
• DO NOT cover the instruction manual. Keep it on the side
of the water heater or nearby for future reference.
DISHWASHER
TOGGLE
SWITCH
• DO obtain new warning and instruction labels from the
manufacturer for placement on the blanket directly over
the existing labels.
FIELD SUPPLIED TEMPERATURE
CONTROL INSTALLED IN THE
CIRCULATING LOOP RETURN LINE
NOTE: USE SEPARATE 120 VAC POWER
SUPPLY FOR PUMP CIRCUIT. DO NOT
SHARE POWER WITH WATER HEATER AS
THIS MAY CAUSE ELECTRICAL LINE NOISE
AND LEAD TO ERRATIC CONTROL SYSTEM
OPERATION.
• DO inspect the insulation blanket frequently to make
certain it does not sag, thereby obstructing the
combustion air flow.
L1 HOT
120 VAC
POWER
HARD WATER
Where hard water conditions exist, water softening or the threshold
type of water treatment is recommended. This will protect the
dishwashers, coffee urns, water heaters, water piping and other
equipment. See the Maintenance Section in this manual for
sediment and lime scale removal procedures.
CIRC
PUMP
MOTOR
L2 NEUTRAL
FIGURE 5.
9
INSTALLATION REQUIREMENTS
MIXING VALVES
GAS SUPPLY SYSTEMS
Low pressure building gas supply systems are defined as those
systems that cannot under any circumstances exceed 14” W.C.
(1/2 PSI Gauge). These systems do not require pressure regulation.
Measurements should be taken to insure that gas pressures are stable
and fall within the requirements stated on the water heater rating plate.
readings should be taken with all gas burning equipment off (static
pressure) and with all gas burning equipment running at maximum rate
(dynamic pressure). The gas supply pressure must be stable within 1.5”
W.C. from static to dynamic pressure to provide good performance.
Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy
combustion or nuisance outages. Increases or spikes in static pressure
during off cycles may cause failure to ignite or in severe cases damage
to appliance gas valves. If your low pressure system does not meet
these requirements, the installer is responsible for the corrections.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the physically
or mentally disabled are at highest risk
for scald injury.
Feel water before bathing or showering.
Temperature limiting devices such as
mixing valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
Water heated to a temperature which will satisfy clothes washing, dish
washing, and other sanitizing needs can scald and cause permanent
injury upon contact. Short repeated heating cycles caused by small
hot water uses can cause temperatures at the point of use to exceed
the water heater’s temperature setting by up to 20°F (11°C).
High Pressure building supply systems use pressures that exceed
14” W.C. (1/2 PSI Gauge). These systems must use field supplied
regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI
Gauge). Appliances require gas regulators that are properly sized for the
water heater input and deliver the rating plate specified pressures. Gas
supply systems where pressure exceeds 5 PSI often require multiple
regulators to achieve desired pressures. Systems in excess of 5 PSI
building pressure should be designed by gas delivery professionals
for best performance. Water heaters connected to gas supply systems
that exceed 14” W.C. (1/2 PSI Gauge) at any time must be equipped
with a gas supply regulator.
Some people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the infirm and the
physically/mentally disabled. Table 2 shows the approximate timeto-burn relationship for normal adult skin. If anyone using hot water
provided by the water heater being installed fits into one of these
groups or if there is a local code or state law requiring a certain water
temperature at the point of use, then special precautions must be taken.
In addition to using the lowest possible temperature setting that
satisfies demand of the application a Mixing Valve should be installed
at the water heater or at hot water taps to further reduce system water
temperature. See Figure 6.
GAS PRESSURE REQUIREMENTS
100 gallon natural gas model requires a minimum gas supply pressure
of 5” w.c. (1.25 kPa); 75 gallon natural gas model requires a minimum
gas supply pressure of 6” w.c. (1.49 kPa). The minimum supply
pressure is measured while gas is flowing (dynamic pressure). The
supply pressure (dynamic) should never fall below the specified
minimum supply pressure. The supply pressure should be measured
with all gas fired appliances connected to the common main firing at full
capacity. If the supply pressure drops more than 1.5” W.C. (0.37 kPa)
as gas begins to flow to the water heater then the supply gas system
including the gas line and/or the gas regulator may be restricted or
undersized. See Supply Gas regulator section and Gas Piping section
of this manual. The gas valve on all models has a maximum gas supply
pressure limit of 14” W.C. (3.48 kPa) The maximum supply pressure
is measured while gas is not flowing (static pressure).
Mixing valves are available at plumbing supply stores. Consult
a Qualified Installer or Service Technician. Follow mixing valve
manufacturer’s instructions for installation of the valves.
TABLE 2.
SUPPLY GAS REGULATOR
The maximum allowable gas supply pressure for this water heater
is 14.0 inches W.C. (3.48 kPa). Install a positive lock-up gas pressure
regulator in the gas supply line if inlet gas pressure can exceed 14.0
inches W.C. (3.48 kPa) at any time. regulators must be sized/used
according to manufacturer’s specifications.
Water
Temperature °F
Time for
1st Degree Burn
(Less Severe Burns)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110
116
116
122
131
140
149
154
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
HOT WATER
OUTLET
If a positive lock-up regulator is required follow these instructions:
12” TO 15”
(30-38 cm)
1. Positive lock-up gas pressure regulators must be rated at or above
the input Btu/hr rating of the water heater they supply.
TEMPERED WATER
OUTLET
2. Positive lock-up gas pressure regulator(s) should be installed no
closer than 3 feet (1 meter) and no farther than 8 feet (2.4 meters)
of equivalent length from the water heater’s inlet gas connection.
CHECK
VALVE
COLD
WATER
INLET
3. After installing the positive lock-up gas pressure regulator(s) an initial
nominal supply pressure setting of 7.0” W.C. while the water heater
is operating is recommended and will generally provide good
water heater operation. Some additional adjustment maybe required
later to maintain a steady gas supply pressure.
CHECK
VALVE
MIXING
VALVE
TO TANK
INLET
4. When installing multiple water heaters in the same gas supply
system it is recommended that individual positive lock-up gas
pressure regulators be installed at each unit.
FIGURE 6.
10
WATER PIPING
WATER (POTABLE) HEATING AND SPACE HEATING
This water heater shall not be connected to any heating systems
or component(s) used with a non-potable water heating appliance.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall not
be introduced into this system.
When the system requires water for space heating at temperatures
higher than required for domestic water purposes, a mixing valve
must be installed. Please refer to Figure 6 for suggested piping
arrangement.
These water heaters cannot be used in space heating applications
only.
FIGURE 7.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected to
copper pipe.
CLOSED WATER SYSTEMS
Water supply systems may, because of code requirements or
such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back flow preventers. Devices such as these cause
the water system to be a closed system.
Figure 7 shows the typical attachment of the water piping to the
water heater.
TEMPERATURE-PRESSURE RELIEF VALVE
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase in
water pressure due to thermal expansion. Thermal expansion
can cause premature tank failure (leakage). This type of failure
is not covered under the limited warranty. Thermal expansion
can also cause intermittent Temperature-Pressure Relief Valve
operation: water discharged from the valve due to excessive
pressure build up. This condition is not covered under the limited
warranty. The Temperature-Pressure Relief Valve is not intended
for the constant relief of thermal expansion.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service technician to have
a thermal expansion tank installed.
This water heater is provided with a properly rated/sized and
certified combination Temperature-Pressure Relief Valve (T&P
valve) by the manufacturer. The valve is certified by a nationally
recognized testing laboratory that maintains periodic inspection
of production of listed equipment of materials as meeting the
requirements for Relief Valves for Hot Water Supply Systems,
ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.
If replaced, the new T&P valve must meet the requirements
of local codes, but not less than a combination TemperaturePressure Relief Valve rated/sized and certified as indicated in
the above paragraph. The new valve must be marked with a
maximum set pressure not to exceed the marked hydrostatic
working pressure of the water heater (150 psi = 1,035 kPa)
and a discharge capacity not less than the water heater Btu/
hr or kW input rate as shown on the water heater’s model
rating label.
11
NOTE: In addition to the factory installed Temperature-Pressure
Relief Valve on the water heater, each remote storage tank that
may be installed and piped to a water heating appliance must also
have its own properly sized, rated and approved TemperaturePressure Relief Valve installed. Call the toll free technical support
phone number listed on the back cover of this manual for technical
assistance in sizing a Temperature-Pressure Relief Valve for remote
storage tanks.
For safe operation of the water heater, the Temperature-Pressure
Relief Valve must not be removed from its designated opening nor
plugged. The Temperature-Pressure Relief Valve must be installed
directly into the fitting of the water heater designed for the relief valve.
Install discharge piping so that any discharge will exit the pipe within
6 inches (15.2 cm) above an adequate floor drain, or external to the
building. In cold climates it is recommended that it be terminated at
an adequate drain inside the building. Be certain that no contact is
made with any live electrical part. The discharge opening must not
be blocked or reduced in size under any circumstances. Excessive
length, over 30 feet (9.14 m), or use of more than four elbows can
cause restriction and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between the
Temperature-Pressure Relief Valve and the tank. Do not connect
discharge piping directly to the drain unless a 6” (15.2 cm) air gap is
provided. To prevent bodily injury, hazard to life, or property damage,
the relief valve must be allowed to discharge water in adequate
quantities should circumstances demand. If the discharge pipe is
not connected to a drain or other suitable means, the water flow
may cause property damage.
CAUTION
Water Damage Hazard
•
Temperature-Pressure Relief Valve discharge
pipe must terminate at adequate drain.
T&P Valve Discharge Pipe Requirements:
• Shall not be smaller in size than the outlet pipe size of the valve,
or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
Temperature-Pressure Relief Valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor drain
or external to building. In cold climates, it is recommended
that discharge pipe be terminated at an adequate drain inside
building.
• Shall not have any valve or other obstruction between the
relief valve and the drain.
NOTE: The purpose of a Temperature-Pressure Relief Valve is to
prevent excessive temperatures and pressures in the storage tank.
The T&P valve is not intended for the constant relief of thermal
expansion. A properly sized thermal expansion tank must be installed
on all closed systems to control thermal expansion, see Closed
Water Systems and Thermal Expansion on page 11.
If you do not understand these instructions or have any questions
regarding the Temperature-Pressure Relief Valve call the toll free number
listed on the back cover of this manual for technical assistance.
FILLING THE WATER HEATER
Never use this water heater unless it is completely full of water. To
prevent damage to the tank, the tank must be filled with water. Water
must flow from the hot water faucet before turning “ON” gas to the
water heater.
To fill the water heater with water:
1. Close the water heater drain valve by turning the handle to the
right (clockwise). The drain valve is on the lower front of the water
heater.
2. Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when the
water heater is in use.
3. To insure complete filling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow is
obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as
needed.
AIR REQUIREMENTS
Breathing Hazard - Carbon Monoxide Gas
Install water heater in accordance with
the Instruction Manual and NFPA 54.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Burn hazard.
Do not place chemical vapor emitting
products near water heater.
Hot water discharge.
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
The Temperature-Pressure Relief Valve must be manually operated
at least twice a year. Caution should be taken to ensure that (1) no
one is in front of or around the outlet of the Temperature-Pressure
Relief Valve discharge line, and (2) the water manually discharged
will not cause any bodily injury or property damage because
the water may be extremely hot. If after manually operating the
valve, it fails to completely reset and continues to release water,
immediately close the cold water inlet to the water heater, follow the
draining instructions in this manual, and replace the TemperaturePressure Relief Valve with a properly rated/sized new one.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
For safe operation an adequate supply of fresh uncontaminated air for
combustion and ventilation must be provided.
An insufficient supply of air can cause recirculation of combustion
products resulting in contamination that may be hazardous to life.
Such a condition often will result in a yellow, luminous burner flame,
causing sooting of the combustion chamber, burners and flue tubes
and creates a risk of asphyxiation.
Do not install the water heater in a confined space unless an adequate
supply of air for combustion and ventilation is brought in to that space
using the methods described in the Confined Space section that follows.
Never obstruct the flow of ventilation air. If you have any doubts or
questions at all, call your gas supplier. Failure to provide the proper
12
OUTDOOR AIR THROUGH TWO OPENINGS
amount of combustion air can result in a fire or explosion and cause property
damage, serious bodily injury or death.
UNCONFINED SPACE
An Unconfined Space is one whose volume is not less than 50
cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the
total input rating of all appliances installed in the space. Rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconfined space.
Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers and fireplaces shall also be
considered in determining the adequacy of a space to provide
combustion, ventilation and dilution air.
UNUSUALLY TIGHT CONSTRUCTION
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of unusually tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier, etc.)
additional air must be provided using the methods described in
the Confined Space section that follows.
FIGURE 8.
CONFINED SPACE
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. The openings shall communicate directly with the
outdoors. See Figure 8.
A Confined Space is one whose volume is less than 50 cubic feet per
1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all
appliances installed in the space.
Openings must be installed to provide fresh air for combustion, ventilation
and dilution in confined spaces. The required size for the openings is
dependent on the method used to provide fresh air to the confined space
and the total Btu/hr input rating of all appliances installed in the space.
Each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of all
appliances installed in the enclosure. Each opening shall not be less
than 100 square inches (645 cm2).
DIRECT VENT APPLIANCES
OUTDOOR AIR THROUGH ONE OPENING
Appliances installed in a Direct Vent configuration that derive all
air for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total appliance input Btu/hr
calculations used to determine the size of openings providing fresh
air into confined spaces.
EXHAUST FANS
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed in
the same space with a water heater, sufficient openings to provide
fresh air must be provided that accommodate the requirements
for all appliances in the room and the exhaust fan. Undersized
openings will cause air to be drawn into the room through the water
heater’s vent system causing poor combustion. Sooting, serious
damage to the water heater and the risk of fire or explosion may
result. It can also create a risk of asphyxiation.
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions that follow do not
take in to account the presence of louvers, grilles or screens in the openings.
The required size of openings for combustion, ventilation and dilution
air shall be based on the “net free area” of each opening. Where the
free area through a design of louver or grille or screen is known, it shall
be used in calculating the size of opening required to provide the free
area specified. Where the louver and grille design and free area are not
known, it shall be assumed that wood louvers will have 25% free area
and metal louvers and grilles will have 75% free area. Non motorized
louvers and grilles shall be fixed in the open position.
FIGURE 9.
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided. See
Figure 9. The water heater shall have clearances of at least 1 inch
(25 mm) from the sides and back and 6 inches (150 mm) from the
front of the appliance. The opening shall directly communicate with
the outdoors or shall communicate through a vertical or horizontal duct
to the outdoors or spaces that freely communicate with the outdoors
and shall have a minimum free area of the following:
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions shall be used to calculate the size,
number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces
only. Do not refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 14 for complete
venting installation instructions.
13
1.
1 square inch per 3000 Btu/hr (733 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2.
Not less than the sum of the areas of all vent connectors in
the space.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
enclosure. The vertical ducts shall communicate directly with the
outdoors. See Figure 11.
Each duct opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches.
AIR FROM OTHER INDOOR SPACES
FIGURE 10.
The confined space shall be provided with two permanent horizontal
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
enclosure. The horizontal ducts shall communicate directly with the
outdoors. See Figure 10.
Each duct opening shall have a minimum free area of 1 square inch
per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating of
all appliances installed in the enclosure.
FIGURE 12.
When ducts are used, they shall be of the same cross sectional area
as the free area of the openings to which they connect. The minimum
dimension of rectangular air ducts shall be not less than 3 inches.
The confined space shall be provided with two permanent openings,
one commencing within 12 inches (300 mm) of the top and one
commencing within 12 inches (300 mm) of the bottom of the enclosure.
See Figure 12.
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
Each opening shall communicate directly with an additional room(s)
of sufficient volume so that the combined volume of all spaces meets
the criteria for an Unconfined Space.
The illustrations shown in this section of the manual are a
reference for the openings that provide fresh air into confined
spaces only.
Each opening shall have a minimum free area of 1 square inch per
1,000 Btu/hr (2200 mm2 per kW) of the aggregate input rating of all
appliances installed in the enclosure. Each opening shall not be less
than 100 square inches (645 cm2).
DO NOT refer to these illustrations for the purpose of vent
installation. See Venting Installation on page 14 for complete
venting installation instructions.
VENTING
FIGURE 11.
The confined space shall be provided with two permanent vertical
ducts, one commencing within 12 inches (300 mm) of the top and
one commencing within 12 inches (300 mm) of the bottom of the
14
If the water heater is being installed as a replacement for an
existing heater in pre-existing venting, a thorough inspection of
existing venting system must be performed prior to any installation
work.
The vent pipe from the water heater must be no less than the
diameter of the draft hood outlet on the water heater and must
slope upward at least 1/4 inch per linear foot (21 mm per meter).
See Figure 14.
VENT DAMPERS - Any vent damper, whether it is operated
thermally or otherwise must be removed if its use inhibits proper
drafting of the water heater.
All vent gases must be completely vented to the outdoors of the
structure (dwelling). Install only the draft hood provided with the
new water heater and no other draft hood.
Thermally Operated Vent Dampers: this gas-fired water heater
has a thermal efficiency at or above 80% which may produce
a relatively low flue gas temperature. Such temperatures may
not be high enough to properly open thermally operated vent
dampers. This would cause spillage of the flue gases and may
cause carbon monoxide poisoning. Vent dampers must bear
evidence of certification as complying with the current edition of
the American National Standard ANSI Z21.66 CGA 6.14 (covering
electrically and mechanically actuated vent dampers). Before
installation of any vent damper, consult the local gas utility for
further information.
Vent pipes must be secured at each joint with sheet metal screws.
To insure proper venting of this gas-fired water heater, the correct
vent pipe diameter must be utilized. Any additions or deletions
of other gas appliances on a common vent with this water heater
may adversely affect the operation of the water heater. Consult
your gas supplier if any such changes are planned.
FIGURE 14.
For proper venting in certain installations, a larger diameter vent
pipe may be necessary. Consult your gas supplier to aid you in
determining the proper venting for your water heater from the
vent tables in the current edition of the National Fuel Gas Code
ANSI Z223.1/NFPA 54.
There must be a minimum of 6” (153 mm) clearance between single
wall vent pipe and any combustible material. Fill and seal any
clearance between single wall vent pipe and combustible material
with mortar mix, cement, or other noncombustible substance. For
other than single wall, follow vent pipe manufacturer’s clearance
specifications. To insure a tight fit of the vent pipe in a brick chimney,
seal around the vent pipe with mortar mix cement.
Periodically check the venting system for signs of obstruction or
deterioration and replace if needed.
Failure to have required clearances between vent piping and
combustible material will result in a fire hazard.
The combustion and ventilation air flow must not be obstructed.
Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
The water heater with draft hood installed must be connected
to a chimney or listed vent pipe system, which terminates to the
outdoors. Never operate the water heater unless it is vented to the
outdoors and has adequate air supply to avoid risks of improper
operation, explosion or asphyxiation.
Align the legs of the draft hood with the holes provided. Insert
the legs and secure the draft hood to the water heater’s top
with the four screws provided as shown in Figure 13. Do not
alter the draft hood in any way. If you are replacing an existing
water heater, be sure to use the new draft hood supplied with
the water heater.
Obstructed or deteriorated vent systems may present serious
health risk or asphyxiation.
SHEET METAL SCREWS (FOUR PROVIDED)
DRAFT HOOD
LEGS
LEGS
HOLE
HOLE
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes, bleach and process chemicals are typical
compounds which are potentially corrosive.
JACKET TOP
INSTALL THE DRAFT HOOD WITH
THE FOUR SCREWS PROVIDED.
FIGURE 13.
15
GAS PIPING
TABLE 4.
LENGTH
IN
METERS
Contact your local gas service company to ensure that adequate
gas service is available and to review applicable installation codes
for your area.
Size the main gas line in accordance with Table 3. The figures shown
are for straight lengths of pipe at 0.5 in. W.C. pressure drop, which
is considered normal for low pressure systems. Note: Fittings such
as elbows, tees and line regulators will add to the pipe pressure
drop. Also refer to the current edition of the National Fuel Gas Code
(NFPA 54).
Make sure gas supplied is same type listed on model rating plate.
The inlet gas pressure must not exceed 14 inch water column (2.6
kPa) for natural and propane (L.P.) gas. The minimum inlet gas
pressure shown on rating plate is that which will permit firing at
rated input.
If the gas control valve is subjected to pressures exceeding 1/2 pound
per square inch (3.5 kPa), the damage to the gas control valve could
result in a fire or explosion from leaking gas.
If the main gas line shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54
and your gas supplier concerning pipe size.
There must be:
• A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
• A sediment trap ahead of the gas control valve to help prevent dirt
and foreign materials from entering the gas control valve.
• A flexible gas connector or a ground joint union between the shut
off valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the water
heater. Use a soapy water solution, not a match or open flame. Rinse
off soapy solution and wipe dry.
NOMINAL IRON PIPE SIZES (INCHES)
INPUT IN KW
1/2"
3/4"
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"
3
51
105
199
410
615
1160
1845
3221
6735
4"
6
35
73
142
278
428
805
1277
2255
4626
9
28
59
110
225
346
644
1031
1830
3748
12
24
50
94
193
290
556
878
1552
3192
15
21
44
83
170
264
492
776
1391
2840
18
19
40
76
155
237
445
703
1259
2577
21
18
37
70
143
220
410
659
1142
2372
24
17
35
64
135
202
381
600
1083
2196
27
16
32
60
126
190
357
571
1010
2108
31
15
30
57
117
182
337
542
952
1962
38
13
27
51
105
161
299
483
864
1757
46
12
25
47
95
146
278
439
776
1610
53
11
23
42
88
135
249
401
717
1464
61
10
21
40
82
126
234
375
688
1347
Use pipe joint compound or teflon tape marked as being resistant to
the action of petroleum [Propane (L.P.)] gases.
The water heater and its gas connection must be leak tested before
placing the water heater in operation.
The water heater and its individual shut-off valve shall be
disconnected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of 1/2 pound per
square inch (3.5 kPa). It shall be isolated from the gas supply piping
system by closing its individual manual shut-off valve during any
pressure testing of the gas supply piping system at test pressures
equal to or less than 1/2 pound per square inch (3.5 kPa).
Connecting the gas piping to the gas control valve of the water heater
can be accomplished by either of the two methods shown in Figures
15 and 16.
The minimum inlet gas pressure shown on the rating plate is that
which will permit firing at the rated input.
TABLE 3. GAS SUPPLY LINE SIZES (IN INCHES)*
MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR
LENGTH
IN
FEET
NOMINAL IRON PIPE SIZES (INCHES)
INPUT IN THOUSANDS (BTU/HR)
1/2"
3/4"
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"
10
175
360
680
1400
2100
3960
6300
11000
23000
4"
20
120
250
465
950
1460
2750
4360
7700
15800
30
97
200
375
770
1180
2200
3520
6250
12800
40
82
170
320
660
990
1900
3000
5300
10900
50
73
151
285
580
900
1680
2650
4750
9700
60
66
138
260
530
810
1520
2400
4300
8800
70
61
125
240
490
750
1400
2250
3900
8100
80
57
118
220
460
690
1300
2050
3700
7500
90
53
110
205
430
650
1220
1950
3450
7200
100
50
103
195
400
620
1150
1850
3250
6700
125
44
93
175
360
550
1020
1650
2950
6000
150
40
84
160
325
500
950
1500
2650
5500
175
37
77
145
300
460
850
1370
2450
5000
200
35
72
135
280
430
800
1280
2280
4600
FIGURE 15. GAS PIPING WITH FLEXIBLE CONNECTOR.
FIGURE 16. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
16
SEDIMENT TRAPS
Contaminants in the gas lines may cause improper operation of
the gas control valve that may result in fire or explosion. Before
attaching the gas line be sure that all gas pipe is clean on the
inside. To trap any dirt or foreign material in the gas supply
line, a sediment trap must be incorporated in the piping. The
sediment trap must be readily accessible. Install in accordance
with the “Gas Piping” section. Refer to the current edition of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54.
A sediment trap shall be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The
sediment trap shall be either a tee fitting with a capped nipple in the
bottom outlet or other device recognized as an effective sediment
trap. If a tee fitting is used, it shall be installed in conformance with
one of the methods of installation shown in the Figures 15 and 16.
17
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a
fire or explosion may result causing property damage, personal
injury or loss of life.
FLAMMABLE
BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES
A. This appliance has a pilot which is lit by a piezo-
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push down or turn the gas
electric spark gas ignition system. When lighting
the pilot, follow these instructions exactly.
B. BEFORE LIGHTING smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.
control knob. Never use tools. If the knob will
not push down or turn by hand, don't try to repair
it, call a qualified service technician. Force or
attempted repair may result in fire or explosion.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not use any
phone in your building.
D. Do not use this appliance if any part has been
under water. Immediately contact a qualified
installer or service agency to replace a flooded
water heater. Do not attempt to repair the unit!
It must be replaced!
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
LIGHTING INSTRUCTIONS
OFF
OFF
PILOT
PILOT
"PILOT" POSITION
TOP KNOB
STOP! Read the safety information
above on this label.
2. Set the thermostat to the lowest setting by turning
thermostat dial fully clockwise
until it stops.
3. Push the gas control knob down slightly and turn
clockwise
to "OFF". SEE FIGURE 'A'.
NOTE: Knob cannot be turned from "PILOT" to "OFF"
unless knob is pushed down slightly. Do not force.
4. Remove the outer door located below
the gas control unit.
5. Wait five (5) minutes to clear out any gas. If you
then smell gas,
STOP! Follow "B" in the
safety information
above on this label. If
you do not smell gas,
go to next step.
6. This unit is equipped with a push button pilot ignitor,
which is used to light the pilot. Locate the ignitor
on the gas control.
7. Turn gas control knob counterclockwise
to "PILOT". SEE FIGURE 'B'.
8. The pilot is located on the left front corner of the burner.
It can be located by looking through the sight glass to
the left while pressing the piezo ignitor button
several times. Look for a spark at the pilot location .
1.
MAIN BURNER
ON
THERMOSTAT
DIAL
PILOT
"OFF" POSITION
THERMOCOUPLE &
BURNER TUBEPILOT
FIGURE 'C'
ON
GAS CONTROL
FIGURE 'B'
ON
PIEZO
IGNITOR
GENERATOR
FIGURE 'A'
OFF
GAS CONTROL
KNOB
"ON" POSITION
FIGURE "D"
9. Once the pilot has been found, push the gas knob
all the way down. Immediately press the pilot ignitor
button rapidly (4) to (5) times. If the pilot does not
light, repeat step (3) through (9).
10. Continue to hold the gas control knob down for about
one (1) minute after the pilot is lit. Release the gas
control knob and it will pop back up. Pilot should
remain lit. If it goes out , repeat step (3) through (9).
It may take several minutes for air to clear the lines
before the pilot will light.
If knob does not pop up when released, stop and
immediately call your service technician or gas
supplier.
If the pilot will not stay lit after several tries,
turn the gas control knob clockwise to 'OFF' and
call your service technician or gas supplier.
SEE FIGURE 'A'
11. Replace the outer door.
12. At arm's length away, turn gas control knob
counterclockwise
to 'ON'. SEE FIGURE 'C'.
13. Set thermostat to desired setting.
DANGER: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
TO TURN OFF GAS TO APPLIANCE
1. S e t t h e t h e r m o s t a t t o l o w e s t s e t t i n g .
2. Push gas control knob down slightly and turn clockwise
to 'OFF'. Do not force. SEE FIGURE 'A'.
18
TEMPERATURE REGULATION
Short repeated heating cycles caused by small hot water uses can
cause temperatures at the point of use to exceed the thermostat
setting by up to 30°F (16.7°C). If you experience this type of use
you should consider using lower temperature settings to reduce
scald hazards.
Never allow small children to use a hot water tap, or to draw their own
bath water. Never leave a child or handicapped person unattended
in a bathtub or shower.
Any water heater’s intended purpose is to heat water. Hot water
is needed for cleansing, cleaning, and sanitizing (bodies, dishes,
clothing). Untempered hot water can present a scald hazard.
Depending on the time element, and the people involved (adults,
children, elderly, infi rm, etc.) scalding may occur at different
temperatures.
The thermostat of this water heater has been factory set at its lowest
position (PILOT LIGHTING). It is adjustable and must be reset to
the desired temperature setting to reduce the risk of scald injury.
The mark ( ) indicative of approximately 120°F (49°C) is preferred
starting point. Some States have a requirement for a lower setting.
NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is
recommended by most dishwasher manufacturers.
Turn the water temperature dial clockwise (
) to decrease the
temperature, or counterclockwise (
) to increase the temperature.
Should overheating occur or the gas supply fail to shut off, turn off the
manual gas control valve to the water heater.
HOTTER WATER CAN SCALD: Water heaters are intended to produce
hot water. Water heated to a temperature which will satisfy space
heating, clothes washing, dish washing, and other sanitizing needs
can scald and permanently injure you upon contact. Some people
are more likely to be permanently injured by hot water than others.
These include the elderly, children, the infirm, or physically/mentally
handicapped. If anyone using hot water in your home fits into one of
these groups or if there is a local code or state law requiring a certain
temperature water at the hot water tap, then you must take special
precautions. In addition to using the lowest possible temperature
setting that satisfies your hot water needs, a means such as a mixing
valve should be used at the hot water taps used by these people or
at the water heater. Mixing valves are available at plumbing supply or
hardware stores, see Figure 6. Follow manufacturer’s instructions for
installation of the valves. Before changing the factory setting on the
thermostat, read the “Temperature Regulation” section in this manual,
see Figures 17 and 18.
FIGURE 17.
Temperature
Time to Produce 2nd & 3rd
Setting
Degree Burns on Adult Skin
VERY HOT = APPROX.160°F (71°C)
About 1/2 second
C = APPROX.150°F (65°C)
About 1-1/2 seconds
B = APPROX.140°F (60°C)
Less than 5 seconds
A = APPROX.130°F (54°C)
= APPROX.120°F (49°C)
LOW = APPROX. 90°F (32°C)
About 30 seconds
More than 5 minutes
--------
FIGURE 18.
FOR YOUR INFORMATION
START UP CONDITIONS
appear to be leaking when in fact the water is condensation. This
usually happens when:
DRAFT HOOD OPERATION
a. A new water heater is fi lled with cold water for the fi rst time.
Check draf t hood operation by per for ming a worst c ase
depressurization of the building. With all doors and windows
closed, and with all air handling equipment and exhaust fans
operating such as furnaces, clothes dryers, range hoods and
bathroom fans, a match fl ame should still be drawn into the draft
hood of the water heater with its burner fi ring. If the fl ame is not
drawn toward the draft hood, shut off water heater and make
necessary air supply changes to correct.
b. Burning gas produces water vapor in water heaters, particularly
high effi ciency models where fl ue temperatures are lower.
c. Large amounts of hot water are used in a short time and the
refi ll water in the tank is very cold.
Moisture from the products of combustion condense on the cooler
tank surfaces and form drops of water which may fall onto the
burner or other hot surfaces to produce a “sizzling” or “frying” noise.
CONDENSATION
Excessive condensation can cause pilot outage due to water
running down the flue tube onto the main burner and putting out
the pilot.
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water heater may
19
Because of the suddenness and amount of water, condensation
water may be diagnosed as a “tank leak”. After the water in the tank
warms up (about 1-2 hours), the condition should disappear.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less
active material, and then chlorinating the water heater
tank and all hot water lines. Contact the local water
heater supplier or service technician for further information
concerning an Anode Replacement Kit and this chlorination
treatment.
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation. The water
heater must be sized properly to meet the family’s demands for hot
water including dishwashers, washing machines and shower heads.
If the smelly water persists after the anode replacement and chlorination
treatment, we can only suggest that chlorination or aeration of the water
supply be considered to eliminate the water problem.
Excessive condensation may be noticed during the winter and early
spring months when incoming water temperatures are at their lowest.
Do not remove the anode leaving the tank unprotected. By doing
so, all warranty on the water heater tank is voided.
Good venting is essential for a gas fired water heater to operate properly
as well as to carry away products of combustion and water vapor.
“AIR” IN HOT WATER FAUCETS
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
parts during periods of heat-up and cool-down do not necessarily
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner area
during heating and cooling periods and should be considered normal.
See “Condensation” in this section.
HYDROGEN GAS: Hydrogen gas can be produced in a
hot water system that has not been used for a long period
of t im e (g e ne r ally t wo we eks o r m o re). Hydr o g e n g as
is ex t remely f lammable and ex pl o sive. To prevent t he
possibility of injur y under these conditions, we recommend
the hot water faucet, located far thest away, be opened for
several minutes before any electric al appliances which
are c onnected to the hot water system are used (such
as a dishwasher or washing machine). If hydrogen gas is
present, there will probably be an unusual sound similar
to air escaping through the pipe as the hot water faucet is
opened. There must be no smoking or open flame near the
faucet at the time it is open.
OPERATIONAL CONDITIONS
SMELLY WATER
In each water heater there is installed at least one anode rod for
corrosion protection of the tank. Certain water conditions will cause a
reaction between this rod and the water. The most common complaint
associated with the anode rod is one of a “rotten egg smell” in the
hot water. This odor is derived from hydrogen sulfide gas dissolved
in the water. The smell is the result of four factors which must all be
present for the odor to develop:
a. A concentration of sulfate in the supply water.
HIGH WATER TEMPERATURE SHUT OFF SYSTEM
b. Little or no dissolved oxygen in the water.
This water heater is equipped with an automatic gas Shut-off
system. This system works when high water temperatures are
present. The high temperature Shut-off is built into the gas control
valve. It automatically resets when the temperature at thermostat
level drops below 120 degrees Fahrenheit.
c. A sulfate reducing bacteria which has accumulated within the
water heater (this harmless bacteria is nontoxic to humans).
d. An excess of active hydrogen in the tank. This is caused by the
corrosion protective action of the anode.
20
PERIODIC MAINTENANCE
VENTING SYSTEM INSPECTION
sooting can result in a fi re causing death, serious injury, or
property damage.
Flame Characteristics
Correct Flame
Red/Orange
FIGURE 19.
Natural Gas (Low Nox)
Burner Door Assembly
Use brush on this surface
Burner
Pilot Assembly
At least once a year a visual inspection should be made of the venting
system. You should look for:
1. Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
2. Damage or deterioration which could cause improper venting
or leakage of combustion products.
FIGURE 20.
3. Rusted flakes around top of water heater.
BURNER CLEANING
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gases which could cause deadly asphyxiation.
If inspection of the burner shows that cleaning is required, turn
the gas control knob clockwise (
) to the “OFF” position,
depressing slightly.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
NOTE: The knob cannot be turned from “PILOT” to “OFF”
unless knob is depressed slightly. DO NOT FORCE.
Check the burner to see if it’s dirty or clogged. The burner may be
cleaned with a soft paint brush, see Figure 20. Do not use a wire
brush or any tool that may damage the burner screen. Important: Do
not use the burner if the burner screen is damaged. NOTE: Damage
may be rips or holes in the burner screen. Discoloration is normal.
If after inspection of vent system you found sooting or deterioration,
something is wrong. Call the local gas utility to correct problem and
clean or replace the flue and venting before resuming operation of
water heater.
HOUSEKEEPING
BURNER INSPECTION
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a qualified installer or service technician to replace a flooded
water heater. Do not attempt to repair the unit! It must be replaced!
Fire and Explosion Hazard
Do not obstruct combustion air
openings at the bottom of the
water heater.
At least once a year a visual inspection should be made of the main
burner and pilot burner, see Figure 19. Inspect burner fl ames through
viewport. Flames should be very small with a blue haze and small
amounts of yellow or orange at the edges. After several minutes of
operation the burner screen may glow red.
Do not use or store flammable vapor
products such as gasoline, solvents
or adhesives in the same room or area
near water heater or other appliance.
You should check for sooting. Soot is not normal and will impair
proper combustion.
Can cause serious injury or death.
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until
repairs are made, because failure to correct the cause of the
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
21
INSTALLED IN SUITABLE AREA: To insure sufficient ventilation
and combustion air supply, proper clearances from the water
heater must be maintained. See Facts to Consider About The
Location section. Combustible materials such as clothing,
cleaning materials, or flammable liquids, etc. must not be placed
against or adjacent to the water heater which can cause a fire.
TEMPERATURE-PRESSURE RELIEF VALVE TEST
Burn hazard.
Hot water discharge.
ANODE ROD INSPECTION
Keep clear of TemperaturePressure Relief Valve
discharge outlet.
CAUTION
Property Damage Hazard
•
•
It is recommended that the Temperature-Pressure Relief Valve should
be checked to ensure that it is in operating condition every 6 months.
Avoid water heater damage.
When checking the Temperature-Pressure Relief Valve operation, make
sure that (1) no one is in front of or around the outlet of the TemperaturePressure Relief Valve discharge line, and (2) that the water discharge
will not cause any property damage, as the water may be extremely
hot. Use care when operating valve as the valve may be hot.
Inspection and replacement of anode rod required.
The anode rod is used to protect the tank from corrosion. Most hot
water tanks are equipped with an anode rod. The submerged rod
sacrifices itself to protect the tank. Instead of corroding the tank,
water ions attack and eat away the anode rod. This does not affect
water’s taste or color. The rod must be maintained to keep the tank
in operating condition.
To check the relief valve, lift the lever at the end of valve several times,
see Figure 21. The valve should seat properly and operate freely.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet
to the water heater and drain the water heater, see Draining And
Flushing on page 24. Replace the Temperature-Pressure Relief Valve
with a properly rated/sized new one, see Temperature-Pressure
Relief Valve on page 11 for instructions on replacement.
Anode deterioration depends on water conductivity, not necessarily
water condition. A corroded or pitted anode rod indicates high water
conductivity and should be checked and/or replaced more often than
an anode rod that appears to be intact. Replacement of a depleted
anode rod can extend the life of your water heater. Inspection should
be conducted by a qualified service technician, and at a minimum
should be checked annually after the warranty period.
TEMPERATURE-PRESSURE
RELIEF VALVE
Artificially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions.
The use of a water softener may decrease the life of the water
heater tank.
The anode rod should be inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates
its replacement.
DISCHARGE PIPE
FIGURE 21.
NOTE: Artificially softened water requires the anode rod to be
inspected annually.
If the Temperature-Pressure Relief Valve on the water heater weeps
or discharges periodically, this may be due to thermal expansion.
The following are typical (but not all) signs of a depleted anode rod:
• The majority of the rods diameter is less than 3/8”.
NOTE: Excessive water pressure is the most common cause of
Temperature-Pressure Relief Valve leakage. Excessive water
system pressure is most often caused by “thermal expansion”
in a “closed system.” See Closed Water Systems and Thermal
Expansion on page 11. The Temperature-Pressure Relief Valve
is not intended for the constant relief of thermal expansion.
• Significant sections of the support wire (approx. 1/3 or more of
the anode rod’s length) are visible.
Temperature-Pressure Relief Valve leakage due to pressure
build up in a closed system that does not have a thermal
expansion tank installed is not covered under the limited
warranty. Thermal expansion tanks must be installed on all
closed water systems.
DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF
VALVE OPENING. THIS CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH.
If the anode rod show signs of either or both it should be replaced.
NOTE: Whether re-installing or replacing the anode rod, check for
any leaks and immediately correct if found.
In replacing the anode:
1. Turn off gas supply to the water heater.
2. Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons of water from tank. (Refer to
“Draining and Flushing” for proper procedures). Close drain valve.
4. Remove old anode rod.
5. Use Teflon® tape or approved pipe sealant on threads and install
new anode rod.
6. Turn on water supply and open a nearby hot water faucet to purge
air from water system. Check for any leaks and immediately
correct any if found.
7. Restart the water heater as directed in this manual. See the
Repair Parts Illustration for anode rod location.
Explosion Hazard
Temperature-Pressure Relief Valve
must comply with ANSI Z21.22CSA 4.4 and ASME code.
Properly sized temperaturepressure relief valve must be
installed in opening provided.
Can result in overheating and
excessive tank pressure.
Can cause serious injury or death.
22
DRAINING AND FLUSHING
TO FLUSH THE WATER HEATER STORAGE TANK:
1.
Ensure the cold water inlet valve is open.
2.
Open a nearby hot water faucet and let the water run until
the water is no longer hot. Then close the hot water faucet.
3.
Connect a hose to the drain valve and terminate it to an
adequate drain.
4.
Ensure the drain hose is secured before and during the
entire flushing procedure. Flushing is performed with
system water pressure applied to the water heater.
5.
Open the water heater drain valve to flush the storage tank.
6.
Flush the water heater storage tank to remove sediment
and allow the water to flow until it runs clean.
Hot water discharge.
7.
Close the water heater drain valve when flushing is
completed.
Keep hands clear of drain
valve discharge.
8.
Remove the drain hose.
9.
Fill the water heater - see Filling The Water Heater in this manual.
It is recommended that the water heater storage tank be
drained and flushed every 6 months to reduce sediment
buildup. The water heater should be drained if being shut down
during freezing temperatures. See Installation Considerations
in this manual for the location of the water heater components
described below.
Burn harzard.
10. Turn on the gas supply to the water heater at the Main Gas
Shutoff Valve.
11. Allow the water heater to complete several heating cycles
to ensure it is operating properly.
TO DRAIN THE WATER HEATER STORAGE TANK:
1.
Turn off the gas supply at the Main Gas Shutoff Valve if
the water heater is going to be shut down for an extended
period.
2.
Ensure the cold water inlet valve is open.
3.
Open a nearby hot water faucet and let the water run until
the water is no longer hot.
4.
Close the cold water inlet valve to the water heater.
5.
Connect a hose to the water heater drain valve and
terminate it to an adequate drain.
6.
Open the water heater drain valve and allow all the water
to drain from the storage tank.
7.
Close the water heater drain valve when all water in the
storage tank has drained.
8.
Close the hot water faucet opened in Step 4.
9.
If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
SERVICE
Before calling for repair service, read the “Start Up Conditions”
and “Operational Conditions” found in the “For Your Information”
section of this manual.
If a condition persists or you are uncertain about the operation
of the water heater contact a service technician. If you are
not thoroughly familiar with gas codes, your water heater, and
safety practices, contact your gas supplier or qualified installer
to check the water heater.
Use the ”Leakage Checkpoints” guide to check a “Leaking”
water heater. Many suspected “Leakers” are not leaking tanks.
Often the source of the water can be found and corrected.
Read this manual first. Then before checking the water heater
make sure the gas supply has been turned “OFF”, and never
turn the gas “ON” before the tank is completely full of water.
Never use this water heater unless it is completely filled with
water. To prevent damage to the tank, the tank must be filled
with water. Water must flow from the hot water faucet before
turning “ON” gas to the water heater.
23
REPLACING PARTS
REPLACEMENT PARTS
Natural Gas Burner (Ultra Low Nox)
IMPORTANT: The following maintenance procedures should be
performed by a qualified person.
Check the burner screen to see if it is dirty or clogged. The
burner screen may be cleaned with a soft paint brush. Do not
use a wire brush or any tool that might damage the burner
screen.
Replacement parts may be ordered through your plumber or the
local distributor. Parts will be shipped at prevailing prices and billed
accordingly. When ordering replacement parts, always have the
following information ready:
1.
2.
3.
!MPORTANT: Do not use the burner if the burner screen is
damaged.
NOTE: Damage would be rips or holes in the burner screen.
Discoloration is normal.
model, serial and product number
item number
parts description
See “Repair Parts” section for a list of available repair parts.
Natural Gas (Low Nox)
Burner Door Assembly
Removing the Burner Door Assembly
1.
Turn off the gas to the water heater at the manual gas shut-off
valve (Figure 1).
2.
Turn the gas control knob on the combination gas control valve/
thermostat clockwise to the off position.
3.
Remove the outer door.
4.
Disconnect the thermocouple (right-hand thread), pilot tube,
the ignitor wire from the ignitor button, and manifold tube at the
thermostat (Figure 21).
5.
Remove the four screws at corners and the two sets of nuts
and clips in the middle securing the burner door assembly to
the combustion chamber (Figure 21.).
6.
Grasp the manifold tube and push down slightly to free the
manifold tube, pilot tube and thermocouple.
7.
Carefully remove the burner door assembly from the combustion
chamber. Be careful not to damage the burner screen or pilot
assembly.
Use brush on this surface
Burner
Pilot Assembly
FIGURE 22
Replacing the Pilot Assembly:
FIGURE 21
24
1.
Follow the instructions in “Removing the Burner Door
Assembly” section to remove the assembly.
2.
Remove the screw securing the pilot assembly to the
burner and keep it for reuse later.
3.
Remove the old pilot assembly (including the ignitor
wire) from the burner door assembly.
4.
Use the screw removed previously step to secure the
new pilot assembly to the burner.
5.
Insert the ignitor wire, pilot tube and thermocouple
through the hole in the burner door. Secure the grommet
through the hole in the burner door and make sure good
seal.
6.
Follow the instructions in “Replacing the Burner Door
Assembly” section to reinstall the assembly.
Replacing the Burner Door Assembly
Piezoelectric Igniter System
The piezoelectric igniter system consists of the igniter button,
electrode and wire. The pilot is ignited by an electric spark generated
when the igniter button is pressed. The electrode should be centered
between the pilot and thermocouple (Figure 23). Use only factory
authorized piozoelectric igniter parts for replacement.
WARNING
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shut-off valve.
Watch the electrode tip while activating the igniter. A visible spark
should jump from the electrode. To avoid shock, do not touch the
burner or any metal part on the pilot or pilot assembly. If no spark is
visible, check the wire connections and make sure the electrode is
not broken. Replace the electrode if defective. Note: The electrode is
part of the pilot assembly and cannot be replaced seperately. Dirt and
rust on the pilot or electrode tip can prevent the ignitor spark. Wipe
clean with a damp cloth and dry completely. Rust can be removed
from the electrode tip and metal surfaces by lightly sanding with an
emory cloth or fine grit sandpaper.
Explosion Hazard
Tighten burner door screws
securely.
Remove any fiberglass between gasket
and combustion chamber.
Replace viewport if glass is missing or
damaged.
Thermocouple
Replace manifold component block if missing
or removed.
Electrode
Replace door gasket if damaged.
Pilot
Failure to follow these instructions can
result in death, explosion, or fire.
1.
Check the door gasket for damage or imbedded debris prior
to installation.
2.
Inspect the viewport for damage and replace as required.
3.
Insert the burner door assembly into the combustion chamber
and slide it completely forward. Note: When inserting the
burner door assembly, tip the burner end up slightly to ensure
it engages with the burner bracket.
4.
Inspect the door gasket and make sure there is no fiberglass
insulation between the door gasket and the combustion chamber.
5.
Replace the two sets of nuts and clips and the four screws securing
the burner door assembly to the combustion chamber and tighten
securely. Once the burner door assembly is tightened, visually
inspect the door gasket between the burner door assembly and the
combustion chamber for spaces or gaps that would prevent a seal.
IMPORTANT: Do not operate the water heater if the door gasket
does not create a seal between the burner door assembly and the
combustion chamber.
6.
Reconnect the manifold tubing, pilot tubing and thermocouple to
the thermostat. Do not cross-thread or apply any thread sealant
to these fittings. The thermocouple nut should be started and
turned all the way by hand. An additional 1/2 - 3/4 turn with a 7/16”
open end wrench will then be sufficient to seat the lockwasher.
7.
Reconnect the ignitor wire.
8.
Turn the gas on and refer to the “Lighting Instructions”
9.
Check for leaks by brushing on an approved leak detection
solution. Bubbles will show a leak. Correct any leak found.
FIGURE 23
10. Replace the outer door.
25
Removing and Replacing the Gas Control Valve/
Thermostat:
6.
IMPORTANT: The gas control valve/thermostat is a standard valve
with a right hand thread thermocouple. Use only factory authorized
replacement parts.
To remove the gas control valve/thermostat, thread a correctly
sized pipe into the the inlet and use it to turn the gas valve
(counterclockwise). Do not use a pipe wrench or equivalent to
grip body. Damage may result causing leaks. Do not insert any
sharp objects into the inlet or outlet connections. Damage to
the gas control valve/thermostat may result.
Removing the Gas Valve:
Replacing the Gas Valve:
1.
Turn the gas control knob on the combination gas control
valve/thermostat clockwise to the “OFF” position. See “Lighting
Instructions” on water heater.
2.
Turn off the gas at the manual shut-off valve on the gas supply
pipe (Figure 1).
To replace the gas control valve/thermostat, reassemble in reverse
order. When replacing the gas control valve/thermostat, thread a
correctly sized pipe into the inlet and use it to turn the gas control valve/
thermostat (clockwise). DO NOT OVERTIGHTEN, damage may result.
3.
Drain the water heater. Refer to the “Draining and Flushing”
section and follow the procedure.
4.
Disconnect the igniter wire from the igniter. Note: There are two
types of igniters. If you have the round igniter, first remove the
igniter from the bracket by depressing front and rear holding tabs
and lift. Next remove igniter bracket from the gas valve. If you
have the square igniter slide the igniter bracket backwards away
from the gas valve to remove it. Disconnect the thermocouple
(right-hand threads), pilot tube and manifold tube at the gas
control valve/thermostat (Figure 21).
5.
• Be sure to use approved Teflon® tape or pipe joint compound on the
gas piping connections and fitting on the back of the gas control
valve/thermostat that screws into the tank.
• Be sure to remove the pilot ferrule nut from the new gas control
valve/thermostat.
• Turn the gas supply on and check for leaks. Test all connections
by brushing on an approved noncorrosive leak-detection solution.
Bubbles will show a leak. Correct any leak found.
• Be sure tank is completely filled with water before lighting and
activating the water heater. Follow the “Lighting Instructions”.
• If additional information is required, contact the Service
Department at: 1-877-817-6750
Refer to “Gas Piping” section (Figure 14) and disconnect the
ground joint union in the gas piping. Disconnect the remaining
pipe from the gas control valve/thermostat.
TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.
Operational Checklist
1.
2.
3.
4.
Burner door gasket properly sealed.
Viewport not damaged or cracked.
No leaks at pilot and manifold connection.
Burner door screws securely tightened.
Flue Baffle Installation:
Baffle Tab
Extentions
For 100 gallon unit, baffle tab extensions should be oriented
toward the outside of the heater when installed correctly. Refer
to Figure 24 for correct placement of baffles.
For 75 gallon unit, baffle tabs (one each near the top of each
baffle) should be oriented toward the inside of the heater when
installed correctly. Refer to Figure 25 for correct placement
of baffles.
NOTE: Do not operate this water heater unless the baffles
are installed correctly. Failure to do so can result in poor
combustion and high flue gas temperatures.
FIGURE 24
FIGURE 25
26
LEAKAGE CHECKPOINTS
Read this manual first. Then before checking the water heater make
sure the gas supply has been turned “OFF”, and never turn the gas
“ON” before the tank is completely full of water.
Never use this water heater unless it is completely filled with water
to prevent damage to the tank. Water must flow from the hot water
faucet before turning “ON” gas to the water heater.
A. Water at the draft hood is water vapor which has condensed out
of the combustion products. This is caused by a problem in the
vent. Contact a qualified service technician.
B. *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
E. *The temperature-pressure relief valve may be leaking at the
tank fitting.
F. Water from a drain valve may be due to the valve being slightly
opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can condense
on the cooler surfaces of the tank. Droplets form and drip onto
the burner or run on the floor. This is common at the time of
start-up after installation and when incoming water is cold.
I. Water in the water heater bottom or on the floor may be from
condensation, loose connections, or the relief valve. DO NOT
replace the water heater until a full inspection of all possible water
sources is made and necessary corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
*
27
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
“Draining” instructions in the “Periodic Maintenance” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. Then follow “Filling the Water Heater” instructions
in the “Installing the New Water Heater” section.
REPAIR PARTS
Key No.
Part Description
1
Pipe Nipple
2
Burner Tube
3
Burner Head
4
Thermocouple
5
Pilot
6
Draft Hood
7
Inlet Tube
8
Flue Baffle Assembly
9
Anode Rod
10
Outer Door
11
Gas Control Valve/Thermostat
12
T & P Relief Valve
13
Drain Valve
14
Pilot Tube
15
Orifices
*16
Metal Drain Pan
*17
Instruction Manual
8
9
7
12
11
* Not Shown.
13
Now that you have purchased this water heater, should a need
ever exist for repair parts or service, simply contact the company
it was purchased from or direct from the manufacturer listed on
the rating plate on the water heater.
10
Be sure to provide all pertinent facts when you call or visit.
DRAIN PAN
16
Selling prices will be furnished on request or parts will
be shipped at prevailing prices and you will be billed
accordingly.
The model number of your Gas Water Heater will be found on the
rating place located above the gas control valve.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
•
•
•
•
14
4
3
2
5
MODEL NUMBER
TYPE GAS (NATURAL)
SERIAL NUMBER
PART DESCRIPTION
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
15
3/4” T&P RELIEF VALVE
AUTOMATIC, SELF-CLOSING TYPES
PRESS
150 LBS.
12
28
A=
2.13”
TEMP
RELIEF
210°F
A
TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent.
Problem
WATER LEAKS
LEAKING T&P VALVE
SMELLY WATER
PILOT WILL NOT LIGHT
Cause
Improperly sealed, hot or cold supply connection,
relief valve, or thermostat threads.
Leakage from water lines.
Condensation of flue products.
Thermal expansion in closed water system.
Solution
Tighten thread connections.
High sulfate or mineral content in water supply.
Inspect water lines and connections.
Refer to “Condensation” section.
Install thermal expansion tank (DO NOT plug T&P valve).
Check relief valve for proper operation. Replace if
necessary.
(DO NOT plug T&P valve).
Drain and flush water heater thoroughly, then refill.
Bacteria in water supply.
Gas control knob not positioned correctly.
Main gas supply off.
Chlorinate or aerate water supply.
Refer to “Lighting Instructions”.
Turn off main gas shut-off valve.
Ignitor wire not connected.
Check ignitor wire connection.
Faulty ignitor.
Air in gas line
Dirt in gas line
Replace ignitor.
Bleed the air from the gas line
Notify utility-install dirt trap in gas line
Pilot line or orifice clogged
Cold drafts
Thermostat ECO switch open
Low gas pressure
Clean, locate source and correct
Locate source and correct
Replace thermostat
Check with gas utility company
See maintenance section for inspection and cleaning of
burner
Clean pilot
Replace pilot assembly and/or thermocouple.
Replace Gas Control
Light pilot
Turn temp. dial to desired temperature
Check with gas utility company
Notify utility-inatall trap in gas line
Improperly seated valve.
Combustion air obstructed
Pilot dirty
Thermocouple malfunction.
Defective gas control.
Pilot not lit
Thermostat set too low
No gas
BURNER WILL NOT STAY LIT Dirt in the gas lines
Pilot line clogged
Clean, locate source and correct
Main burner line clogged
Clean, locate source and correct
Non-functioning thermostat
Replace thermostat
Heater installed in a confined area
Provide fresh air ventilation
Thermocouple tip is not in contact with pilot flame. Insert thermocouple correctly.
PILOT OUTAGE
NO HOT WATER
Dirty pilot burner.
Thermocouple malfunction.
Defective gas control.
Pilot not lit or thermostat not on.
Clean pilot assembly.
Replace pilot assembly and/or thermocouple.
Replace gas control.
Refer to “Lighting Instructions”.
Thermostat set too low.
Refer to “Temperature Regulation”
Low gas pressure.
Incoming water is unusually cold.
Contact your gas supplier.
Allow more time for water heater to re-heat.
Leaking hot water pipes or fixtures.
High temperature limit switch activated.
Heater undersized.
Thermostat set too high.
Have plumber to check and repair leaks.
Contact a service agency to determine cause.
Reduce hot water usage.
Refer to “Temperature Regulation”.
WATER HEATER SOUNDS
Condensation dripping on burner.
Refer to “Condensation”.
SIZZLING OR RUMBLING
SOUND
Sediment or calcium in bottom of tank.
NOT ENOUGH HOT WATER
WATER TOO HOT
SOOTING
Improper combustion.
Clean sediment from tank. Refer to “Draining” instructions in the maintenance section of manual.
No adjustment available. Contact a service agency
to determine cause.
Lack of sufficient supply air
VENT GAS ODORS
Improperly installed vent piping.
Contact a qualified service agency to determine cause.
Downdraft.
Poor combustion.
29
NOTES
30
NOTES
31
®Teflon is a registered trademark of E.I. Du Pont De Nemours and Company
A.O. Smith Corporation. All Rights Reserved.
Limited Warranty provided by Manufacturer.
32
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