Residential GasWater Heaterlnstallation

lnstructions and

Not for use in the United States or Canada

WARNING: lf the information in theseinstructions is not followed exactly, a fireor explosion may result causing propertydamage, personal injury or death.

Do not store or use gasoline or otherflammable vapors and liquids in the vicihityof this or any other appliance.

WHAT TO DO IF YOU SMELL GAS. Do not try to light any appliance.. Do not touch any electrical switch;

do not use any telephone in yourbuilding.

. lmmediately call your gas supplierfrom a neighbor's telephone. Followthe gas supplier's instructions.

. lf you cannot reach your gas supplier,call the fire department.

lnstallation and service must be performedby a qualified installer, service agency orthe gas supplier.

To obtain technical, warranty, or service assistance contactplace of purchase or local distributor.

When calling for assistance, please have the followinginformation ready:1 Model number2 7 digit product number

\3. Serial number4. Date of installation5. Place of purchase

Table of Contents 2

651 0308March 2004

Residential GasWater Heaterlnstallation

lnstructions and

Not for use in the United States or Canada

WARNING: lf the information in theseinstructions is not followed exactly, a fireor explosion may result causing propertydamage, personal injury or death.

Do not store or use gasoline or otherflammable vapors and liquids in the vicinityof this or any other appliance.

WHAT TO DO IF YOU SMELL GAS. Do not try to light any appliance.. Do not touch any electrical switch;

do not use any telephone in yourbuilding.

. lmmediately call your gas supplierfrom a neighbor's telephone. Followthe gas supplier's instructions.

. lf you cannot reach your gas supplier,call the fire department.

lnstallation and service must be performedby a qualified installer, service agency orthe gas supplier.

To obtain technical, warranty, or service assistance contactplace of purchase or local distributor.

When calling for assistance, please have the followinginformation ready:1- Model number2 7 digit product number

\3. Serial number4. Date of installation5. Place of purchase

Table of Contents 2

651 0308March 2004

Your safety and the safety of others are very important.We have provided many important safety messages in this manual and on your appliance. Always read and obey allsafety messages.

This is the safety alert symbol.This symbol alerts you to potential hazards that can kill or hurt you and others.All safety messages will follow the safety alert symbol and either the word "DANGER" oT"WARNING" These words mean:

You can be killed or seriously injured if you don'timmediately follow instructions.

You can be killed or seriously injured if you don'tfollow instructions.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell youwhat can happen if the instructions are not followed.

lmportant lnstructionsDo not use this appliance if any part has been under water. lmmediateheaters subjected to flood conditions or anytime the gas controls, mainwater require replacement of the entire water heater.Hydrogen gas can be produced in a hot water system that has not beetwo weeks or more.) Hydrogen gas is extremely flammable and can igtprevent the possibility of injury under these conditions, we recommendminutes at the kitchen sink before using any electrical appliance whichhydrogen is present, there will probably be an unusual sound such as ibegins to flow. Do not smoke or have any open flame near the faucet e

ctionsrmediately call a qualified service technician. Waterl;ols, main burner or pilot have been submerged in

; not been used for a long period of time (generallyrd can ignite when exposed to a spark or flame. Toommend the hot water faucet be opened for severalce which is connected to the hot water system. lfsuch as air escaping through the faucet as water> faucet at the time it is open.

INSTALLING YOUR GAS WATER HEATERConsumer lnformationThis water heater is designed as a Category l, non-directvented water heater which takes its combustion air eitherfrom the installation area or from air ducted to the unit fromthe outside.

This water heater must be installed according to the localauthorities having jurisdiction over your installation. Checkyour phone listings for the local authorities having jurisdictionover your installation.

Gonsumer Responsi bi I itiesThis manual has been prepared to acquaint you with theinstallation, operation, and maintenance of your gas waterheater and provide important safety information in theseareas.

Read all of the instructions thoroughly before attempting_ the installation or operation of this water heater.

\)Dr not discard this manual. You or future users of thiswater heater will need it for future reference.Service to the water heater should only be performedby a qualified service technician.

Examples of qualified service technicians include:those trained in the plumbing and heating industry,local gas utility personnel, or an authorized serviceperson.

The manufacturer and seller of this water heater willnot be liable for any damages, injurl

nOoperating instructions outlined in this manual.lf you lack the necessary skills required to properly installthis water heater, or you have difficulty following theinstructions, you should not proceed but have a qualifiedservice technician perform the installation of this waterheater.

_ A data plate identifying your water heater can be foundyflext to the gas control valve/thermostat. When referring- to your water heater, always have the information listed

on the data plate readily available.

Retain your original receipt as proof of purchase.

Unpacking the Water Heater

lmportant: Do not remove any permanent instructions,labels, or the data label from outside of the water heateror on the inside of panels.. Remove exterior packaging and place installation

components aside.. lnspect all parts for damage prior to installation and

start-up.. Completely read all instructions before attempting

to assemble and rnstall this product.. After installation, dispose of packaging material in

the proper manner.

Excessive Weight HazardUse two or more people to move andinstall water heater unless properhandling equipment is utilized.Failure to do so can result in back orother injury.

AU"Oors from flammable liquids willexplode and catch fire causing death orsevere burns.Do not use or store flammable productssuch as gasoline, solvents or adhesivesin the same room or area near the waterheater.

Keep flammable products:1. far away from heater2. in approved containers,3. tightly closed and4. out of children's reach.Water heater has a main burner and pilotflame. The pilot flame:f . is on all the time and2. will ignite flammable vapors.Vapors:1. cannot be seen,2. are heavier than air,3. go a long way on the floor and4. can be carried from other rooms to

the pilot flame by air currents.Do not install this water heater whereflammable products will be stored.

Location Requirements

Do not use or store flammable products such as gasoline,solvents, or adhesives in the same room or area near thewater heater. If such flammables must be used, all gasburning appliances in the vicinity must be shut off andtheir pilot lights extinguished. Open the doors and windowsfor ventilation while flammable substances are in use.lf flammable liquids or vapors have spilled or leaked inthe area of the water heater, leave the area immediatelyand call the fire department from a neighbor's home. Donot attempt to clean the spill until all ignition sources havebeen extinguished.

Carbon Monoxide Poisoning HazardDo not install in a mobile home.Doing so can result in death or carbonmonoxide poisoning.

lf installation in a garage is the only option, this waterheater must be installed with the bottom no less than 1Binches above the floor (see Figure 1.) This is to reducebut not eliminate the risk of igniting flammable vaporswhich may be present in a garage. The water heatermust be located or protected to avoid physical damageby vehicles or flooding.

Site Location. Select a location near the center of the water piping

system. The water heater must be installed indoorsand in a vertical position on a level surface. DO NOTinstall in bathrooms, bedrooms, or any other occupiedroom normally kept closed.

with minimal length and elbows.. Locate the water heater near the existing gas piping.

lf installing a new gas line, locate the waler heaier [ominimize the pipe length and elbows.

Note: For local installation requirements see "Consumerlnformation" page 3.

lmportant: The water heater should be located in anarea where leakage of the tank or connections will notresult in damage to the area adjacent to the waterheater or to lower floors of the structure. Due to thenormal corrosive action of the water, the tank willeventually leak after an extended period of time.Also any external plumbing leak, including thosefrom improper installation, may cause early failureof the water tank due to corrosion if not repaired.lf the homeowner is uncomfortable with makingthe repair a qualified service technician should becontacted. A suitable metal drain pan should beinstalled under the water heater as shown below, tohelp protect the property from damage which mayoccur from condensate formation or leaks in the pipingconnections or tank. The pan must limit the water levelto a maximum depth of 1-314" and be two inches widerthan the heater and piped to an adequate drain. Thepan must not restrict combustion air flow. Locatethe water heater near a suitable indoor drain. Outsidedrains are subject to freezing temperatures which canobstruct the drain line. The piping should be at least314" lD and pitched for proper drainage. Under nocircumstances will the manufacturer or seller of thiswater heater be held liable for any water damage whichis caused by your failure to follow these instructions.

Pipe toadequate

drain

(D

The water heater should be located in an area notsubject to freezing temperatures. Water heaters locatedin unconditioned spaces (i.e., attics, basements, etc.)may require insulation of the water piping and drainpiping to protect against freezing. The drain andcontrols must be easily accessible for operation andservice. Maintain proper clearances as specified onthe data plate.

Do not locate the water heater near an air-movingdevice. The operation of air-moving devices such asexhaust fans, ventilation systems, clothes dryers, fire-places, etc., can affect the proper operation of thewater heater. Special attention must be given toconditions these devices may create. Flow reversalofflue gases may cause an increase of carbonmonoxide inside of the dwelling (see Figure 2.)

Figure 2Air-movingDevices

Glearances and AccessibilityNotice: Minimum clearances from combustible materialsare stated on the data plate adjacent to the thermostat ofthe water heater.. The water heater is certified for installation on a

combustible floor.

lmportant: lf installing over carpeting, the carpeting mustbe protected by a metal or wood panel beneath the waterheater. The protective panel must extend beyond the fullwidth and depth of the water heater by at least threeinches (76.2mm) in any direction; or if in a alcove or closetinstallation, the entire floor must be covered by the panel.

Figure 3 may be used as a reference guide to locate thespecific clearance locations. A minimum of 24 inches offront clearance should be provided for inspection andservtce.

High Altitude lnput RatingThe input rating on the data plate of this water heater isfor installations up to 2000 feet of elevation. For installationsat elevations above 2000 feet, the rating should be reducedby 4 percent for each 1000 feet above sea level.

Figure 3Minimum ClearanceLocations

Top tView I

Explosion HazardUse a new AGA or GsAapproved gassupply line.lnstall a shut-off valve.Do not connect a natural gas waterheater to a L.P. gas supply.Do not connect a L.P. gas water heater toa natural gas supply.Failure to follow these instructions canresult in death, explosion, or carbonmonoxide poisoning.

Gas RequirementsRead the data plate to be sure the water heater ismade for the type of gas you will be using in yourhome. This information wilf be found on the-datjplatelocated near the gas control valve. lf the informatioh doesnot agree with the type of gas available, do not install orlight. Call your dealer.

Note: An odorant is added by the gas supplier to the gasused by this water heater. This odorant rir'ay fade ove"ran extended period of time. Do not depend upon thisodorant as an indication of leaking gad.

Gas PipingThis.gas piping must be installed according to allrequirements by the local authorities having jurisdictionover your installation.

Tables 1 and2 on page 7 are provided as a sizingreference for commonly used gas pipe materials. ionsultthe "National Fuel Gas Code'-for ihe recommended gaspipe size of other materials.Refer to Figure 4Note: When installing gas piping, apply approved pipejoint compound.1. lnstall a readily accessible manual shut-off valve in

the gas supply line as recommended bv the localutility. Know the location of this valve and how to turnoff the gas to this unit.

2

3

4

Figure 4Gas Piping

Manual Gas

Drip leg

Shut-off Valvel

Check withlocal utilitvfor min. h6ight

| 3 min.uI 17"f.

Ground

Gas Pressurelmportant: The gas supply pressure must not exceedthe maximum supply pressure as stated on the waterheater's data plate. The minimum supply pressure is forthe purpose of input adjustment.

Gas Pressure Testinglmportant: This water heater and its gas connectionmust be leak tested before placing the appliance in \operation.

lf the code requires the gas lines to be tested at a pressureexceeding 14" W .C., the water heater and its manualshuloff valve must be disconnected from the gas supplypiping system and the line capped.lf the gas lines are to be tested at a pressure less than14" W.C., the water heater must be isolated from thegas supply piping system by closing its manual shut_offvalve.

U.L. recognized fuel gas and carbon monoxide (CO)detectors are recommended in all applications and shouldbe installed using the manufacturer,s instructions andlocal codes, rules, or regulatrons.

Note: Air may be present in the gas lines and couldprevent the pilot from lighting on initial start_up. The gaslines should be purged of air by a qualified service -technician after installation of the gas piping system.

LP Gas

Explosion HazardHave a qualified service technician makesure L.P. gas pressure does not exceed13" water column.Failure to do so can result in death,explosion, or fire.

Table 1Natural Gas Pipe Capacity Tabte (Cu. Ft./Hr.)Cglqgty of gas pipe of different diameters and lengths in cuof 0.60 (natural gas.)

ft. per hr with pressure drop of 0.3 in. and specific gravity

100 125 150 't75 2001123t4

1

1-1t41-1t2

132278520

1 0501 600

92190350730

1100

73152285590890

63130245500760

56115215440670

50105195400610

4696

180370560

4390

170350530

4084

160320490

3879

'150

305460

3472

'130

275410

3164

120250380

2859

110225350

2655

100210320

After the length of pipe has been determined, select the-pipe size which will provide the minimum cubic feet per hourrequired for the gas input rating of the water heater. By fbrhula:

Min. Cu Ft. Per Hr. Required=

The gas input of the water heater is marked on the water.heater data plate. The heating value of the gas (BTU/FT )may be determined by consulting the local natural gas utility.

Gas lnput of Water Heater (BTU/HR)Heati n g Va I ue o-GaslBTUffi

tl'

Additional tables are available in the latest edition of the "National Fuel Gas Code", ANSI 2223.1 .

Table 2LP Gas Capacity TableMaximum capacity of pipe in thousands of BTU- pe1 .hoyr of undiluted liquefied petroleum gases (at 1 1 inches watercolumn pressure.) Based on a pressure drop of b.5 inch water column.

4030Length of Pipe, Feet50 60 70 {Rn1nn ,tr4qn80

1t23t4

1

1-1t4

275576

107 12205

189393732

1496

152315590

1212

129267504

1 039

114237448913

103217409834

96196378771

89185346724

83173322677

78162307630

69146275567

63132252511

Example: lnput BTU requirement of the water heater 100.000 BTUH.totat pipe length, 80 feet = 3/4" lpS required.

Combustion Air Supply andVentilation

Carbon Monoxide WarningFollow all vent system requirements bythe local authorities having jurisdictionover your installation.Failure to do so can result in death,explosion, or carbon monoxide poisoning.

lmportant: Air for combustion and ventilation must notcome from a corrosive atmosphere. Any failure due toconosive elements in the atmosphere is excluded fromwarranty coverage.

The following types of installation (not limited to thefollowing) will require outdoor air for combustion due tochemical exposure and may reduce but not eliminate thepresence of corrosive chemicals in the air:. beauty shops. photo processing labs. buildings with indoor pools

l"

. water heaters installed in laundry, hobby, or craftrooms

. water heaters installed near chemical storage areasCombustion air must be free of acid-forming chemicalssuch as sulfur, fluorine, and chlorine. These elements arefound in aerosolsprays, detergents, bleaches, cleaningsolvents, air fresheners, paint, and varnish removers,refrigerants, and many other commercial and householdproducts. When burned ts formhighly corrosive acid co shouldnot be stored or used n inlet.Combustion and ventilation air requirements aredetermined by the location of the water heater. The waterheater may be located in either an open (unconfined) areaor in a confined area or small enclosure such as a closetor small room. Confined spaces are areas with less than50 cubic feet for each 1,000 BTUH of the total input forall gas-using appliances.

Unconfined SpaceA water heater in an unconfined space uses indoor air forcombustion and requires at least 50 cubic feet for each1,000 BTUH of the total input for all gas appliances. Thetable below shows a few examples of the minimum squarefootage (area) required for various BTUH inputs.

lmportant:. The area must be open and be able to provide the

proper air requiremenfs to the water heater. Areasthat are being used for storage or contain large objectsmay not be suitable for water heater installation.

. Water heaters installed in open spaces in buildingswith unusually tight construction may still requireoutdoor air to function properly. ln this situation, outsideair openings should be sized the same as for a conflnedspace.

. Modern home construction usually requires supplyingoutside air into the water heater area.

Confined SpaceFor the correct and proper operation of this waterheater, ample air must be supplied for the combustion,ventilation, and dilution of flue gases. Small enclosuresand confined areas must have two permanent openingsso that sufficient fresh air can be drawn from outside ofthe enclosure. One opening shall be within 12 inches ofthe top and one within 12 inches of the bottom of theenclosure as shown in Figure 5.

The size of each opening (free area) is determined by tl'etotal BTUH input of all gas utilization equipment (i.e., waterheaters, furnaces, clothes dryers, etc.) and the methodby which the air is provided. The BTUH input can be foundon the water heater data plate. Additional air can beprovided by two methods:

1. All air from inside the building.2. All air from outdoors.

Table 3

BTUH Min. Sq. Feet with Typical Roomlnput 8'Ceiling with 8'Ceiling

30,000 188 9 x2145,000 281 14 x2060,000 375 15 x2575,000 469 15 x 3190,000 563 20 x2B105,000 657 20 x 33120,000 750 25 x 30135,000 844 28 x 30

Permanentopenings tothe outside oradditionalrooms withinthe building

12" maximum

Closetor

otherconfined

space

All Air from lnside the BuildingWhen additional air is to be provided to the confined areafrom additional room(s)within the building, the total volumeof the room(s) must be of sufficient size to properly providethe necessary amount of fresh air to the water heater andother gas utilization equrpment in the area. lf you are Lunsure that the structure meets this requirement, contactyour local gas utility company or other qualified agencyfor a safety inspection.

Each of the two openings shall have a minimum freearea of 1 square inch per 1,000 BTUH of the total inputrating of all gas utilization equipment in the confinedarea, but not less than 100 square inches (Figure 6.)

1 squareinch/1 000BTUH(min 100sq. ln.)

Figure 6All Air from lnside BuildingConfi ned Space lnstallation

All Air from OutdoorsOutdoor fresh air can be provided to a confined areaeither directly or by the use of vertical and horizontalducts. The fresh air can be taken from the outdoors orfrom crawl or attic spaces that freely communicate withthe outdoors. Attic or crawl spaces cannot be closed andmust be properly ventilated to the outside.

Ductwork must be of the same cross-sectional area asthe free area of the opening to which they connect. Theminimum dimension of rectangular air ducts cannot beless than three inches.

The size of each of the two openings is determined bythe method in which the air is to be provided. Refer toTable 4 to calculate the minimum free area for eachopening. Figures 7, 8, and 9 are typical examples of eachmethod.

Louvers and Grillesln calculating free area for ventilation and combustion airsupply openings, consideration must be given to the

. .blocking effect of protection louvers, grilles, and screens.l[hese devices can reduce airflow, which in turn may

require larger openings to achieve the required minimumfree area. Screens must not be smaller than 114" mesh.lf the free area through a particular design of louver orgrille is known, it should be used in calculating the specifiedfree area of the opening. lf the design and free area arenot known, it can be assumed that most wood louverswill allow 20 - 25o/o of free area while metal louvers andgrilles will allow 60 -75% of free area.Louvers and grilles must be locked open or interconnectedwith the equipment so that they are opened automaticallyduring equipment operation.

Keep louvers and grilles clean and free of debris or otherobstructions.

* These openings connect directly with the outdoorsthrough a ventilated attic, a ventilated crawlspace, orthrough an outside wall.

Consult the local codes of your area for specific ventilationand combustion air requirements.

AlternateAir Inlet

Outletair to attic1 Sq. inch per4OOO BTUH

lnlet airfrom thecrawlspace

VentFigure 7All Air from Outdoors; lnlet Air from VentilatedCrawl Space/Outlet Air to Ventilated Attic

Figure8 \12"max.All Air from Outdoors

ConfinedSpace

Outlet airto attic1 Sq. inch per4OOO BTUH

lnlet air duct1 sq. inch per4OOO BTUH

Table 4

Minimum Free Area of Permanent Openings for Ventilation andCombustion Air Supply - All Air from Outdloors Only.

Based on the total BTUH input rating for all gas utilizing equipmentwithin the confined space.

OpeningSource

Minimum Free AreaPer Opening

(sq. rn. )ReferenceDrawing

+ Direct tooutdoors

1 Square inch per 4000BTUH

Figure 7

Vertical ducts 1 Square inch per 4000BTUH

Figure 8

Horizontal ducts 1 Square inch per 2000BTUH

Figure 9

Example: A water heater with an input rate of 50,000 BTUH usinghorizontal ducts would require each opening to have a minimum-free area of 25 square inches.Minimum free area = 50,000 BTUH x 1 sq. in / 2000 BTUH = 25Sq. lnches. Figure 9

All Air from OutdoorsUsing Horizontal Ducts

I

I

Vent Pipe SystemThis water heater uses a non-direct, single-pipe ventsystem to remove exhaust gases created by the burningof fossil fuels. Air for combustion is taken from theimmediate water heater location or is ducted in from theoutside (see "Combustion Air Supply and Ventilation".)This water heater must be properly vented for the removalof exhaust gases to the outside atmosphere. Correctinstallation of the vent pipe system is mandatory for theproper and efficient operation of this water heater and isan important factor in the life of the unit.The vent pipe must be installed according to allrequirements by the local authorities having jurisdictionover your installation. The vent pipe installation must notbe obstructed so as to prevent the removal of exhaustgases to the outside atmosphere.

U.L. recognized fuel gas and carbon monoxide (CO)detectors are recommended in allapplications and shouldbe installed using the manufacturer's instructions andlocal codes, rules, or regulations.

lmportant: lf you lack the necessary skills required toproperly install this venting system, you should notproceed, but get help from a qualified service technician.

Drafthood lnstallationAlign the legs of the drafthood with the slots provided.lnsert the legs and secure the drafthood to the waterheater's top with the four screws provided as shown inFigure 10. Do not alter the drafthood in any way. lf youare replacing an existing water heater, be sure to use thenew drafthood supplied with the water heater.

Figure 10Drafthood lnstallation

lnstall the drafthood withthe four screws provided

Sheet Metal Screws (four provided)

Gontaminants in the gas piping may foulthe thermostat causing a malfunction, fire,or explosion. Be sure all gas piping isclean and clear on the inside beforeattaching the gas line.

10

Vent Pipe SizeThe sizing of this vent system must be installed accordingto all requirements by the local authorities having jurisdictionover your installation. lt is important that you follow theguidelines in these instructions for sizing a vent pipesystem. lf a transition to a larger vent size is required, thevent transition connection must be made at the drafthoodoutlet.

Vent Gonnectors1. Type B, Doublewall, U.L. Listed Vent Pipe.2. Singlewall Vent Pipe.Maintain the manufacturer's specified minimum clearancefrom combustible materials when using type B doublewallvent pipe.

Vent connectors made of type B, doublewall vent pipematerial may pass through walls or partitions constructedof combustible material, if the minimum listed clearanceis maintained.

Maintain a six inch minimum clearance from all combustiblematerials when using singlewall vent pipe. \*,lmpoftant: Singlewall vent pipe cannot be used for waterheaters located in attics and may not pass through atticspaces, crawl spaces or any confined or inaccessiblelocation. A singlewall metal vent connector cannot passthrough any interior wall.

When installing a vent connector, please note the following:. lnstall the vent connector avoiding unnecessary bends,

which create resistance to the flow of vent gases.. lnstall without dips or sags with an upward slope of

at least 1i4-inch per foot.. Joints must be fastened by sheet metal screws or

other approved means. lt must be supported tomaintain clearances and prevent separation of jointsand damage.

. The length ofthe vent connector cannot exceed 75%of the vertical vent height.

. The vent connector must be accessible for cleaning,inspection, and replacement. \.-

. Vent connectors cannot pass through any ceiling,floor, firewall, or fire partition.

lmportant: Existing vent systems must be inspected forobstructions, corrosion, and proper installation.

Chimney Gonnectionlmportant: makesure the chobstruction iouslyused for ve. The connector must be installed above the extreme

bottom of the chimney to prevent potential stoppageof the flue gases.

. The connector must be firmly attached and sealed toprevent it from falling out.

. To aid in removing the connector, a thimble or slipjoint may be used.

. The connector must not extend beyond the inner edgeof the chimney as it may restrict the space betweenit and the opposite wall of the chimney (Figure 11.)

Do not terminate the vent connector in a chimney that hasnot been certified for this purpose. Some local codes mayprohibit the termination of vent connectors in a masonrychimney.

Vertical Exhaust Gas VentVertical exhaust gas vents must be installed with U.L.listed type B vent pipe according to the vent manufacture/sinstructions and the terms of its listing.It must be connected to the water heater's drafthood bya certified vent connector or by direcfly originating at thedrafthood opening.

Vertical gas vents must terminate with a listed cap or otherroof assembly and be installed according to theirmanufacturer's instructions.

Gas vents must be supported to prevent damage, jointseparation, and maintain clearances to combustiblematerials (Figures 12 and 13.)lmportant: This gas vent must be terminated in a verticalposition to facilitate the removal of the burnt gases.An unused chimney flue or masonry enclosure may beused as a passageway for the installation of a gas vent(Figure'13.)

lpommon (combined)venting is allowable with vertical- type B vent systems and lined masonry chimneys.Figures 1 1-installations ificapplication. onover your inexamples.

Figure 11Chimney TerminationVent System

l

IMaintain 3fI.min. J

Figure 12Vertical GasVent SystemWith Type BDouble WallVent Pipe

Maintainclearance

+

s/l Listea Vent CaP

2 ft. min above any object-r--^ within 10 ft.horizontally

Type B DoubleWall Vent Pipe

Maintainspecifiedclearance

tVent

connectorslope up

114 in. perft. min

+

Figure 13Venting Througha Chimneywith Type BDoublewallVent Pipe.

Maintainclearance

t'Slope u

114 in.per

ft. min.

+

\

11

:l

-.

Water System PipingPiping lnstallationPiping, fittings, and valves should be installed accordingto the installation drawing (Figure 14.) lf the indoorinstallation area is subject to freezing temperatures, thewater piping must be protected by insulation.

Water supply pressure should not exceed 80% of theworking pressure of the water heater. The working pressureis stated on the water heater's data plate. lf this occurs,a pressure limiting valve with a bypass may need to beinstalled in the cold water inlet line. This should be placedon the supply to the entire house in order to maintainequal hot and cold water pressures.

lmportant: Heat cannot be applied to the water fittingson the heater as they may contain nonmetallic parts. lfsolder connections are used, solder the pipe to the adapterbefore attaching the adapter to the hot and cold waterfittings.

lmportant: Always use a good grade of joint compoundand be certain that all fittings are drawn up tight.

1. lnstall the water piping and fittings as shown in Figure14. Connect the cold water supply (3/4" NPT)to thefitting marked "C". Connect the hot water supply (3/4"NPT) to the fitting marked "H".

lmportant: Some models may contain energy savingheat traps to prevent the circulation of hot water withinthe pipes. Do not remove the inserts within the heat traps.

2. The installation of unions in both the hot and coldwater supply lines is recommended for ease ofremoving the water heater for service or replacement.

3. The manufacturer of this water heater recommendsinstalling a tempering valve or an anti-scald device inthe domestic hot water line as shown in Figure 15.These valves reduce the point-of-use temperature ofthe water by mixing cold and hot water and are readilyavailable for use.

4. lf installing the water heater in a closed water system,install an expansion tank in the cold water line asspecified under "Closed System/Thermal Expansion"(Page 13.)

5. lnstall a shut-off valve in the cold water inlet line. ltshould be located close to the water heater and beeasily accessible. Know the location of this valve andhow to shut off the water to the heater.

6. lnstall a temperature and pressure relief valve in theopening marked "Temperature and Pressure (T & P)Relief Valve" on the water heater. Add a dischargeline to the opening of the T & P relief valve. Followthe instructions under "Temperature and PressureRelief Valve" (Page 14.)

7. After piping has been properly connected to the waterheater, remove the aerator at the nearest hot waterfaucet. Open the hot water faucet and allow the tankto completely fill with water. To purge the lines of anyexcess air, keep the hot water faucet open for threeminutes after a constant flow of water is obtained.Close the faucet and check all connections for leaks.

Figure 15Typical TemperingValve lnstallation

Follow the temperingvalve manufacturer'sinstructions.

Tempered waterto fixtures

12

Please note the following:

DO NOT install this water heater with iron piping. Thesystem should be installed only with piping that is suitabbfor potable (drinkable)water such as copper, CPVC, orpolybutylene. DO NOT use PVC water piping.

DO NOT use any pumps, valves, or fittings that are notcompatible with potable water.

DO NOT use valves that may cause excessive restrictionto water flow. Use full flow ball or gate valves only.

DO NOT use 50/50 tin-lead solder (or any lead basedsolder) in potable water lines. Use 95/5 tin-antimony orother equivalent material.

DO NOT tamper with the gas valve/thermostat, igniter,thermocouple, or temperature and pressure relief valve.Tampering voids allwarranties. Only qualified servicetechnicians should service these components.

DO NOT use with piping that has been treated withchromates, boiler seal, or other chemicals.

DO NOT add any chemicals to the system piping which-1,will contaminate the potable water supply.t

f-13

-l

Glosed System/Thermal ExpansionPeriodic discharge of the temperature and pressurerelief valve may be due to thermal expansion in a closedwater supply system. The water utility supply meter maycontain a check valve, backflow preventer or water pressurereducing valve. This will create a closed water system.During the heating cycle of the water heater, the waterexpands causing pressure inside the water heater toincrease. This may cause the temperature and pressurerelief valve to discharge small quantities of hot water. Toprevent this, it is recommended that a diaphragmtypeexpansion tank (suitable for potable water) be installedon the cold water supply line. The expansion tank musthave a minimum capacity of 1.5 U.S. gallons for every 50gallons of stored water. Contact the local water supplieror plumbing inspector for information on other methodsto control this situation.

lmportant: Do not plug or remove the temperatureand pressure relief valve.

Temperature and PressureRelief Valve

For protection against excessive pressures andtemperatures, a temperature and pressure relief valvemust be installed in the opening marked 'T & P RELIEFVALVE" (see Figure 16.) This valve must be designcertified by a nationally recognized testing laboratory thatmaintains periodic inspection of the production of listedequipment or materials as meeting the requirements forRelief Valves and Automatic Shut-off Devices for HotWater Supply Systems, ANSI 221 .22.fhe function of thetemperature and pressure relief valve is to dischargewater in large quantities in the event of excessivetemperature or pressure developing in the water heater.The valve's relief pressure must not exceed the workingpressure of the water heater as stated on the data plate.

Explosion Hazardlf the temperature and pressure reliefvalve is dripping or leaking, have aqualified service technician replace it.

. Do not plug valve.

. Do not remove valve.Failure to follow these instructions canresult in death or explosion.

Optional locationsome models only

Temperature andPressure Relief Valve

Discharge line 3/4" minDo not cap or plug.

6" max.

-f-I

Drain Pan

Figure 15Temperature and PressureRelief Valve lnstallation

14

lmportant: Only a new temperature and pressure reliefvalve should be used with your water heater. Do not usean old or existing valve as it may be damaged or notadequate for the working pressure of the new water heater.Do not place any valve between the relief valve and thetank.

The Temperature & Pressure Relief Valve:. Must not be in contact with any electrical part.. Must be connected to an adequate discharge line.. Must not be rated higher than the working pressure

shown on the data plate of the water heater.

The Discharge Line:. Must not be smaller than the pipe size of the relief

valve or have any reducing coupling installed in thedischarge line.

. Must not be capped, blocked, plugged or contain anyvalve between the relief valve and the end of thedischarge line.

. Must terminate a maximum of six inches above a floordrain or external to the building.

. Must be capable of withstanding 250"F (121'C) withoutdistortion.

. Must be installed to allow complete drainage of boththe valve and discharge line.

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Special ApplicationsCombination Space Heating/PotableWater SystemSome water heater models are equipped with inleUoutlettappings for use with space heating applications. lf thiswater heater is to be used to supply both space heatingand domestic potable (drinking)water, the instructionslisted below must be followed.. Be sure to follow the manual(s)shipped with the air

handler system.. This water heater is not to be used as a replacement

for an existing boiler installation.. Do not use with piping that has been treated with

chromates, boiler seal or other chemicals and do notadd any chemicals to the water heater piping.

. lf the space heating system requires watertemperatures in excess of 120"F (49'C), a temperingvalve or an anti-scald device should be installed perits manufacturer's instructions in the domestic (potable)hot water supply to limit the risk of scald injury seeFigure 16.

Pumps, valves, piping and fittings must be compatiblewith potable water.

A properly installed flow control valve is required toprevent thermosiphoning. Thermosiphoning is theresult of a continuous flow of water through the airhandler circuit during the off cycle. Weeping (blow off)of the temperature and pressure relief valve (T & P)or higher than normal water temperatures are the firstsigns of thermosiphoning.

The domestic hot water line from the water heatershould be vertical past any tempering valve or supplyline to the air handler to remove air bubbles from thesystem. Othenrvise, these bubbles will be trapped inthe air handler heat exchanger coil, reducing theefficiency.

Do not connect the water heater to any system orcomponents previously used with non-potable waterheating appliances when used to supply potable water.

J

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15

Some jurisdictions may require a backflow preventer inthe incoming cold water line. This may cause thetemperature and pressure relief valve on the water heaterto discharge or weep due to expansion of the heatedwater. A diaphragmtype expansion tank suitable forpotable water will normally eliminate this weeping condition.Please read and follow the manufacturer's instructions forthe installation of such tanks.

Also see "Water System Piping" (Page 12) for additionalinstructions on the safe and correct installation andoperation of this water heater.

Must be vertical toremove air bubbles

Flow Control

Solar lnstallationlf this water heater is used as a solar storage heater oras a backup for the solar system, the water supplytemperatures to the water heater tank may be in excessof 120"F (49'C). A tempering valve or other temperaturelimiting valve must be installed in the water supply line tolimit the supply temperature to 120"F (49'C).

Note: Solar water heating systems can often supply waterwith temperatures exceeding 180'F (83'C) and may resultin water heater malfunction.

Installation Gheckl istWater Heater Location. Centrally located with the water piping system. Located

as close to the gas piping and vent pipe system aspossible.

Located indoors and in a vertical position. Protectedfrom freezing temperatures.

Proper clearances from combustible surfacesmaintained and not installed directly on a carpetedfloor.

Provisions made to protect the area from waterdamage. Drain pan installed and piped to an adequatedrain.

lnstallation area free of corrosive elements andflammable materials.

Sufficient room to service the water heater.

Water heater not located near an air moving device.

Gombustion Air Supply and VentilationSufficient fresh air supply for proper water heateroperation.

Fresh air not taken from areas that contain negativepressure producing devices such as exhaust fans,fireplaces, etc.

Fresh air supply free of corrosive elements andflammable vapors.

Fresh air openings sized correctly with considerationgiven to the blocking effect of louvers and grilles.

Ductwork is the same cross-sectional area as theopenrngs.

16

Vent Pipe SystemDrafthood properly installed.

Vent connectors securely fastened with screws andsupported properly to maintain six inch clearance.

Vent connector made of approved material and sizedcorrectly.

Vent pipe system must be installed according to allrequirements by the local authorities having jurisdictionover your installation.

Flue baffle engaged in slots provided in the flue tube.

Flue way, drafthood, or vent pipe system not obstructedrn any way.

Water System Piping. Temperature and pressure relief valve properly installed

with a discharge line run to an open drain and protectedfrom freezing.

. All piping properly installed and free of leaks. \

. Heater completely filled with water.

. Closed system pressure build-up precautions installed.

. Tempering valve installed per manufacturer'sinstructions.

Gas Supply and Piping. Gas supply is the same type as listed on the water

heater data plate.. Gas line equipped with shut-off valve, union, and drip

leg.

. Approved pipe joint compound used.Adequate pipe size and of approved material.

Chloride-free soap and water solution or other approvedmeans used to check all connections and fittings forpossible gas leaks.

OPERATING YOUR WATER HEATERLighting lnstructionsRead and understand these directions thoroughly beforeattempting to light or re-light the pilot. Make sure the tankis completely filled with water before lighting the pilot.Check the data plate near the gas control valve/thermostatfor the correct gas. Do not use this water heater with anygas other than the one listed on the data plate. lf you haveiny questions or doubts, consult your gas supplier or gasutility company.

L.P.G. (Bottled ProPane) ModelsLiquefied petroleum gas is over 50% heavier than air andin the occurrence of a leak in the system, the gas willsettle at floor level. Basements, crawl spaces, skirtedareas under mobile homes (even when ventilated), closetsand areas below ground level will serye as pockets forthe accumulation of gas. Before lighting an L.P. gas waterheater, smell all around the appliance at floor level. lf yousmell gas, follow the instructions as given in the warningon the front page.

When your L.P. tank runs out of fuel, turn off the gas atall gas appliances including pilot lights. After the tank tsrefilled, ali appliances must be re-lit according to theirmanufactu rer's instructions.

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Figure 18A: Water Heaters Without Piezio lgniter

LIGHTING INSTRUCTIONS

1.STOP! lt is imperative that you read all thesafety warnings before lighting the pilot.

2. Remove outer and inner doors.

3.Turn temperature dial counter'clockwise Oto lowest setting.

7.Turn the gas controlknob counterclockwise6: to "PILOT" Position.

R Liqht match and hold to-'piiot. While holding the lighted match toirilot, depress reset-button all the .way; holdirntil.pildt lights. Continue to hold the buttonfor aliout (1| minute after the pilot is lighted.Release the'reset button and it will pop backup. Pilot should remain lit. lf the pilot lightgbes out, repeat stePs 3 through 8.

* lf reset button does not pop up whenreleased, stop and immediately shut- off gasahead of contiol at line valve or tank' Call yourservice technician or gas supplier.

* lf the pilot will not stay lit after several tries,turn tlie gas control knob clockwise O -to"OFF" position and callyour service technicianor gas supplier.

RESET BUTTONi3o'F (54'c)

.l'o%t tot'"t

GAS{- cotrnol. KNOB

130'F (54")BAR

TEMPERATURE DIAL

4.Turn qas control knobclockivise 2 to the"OFF" position.

5.To clear any gas thatmay have accumulatedwait ten (10) minutes. lf

$.Replace the inner door.

10.Turn the gas controlknob counterclockwiseG to "ON" position.

1 1 .Set temperature dialto desired setting.

l2.Replace outer door.

you then smellgas, STOP! Followtheinstructions as given in the warning onthe front page.

6.rino pilot - follow thesmaller metal tube fromthe thermostat to thepilot.

TO TURN OFF GAS TO APPLIANCE1 .Tulrt temperattrre dial counter-clockwise G 2. Turn gas controlknob clockwise 2

to "OFF" position.to lowest setting.

17

OPERATING YOUR WATER HEATERFigure 188: Water Heaters With Piezio lgniter

TO TURN OFF GAS TO APPLIANCE

Turn the temperature dial counterclockwisefl toits lowest setting,

2. Turn the gas control knob clockwise ft to the"0FF" position,

LIGHTING INSTRUCTIONS

2.

3,

STOPI lt is imperative that you read all the safety

warnings before lighting the pilot.

Remove the outer and inner doors'

Turn the temperature dial counterclockwise f\to its lowest setting,

Turn qas control knobclockfrise A to the "OFF"position,

To clear any gas that maY haveaccumulated wait ten (10) minutes. lfyou then smellgas, STOP! Followtheinstructions as given in the warning onthe front page.

Turn the qas control knobcounterciockwise f\ tothe "PlLOT" position,

(1) minute after the Pilot is lit'Rebase the reset button and it willpop back up, Pilot should remainiit, ttttre pilot light goes out, repeatsteps 3-7,

IMPORTANT: lf the pilot will not stay lit after several

tries, turn gas control knob to "OFF" and call your

service technician or gas supplier'

IMPORTANT lf the reset button does not pop up when

released, stop and immediately shut off the gas at the

line valve or tank, Gall your service technician or gas

supplier,

8, Replace the inner door.9, Turn the gas control knob

counterclockwise flto the "0N" position,

10, Reset the temPeraturedial to the desired setting'

11, Replace the outer door.

120'F (49'C)BAR

RESETBUTTON

1B

Ghecking the Draft

Burn Hazardnot touch vent.

so can result in burns.

After successfully lighting the water heater, allow the unitto operate for 15 minutes and check the drafthood reliefopening for proper draft. Pass a match flame around therelief opening of thedrafthood (see Figure 19.)A steady flame drawn intothe opening indicates properdraft. lf the flame flutters oris blown out, combustionproducts are escaping fromthe relief opening. lf thisoccurs. donotooeratethe 4

]*, heater.until proper adjustments or repairs are madeto the vent pipe system.

Burner Flameslnspect the burnerflames through theviewport and comparethem to the drawings inFigure 20. A properlyoperating burnershould produce a softblue flame. Blue tipswith yellow inner conesare satisfactory. The tips of the flame may have a slightyellow tint. The flame should not be all yellow or have asharp blue-orange color. Contaminated air may cause anorange colored flame. Contact a qualified service tecfrnicianif the flame is not satisfactory.

Stackingftacking occurs when a series of short draws of hot waterft gallons or less) are taken from the water heater tank.

This causes increased cycling of the bumer and can resultin increased water temperatures at the hot water outlet.An anti-scald device is recommended in the hot watersupply line to reduce the risk of scald injury.

Emergency Shut Downlmportant: Should overheating occur or the gas supplyfails to shut off, turn off the water heater's manual gascontrol valve and call a qualified service technician.

Figure 20Flame Characteristics

lncorrcct flamelazy yellow

c

f19

Water Temperature Regulation

The thermostat is adjusted to its lowest temperature whenit is shipped from the factory. Water temperature can beregulated by moving the temperature dial to the preferredsetting. The preferred starting point is 120"F (49"C). Alignthe index bar on the thermostat with the desired watertemperature as shown in Figure 21. There is a hot waterscald potential if the thermostat is set too high.

lmportant: Adjusting the thermostat past the 120'F (49'C)bar on the temperature dial will increase the risk of scaldinjury. Hot water can produce first degree burns within:

120"F (49'C) more than 5 minutes130"F (54'C) al20 seconds140'F (60"C) at 3 seconds150'F (66"C) al1-112 seconds160'F (71'C)at less than 1 second

Note: During low demand periods when hot water is notbeing used, a lower thermostat setting will reduce energylosses and may satisfy your normal hot water needs. lfhot water use is expected to be more than normal, a higherthermostat setting may be required to meet the increaseddemand. When leaving your home for extended periods(vacations, etc.)turn the temperature dial to its lowestsetting. This will maintain the water at low temperatureswith minimum energy losses and prevent the tank fromfreezing during cold weather.

Water temperature over 125"F (52"C) cancause severe burns instantly or death fromscalds.Children, disabled and elderly are at highestrisk of being scalded.Feel water before bathing or showering.Tempering valves are recommended.

Figure 21Robertshaw Gas Valve/Thermostat

130'F (54"C)Bar

130"F (s4'C)

) ry

Operational Cond itionsGondensationMoisture from the products of combustion condenses onthe tank sudace and the outside jacket of the water heaterand forms drops of water which may fall onto the burneror other hot surfaces. This will produce a "sizzling" or"frying" noise. This condensation is normal and shouldnot be confused with a leaking tank. Condensation mayincrease or decrease at different times of the year.

High efficient energy saver water heaters will producelarger amounts of condensation on initial start-up or whena large amount of hot water is being used. Do not confusethis with a "tank leak". Once the water reaches atemperature of 120"F (49'C) and the tank warms up(usually 1-2 hours), the condensation will stop.

lmportant: lt is always recommended that a suitable drainpan be installed under the water heater to protect the areafrom water damage resulting from normal condensationproduction, a leaking tank or piping connections. Refer to"Location Requirements" on page 4. Under nocircumstances is the manufacturer to be held responsiblefor any water damage in connection with this water heater.

Water Heater SoundsDuring the normal operation of the water heater, soundsor noises may be heard. These noises are common andmay result from the following:

1. Normal expansion and contraction of metal partsduring periods of heat-up and cool-down.

2. Condensation causes sizzling and popping within theburner area and should be considered normal.

3. Sediment buildup in the tank bottom will create varyingamounts of noise and may cause premature tankfailure. Drain and flush the tank as directed under"Draining and Flushing".

Smoke/OdorThe water heater may give off a small amount of smokeand odor during the initial start-up of the unit. This is dueto the burning off of oil from metal parls of a new unit andwill disappear after a few minutes of operation.

Safety Shut-offThis water heater is designed to automatically shut-off inthe event of the following:

1. The pilot flame is extinguished for any reason.2. The water temperature exceeds 180'F (83'C.)A thermocouple is used to determine if a pilot flame ispresent and will shut off the gas supply to the main burnerand the pilot burner if the flame is absent.

20

A high temperature limit switch or ECO (Energy Cut Off)in lhe tank is used to shut off the unit if the watertemperature exceeds 180'F (83"C.) The ECO is a singleuse switch and requires complete replacement of theentire thermostat. lf the ECO should function, the waterheater cannot be used untilthe thermostat is replaced bya qualified service technician. Contact your local dealerfor service information.

Anode RodMater OdorEach water heater contains at least one anode rod, whichwill slowly deplete while protecting the glass-lined tankfrom corrosion and prolonging the life of the water heater.Certain water conditions will cause a reaction betweenthis rod and the water. Once the anode is depleted, thetank will start to corrode, eventually developing a leak.The most common complaint associated with the anoderod is a "rotten egg smell" produced from the presence ofhydrogen sulfide gas dissolved in the water. Do notremove this rod permanently as it will void anywarranties, stated or implied. The parts list includes aspecral anode that can be ordered if water odor ordiscoloration occurs. This rod may reduce but noteliminate water odor problems. The water supply systenr.-may require special filtration equipment from a waterconditioning company to successfully eliminate all waterodor problems.

Artificially softened water is exceedingly corrosive becausethe process substitutes sodium ions for magnesium andcalcium ions. The use of a water softener may decreasethe life of the water heater tank.

The anode rod should be removed from the water heatertank every 3 years for inspection. lf the rod is more than50% depleted, the anode rod should be replaced.

ln 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 properprocedures.) Close drain valve.

4. Remove old anode rod.

7.

Use Teflon@ tape or approved pipe sealant on threadsand install new anode rod.

Turn on water supply and open nearby hot waterfaucet to purge air from water system.

Restart the water heater as directed under "OperatingYour Water Heater." See the "Repair Parts lllustration"for anode rod location on page 27.

5.

6

MAINTENANCE OF YOUR WATER HEATERDraining and FlushingIt is recommended that the tank be drained and flushedevery 6 months to remove sediment which may build upduring operation. The water heater should be drained ifbeing shut down during freezing temperatures. To drainthe tank, perform the following steps:

1. Turn off the gas to the water heater at the ManualGas Shut-off Valve.

2. Close the cold water inlet valve.3. Open a nearby hot water faucet.4. Connect a hose to the drain valve and terminate it to

an adequate drain.

Note: The drain hose should be rated for at least 20O"F(93'). lf the drain hose does not have this rating, open thecold water inlet valve and a nearby hot faucet until thev:.ter is no lonoer hot.

#OO"n ttre r,vater heater drain valve and allow all thewater to drain from the tank. Flush the tank with wateras needed to remove sediment.

6. Close the drain valve, refill the tank, and restart theheater as directed under "Operating Your WaterHeater".

lf the water heater is going to be shut down for an extendedperiod, the drain valve should be left open.

lmportant: Condensation may occur when refilling thetank and should not be confused with a tank leak.

Routine PreventativeMaintenanceAt least annually, a visual inspection should be made ofthe venting and air supply system, piping systems, mainburner, and pilot burner. Check the water heater for thefol[owing:.lobrtrr.tions, damage, or deterioration in the venting

system. Make sure the ventilation and combustion airsupplies are not obstructed.

Build up of soot and carbon on the main bumer andpilot burner. Check for a soft blue flame.

Leaking or damaged water and gas piping.

Presence of flammable or corrosive materials in theinstallation area.

Presence of combustible materials near the waterheater.

. Verify proper operation after servicing this water heater.lmportant: lf you lack the necessary skills required toproperly perform this visual inspection, you should notproceed, but get help from a qualified service technician.

f--21

Temperature and PressureRelief Valve

Manually operate the temperature and pressure reliefvalve at least once a year to make sure it is workingproperly (see Figure 22.) To prevent water damage, thevalve must be properlyconnected to a dischargeline which terminates at anadequate drain. Standingclear of the outlet(discharged water may behot), slowly lift and releasethe lever handle on thetemperature and pressurerelief valve to allow thevalve to operate freely andreturn to its closed position. lf the valve fails to completelyreset and continues to release water, immediately shutoff the manual gas valve and the cold water inlet valveand call a qualified service technician.

Figure 22

Explosion Hazardlf the temperature and pressure reliefvalve is dripping or leaking, have aqualified service technician replace it.

. Do not plug valve.

. Do not remove valve.Failure to follow these instructions canresult in death or explosion.

1

Replacement PartsReplacement parts may be ordered through your plumberor the local distributor. Parts will be shipped at prevailingprices and billed accordingly. When ordering replacementparts, always have the following information ready:

1. model, serial, and product number2. type of gas3. item number4. parts descriptionSee page 27 for a list of available repair parts.

Removing the Burner AssemblyTurn off the gas to the water heater at the manualshut-off valve (See Figure 4.)

Turn the gas control knob on the combination gascontrol valve/thermostat clockwise to the "OFF" position(Figure 21.)

Remove the outer and inner doors.

Disconnect thethermocouple, pilot tube,the igniter wire from theigniter button, and manifoldtube at the thermostat.(Figure 23.) Note: L.P.gas systems use reverse(left-hand) threads on themanifold tube.

Grasp the manifold tubeand push down slightly tofree the manifold, pilottube, and thermocouple.

Carefully remove themanifold assembly fromthe burner compartment.Be sure not to damageinternal parts.

7. Check the burner to see if it is dirty or clogged. Theburner may be cleaned with soap and hot water (seeFigure 24.) lf a sooty condition exists, refer to theTroubleshooting Chart, "Smoking and CarbonFormation".

Figure 24Removal and Cleaningof the Burner Assembly

2.

3.

4.

5

6

22

Replacing the Burner Assembly1. lnsert the burner into the burner compartment making

sure that the manifold tab engages with the bracketinside the burner compartment (Figure 25.)The tab islocated at the bottom ofthe burner for L.P.models. The manifoldtube will now line up withthe thermostatconnection.

2. Reconnect the manifoldtube and pilot tube. Donot cross thread thesefittings. L.P. gas systemsuse reverse (left-handed)threads on the manifold tube. Do not apply any threadsealant (pipe dope, Teflon tape, etc.)to theseconnections.

3. Reconnect the thermocouple. The thermocouple nutshould be started and turned all the way in by hand.An additional quarter tum with a 3/8" open end wrenchwill then be sufficient to seat the lockwasher. (

IMPORTANT: Overtightening may damage thethermocouple or the thermostat.

4. Relight the water heater according to the lightinginstructions.

Check for gas leaks with a chlortde-free soap andwater solution or other approved method. FIX ALLLEAKS IMMEDIATELY.

NOTE: The burner assembly shown in Figures 24,25,and 26 is typicalfor Natural Gas models. LPG modelsand models equipped with Low Nox burners will vary inappearance.

(-,

Replacing the Thermocouple1. Remove the burner assembly as directed in "Replacing

the Burner Assembly", page 22.

2. Grasp the thermocouple line and gently pull thethermocouple from the pilot assembly.

3. Push the replacement thermocouple through the holein the pilot bracket until it snaps in place. The end ofthe thermocouple should extend approximately 1/4inch past the tip of the pilot assembly.

4. Replace the burner assembly as directed on page 22.lf the thermocouple will not disengage from the pilotassembly, the entire pilot assembly must be replaced:1, Remove the No. 8-32 screw which holds the pilot

assembly and pilot shield (if provided)to the mainburner. See Figures 26 &27 below.

2. lnstall the replacement pilot assembly to the mainburner making sure the pilot shield (if provided) is inthe correct location.

3. Replace the burner assembly as directed on page 22.

27iAssembly Replacement

. Gas Model

Replacement

Piezoelectric lgniter SystemThe piezoelectric igniter system consists of the igniterbutton, electrode and wire. Gas accumulating in the areasurrounding the pilot is ignited by an electric sparkgenerated when the igniter button is pressed. The sparkgap of .125 inch is set at the factory. (See Figures 2BA& 288 below)

Figure 288L.P. lgniterAssemblv

,r ICIiITORr ltlim{lN

Testing the lgniter SystemTurn off the gas to the water heater at the manual gasshut-off valve. Watch the electrode tip while activating theigniter. A visible spark should jump from the electrode.To avoid shock, do not touch the burner or any metal parton the pilot or pilot assembly. lf no spark is visible, checkthe wire connections and make sure the electrode is notbroken. Replace the igniter if defective. Dirt and rust onthe pilot or electrode tip can prevent the igniter spark.Wipe clean with a damp cloth and dry completely. Rustcan be removed from the electrode tip and metal surfacesby lightly sanding with an emery cloth or fine grit sandpaper.

Figure 28ANatural Gas lgniter Assembly

r IGN1IORI aurroN

f ilEF.tWOCOUPt-f

F,I-F,c'I'RODE

4,,=

23

Removing and Replacing the GasGontrol Va lve/Thermostat1. On the gas control valve/thermostat turn the

temperature dial counterclockwise to its lowest setting.Turn the gas control knob clockwise to the UOFF"

position. See Figure 21 on page 19.

2. Turn off the gas at the manual shutoff valve on thegas supply pipe. See Figure 4 on page 6.

3. Drain the water heater. Refer to section "Draining andFlushing" on page 21 and follow procedure.

4. Disconnect the thermocouple, pilot tube, and manifoldtube at the thermostat. See Figure 23 page 22. Notethat L.P. gas systems use reverse (left-handed)threadson the manifold tube.

5. Refer to Gas Piping Figure 4 on page 6 anddisconnect the ground joint union in the gas piping.Disconnect the remaining pipe from the gasvalve/thermostat.

Turn the gas control valve/thermostat counterclockwise.Remove the gas control valve/thermostat.

IMPORTANT: When removing the gas controlvalve/thermostat do not use pipe wrench or vise to gripbody. Do not insert any type of blunt instrument into theinlet or outlet connections. Using these type tools mayresult in damage to the gas control valve/thermostat.

6. Turn the gas control valve/thermostat counterclockwise.Remove the gas control valve/thermostat.

To replace the gas control valve/therrnostat, reassemblein reverse order.. Be sure to use approved Teflon tape or pipe joint

compound on the gas piping connections and fittingon the back of the gas valve that screws into tank.

. Be sure to remove the pilot ferrule nut from the newgas control valve/thermostat.

. Turn gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicatea leak) or other approved method.

. Be sure tank is completely filled with water beforelighting and activating the water heater. Follow the"Lighting lnstructions" on pages 17 & 18.

. lf additional information is required, contact the placeof purchase or local distributor.

24

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TROUBLESHOOTING CHARTPROBLEM POSSTBLE CAUSE(S) CORRECTIVE ACTION

BURNER WILL NOT IGNITE 1. No gas2. Dirt in the gas lines3. Pilot line clogged4. Main burner line clogged5. Defectivethermocouple6. Defectivethermostat7. Thermostat set too low8. Heater installed in a confined area

1. Check with gas utility company2. Notify utility-install trap in gas line3. Clean, locate source and correct4. Clean, locate source and correct5. Replacethermocouple6. Replace thermostat7. Turn temp. dial to desired temperature.8. Provide fresh air ventilation

BURNER FLAMEYELLOW-LMY

1. lnsufficient secondary air2. Low gas pressure3. Flue clogged4. Main burner line clogged5. Heater installed in a confined area6. Obstruction in main bumer orifice7. Main burner needs adjusting (L.P. only)

1. Provide ventilation to water heater2. Check with gas utility company3. Clean, locate source and correct4. Clean, locate source and correct5. Provide fresh air ventilation6. Clean or replace orifice7 . See page 19, "Burner Flames" for flame

adjustment.

PILOT WILL NOT LIGHT ORREMAIN LIT.

1. Low gas pressure2. Air in gas line3. No gas4. Dirt in gas lines5. Pilot line or orifice clogged6. Thermocouple connection loose7. Defectivethermocouple8. Cold drafts9. Thermostat ECO switch open

1. Check with gas utility company2. Bleed the air from the gas line3. Check with gas utility company4. Notify utility-install dirt trap in gas line5. Clean, locate source and correct6. Finger tightenthen 1/4 turn with wrench7. Replacethermocouple8. Locate source and correct9. Replace thermostat

HIGH OPERATION COSTS 1. lmproper Calibration2. Thermostat set too high3. Sediment or lime in tank

4. Heater too small for job5. Wrong piping connections6. Leaking faucets7. Gas leaks8. Wasted hot water9. Long runs of exposed piping

10. Hot water piping in exposed wall11. No flue baffle

1. Replace thermostat2. Set temperature dial to lower setting.3. Drain/Flush-Provide water treatment if

needed4. lnstall adequate heater5. Correct piping-dip tube must be in cold inlet6. Repair faucets7. Check with utility-repair at once8. Advise customer9. lnsulate piping

10. lnsulate piping1'1. lnstall flue baffle

PILOT FLAME TOO LARGE 1. Wrong pilot bumer 1. Replace with correct burnerINSUFFICIENT HOT WATER 1. Low gas pressure

2. Orifice too small3 lmproper calibration4. Thermostat set too low5. Sediment or lime in tank6. Water heater too small7. Wrong piping connections8. Leaking faucets9. Wasted hot water

1 0. Long runs of exposed piping11. Hot water piping in outside wall

1. Check with gas utility company2. Replace with correct orifice3. Replace thermostat4. Turn temperature dial to lower setting5. Drain/flush-provide water treatment if needed6. lnstall adequate heater7. Correct piping-dip tube must be in cold inlet8. Repair faucets9. Advise customer

10. lnsulate piping11 . lnsulate piping

SLOW HOT WATERRECOVERY

1. lnsufficient secondary air2. Flue clogged3. Low gas pressure4. Orifice too small5. lmpropercalibration6. Thermostat set too low7. Heater too small8. Wrong piping connections9. Wasted hot water

1. Provide ventilation to water heater. Checkflue way, flue baffle and burner.

2. Clean flue, locate source and correct3. Check with gas utility company4. Replace with correct orifice5. Replace thermostat6. Turn temperature dial to lower setting7. lnstall adequate heater8. Correct piping-dip tube must be in cold inlet9. Advise customer

DRIP FROM RELIEF VALVE 1. Excessive water pressure2. Heater stacking3. Closed water system

1. Use a pressure reducing valve and reliefvalve.

2. Lower the thermostat setting3. See page 13, "Closed SystemiThermal

Expansion".

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)

TROU BLESHOOTING CHART (continued)PROBLEM POSSTBLE CAUSE(S) CORRECTIVE ACTION

DISCOLORATION OFJACKET ABOVECOMBUSTION AREA

Burner orifice too largeFlue cloggedHigh gas pressure

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Replace with correct orificeClean, locate source and correctAdjust pressure to proper setting byqualified service personnel only.

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SMOKING AND CARBONFORMATTON (SOOTTNG)

1. lnsufficient secondary air2. Low gas pressure3. Orifice too large4. Flue clogged5. Defectivethermostat6. Heater installed in a confined area7. Burner flame yellow-lazy

1. Provide ventilation to water heater.Check flue way, flue baffle, and burner.

2. Check with gas utility company3. Replace with correct orifice4. Clean, locate source and correct5. Replace thermostat6. Provide fresh air ventilation.7. See "Burner Flame Yellow-Lazy" above.

COMBUSTION ODORS 1. lnsufficient secondary air2. Flue clogged3. Heater installed in a confined area

Provide ventilation to the water heaterClean, locate source and correct.Provide fresh air ventilation.

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CONDENSATION 1. Temperature setting too low 1. lncrease the temperature setting.See page 19.

SMELLY WATER 1. Sulfides in the water 1. Replace the anode with a special anode.THERMOSTAT FAILS TOSHUT OFF

1. Defectivethermostat2. lmpropercalibration

Replace thermostatReplace thermostat

1

2

BURNER FLAME TOO HIGH Insufficient secondary airOrifice too large

1

2Provide ventilation to water heaterReplace with correct orifice

1

2

FLAME BURNS AT ORIFICE 1. Low gas pressure2. Defectivethermostat

Check with gas utility companyReplace thermostat

1

2

PILOT FLAME TOO SMALL Low gas pressurePilot line or orifice cloggedWrong pilot burner

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1. Check with utility2. Clean, locate source and correct3. Replace with correct burner

BURNER FLAME FLOATSAND LIFTS OFF PORTS

1. High gas pressure2. Orifice too large3. Flue clogged4. Heater installed in a confined area5. Cold drafts

1. Check with utility2. Replace with correct orifice3. Clean flue and burner-locate source & correct'4. Provide fresh air ventilation5. Locate source and correct

REPAIR PARTS ILLUSTRATION

When orderrng repair parts always give the followinginformation:

tt 1. Model, serial, and product number2.Type of gas

3.ltem number

4. Parts description

Repair Parts List

NATURAL GAS

Special anode rod (see page 20)

Temperature and Pressure Relief Valve is required,but may not be factory installed

It is imperative the replacement main burner,orifice, manifold, pilot burner, and the thermostatbe ordered for the proper gas type. Natural gasthermostat will be marked "Natural Gas Only".Propane gas thermostats will be marked"For L.P. Gas Only".

AT

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*

ItemNo.

Parts Description

1 DRAFTHOOD

2 REDUCER RING - SOME MODELS Ft.3 FLUE BAFFLE

4 HEAT TRAP (COLD) - SOME N4ODELS

5 HEAT TRAP (HOT) -SOME MODELS

6 COLD WATER DIP TUBE

7 ANODE ROD A8 TEMPERATURE & PRESSURE RELIEF VALVE

(LOCATED TOP OR SIDE) II DRAIN VALVE10 GASVALVEfiHERMOSTAT *11 MANIFOLD *2 ORIFICE *3 MAIN BURNER *3A BURNER NATURAL LOW NOX - NOT PICTURED

4 PILOT ASSEMBLY *5 PILOT TUBE

6 THERMOCOUPLE

7 SCREW 8-32X 312 PH RD MACH

8 SCREW 8-32X .25 SELF TAPPINGq

OUTER DOOR

20 INNER DOOR

21 IGNITER BUTTON -SOME MODELS

22 PILOT SHIELD. SOME MODELS

23 AIR SHUTTER - L.P. MODEL ONLY

24 PIEZOELECTRIC IGNITER ASSEMBLY - SOME MODELS

LEGEND

27

Listed Parts Kits and lllustrationsItem 1: Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter, thermocouple, andretainer clip. (Natural Gas)

Item 2: Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter, thermocouple, andretainer clip. (1.P. Gas)

@ 2OO4 American Water Heater Company. All Rights Reserved. Printed in the U.S.

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