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User Manual (N50T122-403)

1. PAN 6 MAXIMUM AIR GAP AT LEAST 2 GREATER THAN THE N DIAMETER OF THE WATER HEATER PIPED TO AN ADEQUATE DRAIN The water heater should be located in an area not subject to freezing temperatures Water heaters located in unconditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the data plate Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling If the water heater is located in an area that is subjected to lint dirt and oil it may be necessary to periodically clean the flame trap see External Inspection amp Cleaning of the Flame trap section Figure 1A Air moving Devices Exhaust Fan L Reverse flow of gases Clearances and Accessibility NOTE Minimum clearances from combustible surfaces are stated on the data plate adjacent to the gas control valve thermosta
2. Residential Gas Water Heater with the Flame Lock Safety System WARNING If the information in these nsta ation instructions is not followed exactly a fire or explosion may result causing property n stru cti O n S a n d damage personal injury or death Do not store or use gasoline or other U se amp Ca re G U id e flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS NATURAL amp L P GAS MODELS To obtain technical warranty or service assistance during or after Do not try to light any appliance the installation of this water heater visit our website at Do not touch any electrical switch http www whirlpoolwaterheatersupport com do not use any phone in your ar ealltoll ree building 1 877 817 6750 When calling for assistance please have the following information ready Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions 1 Model number 2 7 digit product number 3 Serial number 4 Date of installation 5 Place of purchase If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or Table of Contents gt sisintinccr cena andien atin 2 the gas supplier INSTALLER e AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER OWNER e RETAIN THESE INSTRUCTION
3. To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat clockwise DO NOT OVER TIGHTEN damage may result e 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 that screws into tank e Be sure to remove the pilot ferrule nut from the new gas control valve thermostat e Turn the gas supply on and check for leaks Test the water heater by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found e Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions on page 17 e If additional information is required contact the Service Department at 1 877 817 6750 Flame Lock Safety System Operational Checklist 1 Manifold gasket properly sealed 2 Viewport not damaged or cracked 3 Flame trap free of debris and undamaged 4 Manifold component block properly installed 5 No leaks at pilot and manifold connection 6 Manifold door screws securely tightened 7 Depress the button on the thermal switch TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION BURNER WILL NOT IGNITE Pilot not lit Thermostat set too low No gas
4. Dirt in the gas lines Pilot line clogged Main burner line clogged Non functioning thermopile Non functioning thermostat 4 1 Light pilot 2 Turn temp dial to desired temperature 3 Check with gas utility company 4 Notify utility install trap in gas line 5 Clean locate source and correct 6 Clean locate source and correct 7 Replace thermopile 8 Replace thermostat 9 Provide fresh air ventilation 1 SMELLY WATER Sulfides in the water Replace the anode with a special anode BURNER FLAME YELLOW LAZY Insufficient secondary air Low gas pressure Flue clogged Main burner line clogged PILOT WILL NOT LIGHT OR REMAIN LIT 6 2 4 6 2 Non functioning igniter The thermal switch tripped Thermopile connection loose 4 Air in gas line 5 Proper Lighting Sequence not followed Gas Control Temperature Knob was not held in for sufficient time 6 Low gas pressure 7 Nogas 8 Dirt in gas lines 9 Cold drafts 1 0 Thermostat ECO switch open 26 Heater installed in a confined area 1 2 3 5 7 8 9 Heater installed in a confined area 1 1 3 5 Obstruction in main burner orifice 1 3 Provide ventilation to water heater Check with gas utility company Clean locate source and correct Clean locate source and correct Proper fresh air ventilation Clean or replace orifice Replace igniter pilot assembly See Pilot Light Troubleshooting Flowchart section Seat connector firmly
5. e The majority of the rods diameter is less than 3 8 e Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod show signs of either Figure 20 or both it should be replaced NOTE Anode Rod Depletion 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 7 Check for any leaks and immediately correct any if found 8 Restart the water heater as directed in this manual See the Repair Parts Illustration for anode rod location TEFLON is a registered trademark of E I Du Pont De Nemours and Company 21 Exposed Support Pitted f Anode 54 Rod aed Exposed Support Wire MAINTENANCE OF YOUR WATER HEATER Draining and Flushing Temperature and Pressure It is recommended that the tank be drained and flushed Relief Valve every 6 months to remove sediment which may build up during operation The water heat
6. gas water heater smell all around the appliance at floor level If you smell gas follow the instructions as given in the warning on the front page When your L P tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions Checking the Draft AWARNING Burn Hazard Do not touch vent SiN Doing so can result in burns After successfully lighting the water heater allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the drafthood A steady flame drawn into the opening indicates proper draft If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Figure 17 Drafthood Relief Opening 18 Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 18 A properly operating burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not
7. section of this water heater manual for specific requirements Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air 16 Conditioning amp Refrigeration HVAC R authorized service provider Fresh air supply free of corrosive elements and flammable vapors Fresh air openings sized correctly with consideration given to the blocking effect of louvers and grilles Ductwork is the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 curren
8. 3 The filter can then be vacuumed to remove the build up 4 Before re attaching the filter a visual inspection of the flame trap is recommended Refer to the External Inspection amp Cleaning of the Flame trap section 5 Follow Filter Installation instructions 2 3 to re attach the filter Figure 27 Flame trap visual inspection amp filter installation removal Flashlight Mirror C Connection Posts Outer Connection Points Inner Connection Points External Inspection amp Cleaning of the Flame trap Although not likely to occur if debris collects on the flame trap use a vacuum compressed air or a soft bristle brush to remove it NOTE If unable to inspect or clean the flame trap from underneath follow the Cleaning the Combustion Chamber and Flame trap section instructions Cleaning the Combustion Chamber and Flame trap 1 Follow procedure outlined in Removing the Manifold Assembly 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 28A Use compressed air to clear any dust or debris that may have accumulated in the flame trap 3 Reassemble following the procedure under Replacing the Manifold Assembly Replacing the Manifold Assembly AWARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass
9. Figure 23 Burner Thermopile Connector _ Pilot Thermopile 5 Disconnect the pilot tube Igniter Assembly 7 16 wrench the igniter Button wire from the igniter lead wire and manifold tube ee at 3 4 wrench at the gas Wire control valve thermostat Pilot l Also use needle nose pliers i Scr ws Pilot Thermopile Assembly Manifold Door Igniter Manifold Left Assembly to disconnect the red ire Tube Side and white thermopile L P Gas Cast Iron Burner wires from the gas control valve thermostat See Figures 22 amp 23 NOTE L P Gas systems use ss ee a aca reverse left hand threads on the manifold tube 2 Loosen set screw located on top of the L P burner near 6 Grasp the manifold tube and push down slightly to free the manifold door Gently pull the burner away from the the manifold pilot tube and thermopile manifold door assembly 3 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 24B 7 Carefully remove the manifold assembly from the burner compartment NOTE Be sure not to damage internal parts Figure 23 Burner Assembly Removal Figure 24B Manifold D L P Gas Burner Manifold Door Assembly Manifold Burner Assembly eae a Manifold Component A Thermal
10. It is essential that the filter be installed properly If you encounter difficulty installing the filter or have a question please call the Service amp Warranty Department at 1 877 817 6750 Filter Installation 1 Before attaching the filter remove any dust or debris that may have accumulated in the installation area It is also recommended that a visual inspection of the flame trap be performed Refer to the External Inspection amp Cleaning of the Flame trap section 2 Connect the end points of the filter sections together see Figure 27 to form one long section Wrap this section around the base of the water heater and join at the closest connection point to fit your water heater NOTE If your water heater has a small diameter tank it may be necessary to use both inner connection points 3 Once connected check to ensure a close fit with no gaps between the water heater the filter and the floor see Figure 27 NOTE Depending on the size of your water heater the filter may have some excess material This may be trimmed away 4 It is recommended that the filter be inspected periodically to maintain unrestricted airflow to the water heater Periodic Cleaning of the Filter 1 If periodic inspection of the filter shows a build up on the filter it should be removed and cleaned 2 Toremove the filter locate a set of connection posts see Figure 27 and squeeze them together while pulling outward on the thumb tab
11. Switch Burner Igniter Wire Pilot Tube Manifold Tub Gas Control Valve Thermostat Thermopile and Switch Wire Connections Piezo Igniter Button Pilot Tube Manifold Tube 4 Thermal Switch Viewport Outer Door Not Shown Manifold Door Pilot AssembIy Thermopile Pilot Bracket Retainer Clip Manifold Screw 2 Manifold Component Block Replacing the Pilot Thermopile Assembly 1 Remove the manifold assembly as directed previously 2 Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Fi Figure 25 Figure 25 Thermopile Burner and other Manifold Component Connector fittings not show Block Assembly S for clarity ie Igniter im Wire Manifold Door 3 Locate and remove the screws on the underside of the burner then remove the burner IMPORTANT DO NOT remove the orifice LP Cast Burner models DO NOT require the burner to be removed Remove the screw securing the pilot assembly to the manifold NOTE For cast burner models remove the screw securing the pilot assembly to the burner 4 Using a 7 16 wrench loosen the nut securing the pilot tube to the pilot assembly NOTE To prevent any bending of the pilot bracket use pliers to hold the pilot assembly bra
12. determined by consulting the local natural gas utility Table 2 A LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Size in 10 20 30 40 50 1 2 275 3 4 576 1 1071 1 1 4 2205 Example Length of Pipe Feet 60 70 80 90 100 125 150 Input BTU requirement of the water heater 100 000 BTU HR Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI 2223 1 Combustion Air Supply and Ventilation AWARNING Carbon Monoxide Hazard Water heater must be vented to outdoors Vent must be installed by a qualified person using the installation instructions Examples of a qualified person include gas technicians authorized gas company personnel and authorized service persons Failure to follow these instructions can result in death or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air e be
13. is missing or damaged Replace two piece wire connector if missing or removed Replace door gasket if damaged 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 manifold assembly into the burner compartment making sure that the tab of the manifold tube engages in the slot of the bracket inside the combustion chamber Figure 28B 4 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber 5 Replace the two screws which secure the manifold assembly door to the combustion chamber and tighten securely There should be no space between the gasket part of the manifold door and combustion chamber IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber 6 Reconnect the red wire leads to the thermal switch Figure 25 the manifold tubing 3 4 wrench pilot tubing 7 16 wrench and thermopile wires to the gas control valve thermostat See Figure 22 for the correct position of the thermopile wires Do not cross thread or apply any thread sealant to the fittings NOTE L P Gas systems use reverse left hand threads on the manifold tube Reconnect the igniter wire Turn the gas supply on and refer to
14. structure Due to the normal corrosive action of the water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortable with making the repair a qualified person should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Locate the water heater near an adequate indoor drain The discharge pipe must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Outside drains are subject to freezing temperatures which can obstruct the drain line The piping should be at least 3 4 ID and pitched for proper drainage Under no circumstances will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your failure to follow these instructions DISCHARGE PIPE DO NOT CAP OR PLUG Figure 1 Drain Pan Installation
15. than normal water temperatures are the first signs of thermosiphoning e The domestic hot water line from the water heater should be vertical past any mixing valve or supply line to the air handler to remove air bubbles from the sys tem Otherwise these bubbles will be trapped in the air handler heat exchanger coil reducing the efficiency e Donot connect the water heater to any system or components previously used with non potable water heating appliances when used to supply potable water Some jurisdictions may require a backflow preventer in the incoming cold water line This may cause the temperature and pressure relief valve on the water heater to discharge or weep due to expansion of the heated water A diaphragm type expansion tank suitable for potable water will normally eliminate this weeping condition Please read and follow the manufacturer s instructions for the installation of such tanks Also see Water System Piping section for additional instructions on the proper installation and operation of this water heater Figure 16 Typical Mixing Valve Installation Combination Space Heating Potable Water Heating System WMiistbe vertical t Domestic remove air bubbles Hot Water eda Mixing_ Out o Valve q Water Inlet Hot Water Out Flow Control Valve Pump O Out To r mi l Air Unions Handler 4 Discharge Pipe Do Not Cap or Plug Shut off Valve X Maximu
16. using in your home This information will be found on the data plate located near the gas control valve thermostat If the information does not agree with the type of gas available do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not depend upon this odorant as an indication of leaking gas Gas Piping The gas piping must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Tables 1 and 2 on page 7 provides a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials Refer to Figure 3 NOTE When installing gas piping apply approved pipe joint compound 1 Install a readily accessible manual shut off valve in the gas supply line as recommended by the local utility Know the location of this valve and how to turn off the gas to this unit 2 Install a drip leg if not already incorporated as part of the water heater as shown The drip leg must be no less than three inches long for the accumulation of dirt foreign material and water droplets 3 Install a ground joint union between the gas control valve thermostat and the manual shut off valve This is to allow easy removal of the gas co
17. 000 8 28 x 30 IMPORTANT e The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation e Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space e Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 4 The size of each opening free area is determined by the total BTU HR input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTU HR input can be found on the water heater data plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors Figure 4 Opening Locations Confined Spaces 12 maximum Permane
18. Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the flame arrestor located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the flame trap Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a thermal switch on the door assembly to trip Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Location Requirements
19. S AND WARRANTY FOR FUTURE REFERENCE RETAIN THE ORIGINAL 318051 002 RECEIPT AS PROOF OF PURCHASE October 2010 WATER HEATER SAFETY 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 all safety 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 or WARNING These words mean Y be killed ioushridlursd Hyeu den A DANGER immediately follow instructions A WARN l NG a seriously injured if you don t All safety messages will tell you what the potential hazard is tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed Important Instructions e Do not use this appliance if any part has been under water Immediately call a qualified person Water heaters sub jected to flood conditions or any time the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame To prevent the possibility of injury under these conditions we recommend the hot wate
20. al You or future users of this water heater will need it for future reference Service to the Flame Lock Safety System should only be performed by a qualified person Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel IMPORTANT The manufacturer and seller of this water heater will not be liable for any damages injuries or deaths caused by failure to comply with the installation and operating instructions outlined in this manual If you lack the necessary skills required to properly install this water heater or you have difficulty following the instructions you should not proceed but have a qualified person perform the installation of this water heater Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2 00 and 5 00 A data plate identifying your water heater can be found next 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 AWARNING Excessive Weight Hazard Use two or more people to move and install water heater Failure to do so can result in back or other injury IMPORTANT Do not remove any permanent instructions labels or the data label from either the outside of the wate
21. all Vent Pipe fmm LISTED VENT CAP a MAINTAIN SPECIFIED CLEARANCE SUPPORT MAINTAIN CLEARANCE VENT CONNECTOR CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM UNUSED CHIMNEY Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections 11 Water System Piping Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 13 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures IMPORTANT Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fit
22. and application or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition e The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases e The connector must be firmly attached and sealed to prevent it from falling out e To aid in removing the connector a thimble or slip joint may be used e The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 10 Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with U L listed type B vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 11 and 12 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of t
23. atically R Inlet air duct during equipment operation 1 sq inch per 4000 BTU HR Keep louvers and grilles clean and free of debris or other obstructions Table 3 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on the total BTU HR input rating for all utilizing equip ment within the confined space Minimum Free Area Reference Opening Source Per Opening sq in Drawing Direct to outdoors 1 sq in per 4000 BTU HR Vertical ducts 1 sq in per 4000 BTUHR Figure 7 12 maximum All Air from Outdoors Through Ventilated Attic 1 sq inch per 2000 BTU HR Horizontal ducts 1 sq in per 2000 BTU HR Figure 8A Single Opening 1 sq in per 3000 BTU HR Figure 8B Example A water heater with an input rate of 50 000 BTU HR using horizontal ducts would require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTU HR x 1 sq in 2000 BTU HR 25 Sq Inches Confined Space Outdoor Air Ducts These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation cee Figure 8A 1 sq Inch and combustion air requirements All Air from Outdoors per Using Horizontal Ducts 2000 BTU HR Alternative Opening Location Confined Space Per 3000 BTU HR Figure 8B All Air from Ou
24. auty shops photo processing labs e buildings with indoor pools e water heaters installed in laundry hobby or craft rooms e water heaters installed near chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTU HR of the total input for all gas using appliances Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1 000 BTU HR of the total input for all gas appliances The table below shows a few examples of the minimum square footage area required for various BTU HR inputs Table 2 Minimum Square Feet with 8 Ceiling 30 000 188 9x21 57 50 44 BTU HR Input Typical Room with 8 Ceiling 105 000 6 20 x 33 120 000 7 25 x 30 135
25. be all yellow or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified person if the flame is not satisfactory Water Temperature Stacking Stacking occurs when a series of short draws of hot water 3 gallons or less are taken from the water heater tank This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet Figure 18 Flame Characteristics Tips may have a yellow tint Yellow inner cones are satisfactory Correct flame soft blue This water heater s temperature control has been designed to accurately regulate the water temperature However under certain operating conditions the water temperature may temporarily exceed the dial setting Consequently in addition to setting the temperature no higher than 120 F we recommend the installation of a mixing valve or an anti scald device in the hot water supply line or at the point of use to further reduce the risk of scald injury These devices can be obtained from a plumbing service agency or your retail supplier Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified person Water Temperature Regulation AWARNING Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest r
26. cket while loosening the pilot nut Figure 26 Pilot Thermopile Assembly Connector Thermopile Connector Thermal Switch Connectors 5 Disconnect the red wire connected to the thermal switch then lift the pilot thermopile assembly including the igniter wire from the manifold assembly 6 Pull the pilot tube from the pilot assembly Figure 26 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components 7 Using the old pilot pilot tube assembly as a guide bend the new pilot tube to match the old one Make only the bends closest to the pilot before going to the next step 8 Push the new pilot assembly connectors through the hole in the manifold door See Figure 25 Reconnect the pilot tube and tighten the nut securing it to the pilot assembly IMPORTANT Keep the pilot orifice in the pilot when making the connection DO NOT operate the water heater without the pilot orifice installed Reattach the pilot assembly to the manifold Cast burner models reattach the pilot assembly to the burner 9 Reattach the burner and secure with screws NOTE See figure 24A for correct burner orientation 10 Position the new thermopile wires through the top opening of the manifold component block Figure 25 Be sure the igniter wire is positioned through the middle opening of the manifold component block 11 See Replacing Manifold Assembly Page 25 Filter Installation and Cleaning IMPORTANT
27. connections Refer to Location Requirements on page 4 Under no circumstances is the manufacturer to be held responsible for any water damage in connection with this water heater Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard These noises are common and may result from the following 1 Normal expansion and contraction of metal parts during periods of heat up and cool down 2 Condensation causes sizzling and popping within the burner area and should be considered normal 3 Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure Drain and flush the tank as directed under Draining and Flushing Smoke Odor The water heater may give off a small amount of smoke and odor during the initial start up of the unit This is due to the burning off of oil from metal parts of a new unit and will disappear after a few minutes of operation Safety Shut off This water heater is designed to automatically shut off in the event of the following 1 The pilot flame is extinguished for any reason 2 The water temperature exceeds 189 F 87 C for 155 F models or 199 F 93 C for 180 F models See the data plate for your model 3 Excessive combustion chamber temperatures 4 The ignition of flammable vapors Athermopile is used to determine if a pilot flame is present and will shut off the gas supply to the main bu
28. e any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department conditions or anytime the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS Immediately call a qualified service technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid bottom of combustion chamber and require replacement of the entire water heater LIGHTING INSTRUCTIONS 1 STOP It is imperative that you read all safety warnings 5 Press the gas control temperature knob all the way in before lighting the pilot and hold it in The knob should travel in about 1 4 inch 6 35 mm if it is set to PILOT correctly Turn the gas control temperature knob counterclockwise While holding the gas control temperature knob in to the OFF setting click the igniter button continuously about once a second for up to 90 seconds or until Status Light Gas control 3 j temperature knob lt gt begins to blink When the status light starts blinking release the gas control temperature knob Set the gas control tempera ture knob to the desired setting Igniter Button Status light Index mark Wait ten 10 minutes to clea
29. ed from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank 13 Temperature and Pressure Relief Valve AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion Figure 15A Temperature and Pressure Relief Valve Installation Optional location a some models only Temperature and p Pressure Relief Valve Discharge Pipe Do not cap or plug Drain Line 3 4 ID minimum Maximum Air Gap Floor 7 5S Drain Metal Drain Pan For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE see Figure 15A This valve must be design certified by a nationally recognized testing laboratory that maintains periodic in
30. enings Correct size of of sufficient size See Combustion Air Supply and NO openings to allow Ventilation section in this manual for requirements sufficient air While repeatedly depressing the igniter YES button push in and hold the gas control temperature knob until the pilot is lit and NOwisih 7 Jair handler in th th tar heater maintains a stable flame status light s there a furnace air handler in the same room as the water heater will blink then release the gas control YES temperature knob Does the return air duct for the furnace air handler draw its air from a separate location than the water heater See the Location Requirements section and the Combustion Air Supply section Contact a local Heating Ventilation Air Conditioning amp Refrigeration authorized service provider to correct the combustion air supply ventilation issue Is there proper drafting at the Check the vent drafthood See Checking the jm NO system for restrictions Draft section in this manual obstructions and check YES the vent termination height Refer to the N Set thermostat to desired temperature Section B Pilot light repeatedly goes out Installation Instructions Remove the burner door assembly Are the flame trap and your Water Heater section of this burner free from debris due to excessive lint dirt dust or oil section of this manual for specific requirements Contac
31. er heater A discharge line must be added to the opening of the T amp P Relief Valve Follow the instructions under Temperature and Pressure Relief Valve section 12 7 After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any ex cess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks Figure 13 Water Piping Installation In a closed system use a thermal expansion tank a wee Cold Water Supply to Fixtures Hot Water Outlet lt Main water supply Pressure reducing 4 Cold Water valve with bypass Inlet Valve Temperature and Pressure Relief Valve Discharge Pipe Do Not Cap or Plug Drain line 3 4 ye ID minimum 6 Maximum 1 minimum gt pe Gap Massachussetts Install a vacuum relief in cold water line per E 7 section 19 MGL 142 Floor Drain Metal A Drain Pan 1 3 4 depth maximum Figure 14 Typical Mixing Valve Installation Follow the mixing valve manufacturers instructions Tempered water to fixtures Mixing valve Set to 120 F Please note the following e The system should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybut
32. er should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 1 Turn off the gas to the water heater at the manual gas shut off valve AWARNING 2 Open a nearby hot water faucet until the water is no longer hot Close the cold water inlet valve Explosion Hazard Connect a hose to the drain valve and terminate it to an If the temperature and pressure relief valve adequate drain or external to the building i A 3 pe is dripping or leaking have a qualified 5 Open the water heater drain valve and allow all of the erson replace it water to drain from the tank Flush the tank with water p p as needed to remove sediment Examples of a qualified person include 6 Close the drain valve refill the tank and restart the licensed plumbers authorized gas company heater as directed in this manual If the water heater is going to be shut down for an extended period the drain valve should be left open IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak Routine Preventative Maintenance At least annually a visual inspection should be made of the venting and air supply system piping systems main burner pilot burner and Flame trap Check the water heater for the following e Obstructions damage or deterioration in the venting system Make sure the ventilation and combustion air supplies are not obstructed Build up o
33. etting Closed water system See Closed System Thermal Expansion 2 3 5 6 7 Wrong piping connections 8 1 2 3 Thermostat not functioning properly Improper calibration THERMOSTAT FAILS TO 1 SHUT OFF 2 COMBUSTION ODORS Insufficient secondary air 2 Flue clogged 3 Heater installed in a confined area SMOKING AND CARBON 1 FORMATION SOOTING Insufficient secondary air Low gas pressure Flue clogged 4 Thermostat not functioning properly Heater installed in a confined area Clean locate source and correct Replace thermopile See maintenance section for inspection and cleaning of flame trap Replace water heater eliminate flammable vapors source Call 1 877 817 6750 Set temperature dial to lower setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping Turn temperature dial to desired setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Advise customer Insulate piping Insulate piping Check with gas utility company Provide ventilation to water heater Check flue way flue baffle and burner 2 Clean flue locate source and correct 3 Check with gas utility company 4 Replace thermostat 5 Turn temperature dial to desired set
34. f soot and carbon on the main burner and pilot burner Check for a soft blue flame personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion Manually operate the temperature Temperature and Pressure and pressure relief Relief Valve valve at least once 4 a year to make sure it is working properly To prevent water damage the valve must be properly connected Figure 21 Manual Relief Valve to a discharge line which terminates at an adequate drain Standing clear of the outlet discharged water may be hot slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position If the valve fails to completely reset and continues to release water immediately shut off the manual gas control valve and the cold water inlet valve and call a qualified person e Leaking or damaged water and gas piping Discharge line to drain e Presence of flammable or corrosive materials in the installation area e Presence of combustible materials near the water heater e After servicing this water heater check to make sure it is working properly See Operating Your Water Heater section of this manual IMPORTANT If you lack the necessary skills required to properly perform this visual inspection you should not proceed but get help
35. from a qualified person 22 Replacement Parts Removing the Burner from the IMPORTANT The following maintenance procedures are Manifold Assembly for the Flame Lock Safety System components and should Natural Gas Burner Low Nox amp L P Burner be performed by a qualified person 1 Take off the burner by removing the two 2 screws lo Replacement parts may be ordered through your plumber cated underneath the burner or the local distributor Parts will be shipped at prevailing ee prices and billed accordingly When ordering replacement 2 Check the burner to see if it is dirty or clogged The burner parts always have the following information ready may be cleaned with soap and hot water Figure 24A 1 model serial and product number Figure 24A Manita re ere 2 type of gas Natural gas Low NOx and L P i ala a tana 3 item number BurnerAssembly Thermal Switch 4 parts description Manifold Component See pages 30 31 for a list of available repair parts Removing the Manifold Assembly 1 Turn off the gas to the water heater at the manual shut off valve Figure 3 2 Turn the gas control temperature knob to the OFF position Figure 19A Igniter Wire Viewport ee Tube Manifold Tube Figure 22 Remove the outer door Gas Control Valve Thermostat Remove the two screws 1 4 nut driver securing the manifold door assembly to the combustion chamber
36. he burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 12 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation IMPORTANT Do not common vent this water heater with any power vented appliance Figures 10 12 are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI Z223 1 current edition and the guidelines set forth by prevailing local codes Listed Lined Chimney Figure 10 Chimney Termination Vent System H 2 ft minimum above any object within10 ft horizontally 3 ft minimum Maintain gee Ae ee ee SEEI HH AHHH AHHH Do not extend vent beyond edge of chimney T TH I I Vent Connector I HHH HHH Figure 11 Vertical Gas Vent System With Type B Double Wall Vent Pipe s Listed Vent Cap 4 ms 2 ft minimum above any 3 ft minimum object within10 ft AAN horizontally Maintain Support Strap clearance lt Type B Double Wall Vent Pipe t A Maintain Vent specified connector clearance slope up 1 4 in per ft minimum Figure 12 Venting NOON irik MANUFACTURER S a Chimney SPECIFIED MINIMUM CLEARANCE with Type B Double W
37. ickly as expected when gas supply OFF Replace the gas control valve the unit is shut off This condition thermostat For instructions see Removing and can also occur if the gas control Replacing the Gas Control Valve Thermostat nena ae dias a h a If the pilot flame is not observed when the gas orean e pilot continues tol control valve thermostat knob is set to the OFF operate because the pilot valve is position wait 10 minutes for the thermopile to cool stuck in the open position then attempt to relight the pilot by following the lighting instructions on the water heater s label If this condition returns replace the gas control valve thermostat See Removing and Replacing the Gas Control Valve Thermostat for instructions 28 PILOT LIGHT TROUBLESHOOTING CHART Section A Pilot light will not light new installation Section C Pilot light will not remain lit located in the supply line to the water heater in the on position Have you bled all the air from the pilot tube and gas supply line YES Is the igniter producing a YE spark NO Follow the Testing the Igniter System section in this manual Is the manual gas shut off valve Check for insufficient combustion air Turn the manual gas shut off valve to NO the on position and follow the lighting instructions on the front of the water heater Are the combustion air supply and ventilation op
38. in socket Bleed the air from the gas line Do not attempt to relight if the red light is lit and the pilot flame is not visible through the view port Wait until the red light is no longer lit then follow lighting instructions on the water heater Check with gas utility company Check with gas utility company Notify utility install dirt trap in gas line Locate source and correct 0 Replace thermostat PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION PILOT WILL NOT LIGHT OR 11 REMAIN LIT continued Pilot line or orifice clogged 12 Non functioning thermopile 13 Air for combustion obstructed 14 Flammable vapors incident Flame Lock function utilized HIGH OPERATION COSTS Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall INSUFFICIENT HOT WATER Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure SLOW HOT WATER RECOVERY Insufficient secondary air Flue clogged Low gas pressure 4 Improper calibration Thermostat set too low Water heater too small Wasted hot water DRIP FROM RELIEF VALVE Excessive water pressure Use a pressure reducing valve and relief valve Heater stacking Lower the thermostat s
39. ions of pipe insulation as needed Figure 15B T amp P Relief Valve Insulation T amp P Relief Valve Insulation Manual Relief Lever T amp P Relief Valve T amp P Relief Valve Drain Line Special Applications Combination Space Heating Potable Water System Some water heater models are equipped with inlet outlet tappings for use with space heating applications If this water heater is to be used to supply both space heating and domestic potable drinking water the instructions listed below must be followed e Be sure to follow the manual s shipped with the air handler system e This water heater is not to be used as a replacement for an existing boiler installation e Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping e Ifthe space heating system requires water tempera tures in excess of 120 F a mixing valve or an anti scald device should be installed per its manufacturer s instructions in the domestic potable hot water supply to limit the risk of scald injury e Pumps valves piping and fittings must be compatible with potable water e A properly installed flow control valve is required to pre vent thermosiphoning Thermosiphoning is the result of a continuous flow of water through the air handler circuit during the off cycle Weeping blow off of the temperature and pressure relief valve T amp P or higher
40. isk of being scalded Feel water before bathing or showering Temperature limiting valves are available The thermostat is adjusted to the pilot position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 19A There is a hot water scald potential if the thermostat is set too high NOTE Temperatures shown on the gas control valve thermostat are approximates The actual temperature of the heated water may vary IMPORTANT Adjusting the thermostat past the 120 F bar on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within Table 4 Time for Permanent Burns 2nd amp 3rd Degree Most Severe Bums Time for 1st Degree Burn Less Severe Bums Water Temperature F normal shower temp pain threshold 35 minutes 1 minute 5 seconds 2 seconds 45 minutes 5 minutes 25 seconds 5 seconds 1 second 2 seconds 154 instantaneous 1 seconds U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 Figure 19A Gas Control Valve Thermostat Settings Gas Control Temperature Knob T VAC pior OFF Igniter NOTE During low demand periods when hot water is not being used a lower therm
41. lighting instructions on the front of the power millivolts to keep it lit water heater and record any diagnostic codes See Diagnostic Status Light Code section 1 FLASH EVERY 3 SECONDS Normal operation No corrective action necessary 2 FLASHES Insufficient power millivolts to the 1 Check all wiring connections If problem gas control valve thermostat persists proceed to step 2 2 Replace the thermopile See Replacing the Pilot Thermopile Assembly 4 FLASHES High water temperature has Replace the gas control valve thermostat See activated the over heat sensor Removing and Replacing the Gas Control Valve Thermostat 5 FLASHES Sensor failure Replace the gas control valve thermostat See Removing and Replacing the Gas Control Valve Thermostat 7 FLASHES Gas Control Valve Thermostat Replace the gas control valve thermostat See failure Removing and Replacing the Gas Control Valve Thermostat 8 FLASHES This condition only appears if the Make sure that the gas control valve thermostat gas control temperature knob has knob is set to OFF Wait one minute Remove been turned off and the thermopile the outer door Look through the sight glass for continued to produce electric a pilot flame If a pilot flame is observed with the power This condition can occur gas control valve thermostat knob set to the OFF if the thermopile does not cool position the pilot valve is stuck open Turn the main down as qu
42. m ir Ga 7 p Floor Drain A Metal Drain Pan Massachusetts code does not allow this type of installation Solar Installation If this water heater is used as a solar storage heater or as a backup for the solar system the water supply temperatures to the water heater tank may be in excess of 120 F A mixing valve or other temperature limiting valve must be installed in the water supply line to limit the supply temperature to 120 F The unit must be set to Standard Mode See Operating the Temperature Control System section NOTE Solar water heating systems can often supply water with temperatures exceeding 180 F and may result in water heater malfunction 15 Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident The new technology used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make any required installation upgrades or changes Questions Call 1 877 817 6750 Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located with the water piping system Located as close to the gas piping and vent pipe system as possible
43. nding with an emery cloth or fine grit sandpaper of Removing and Replacing the Gas Control Valve Thermostat IMPORTANT The gas control valve thermostat is a standard valve with wire leads that connect to a thermal switch Removing the Gas Control Valve Thermostat 1 Turn the gas control temperature knob to the OFF position Figure 19A 2 Turn off the gas at the manual shut off valve on the gas supply pipe Figure 3 3 Drain the water heater Refer to the section of Draining and Flushing and follow the procedure 4 Disconnect the igniter wire from the igniter lead wire Use needle nose pliers to disconnect the red and white thermopile wires Disconnect pilot tube 7 16 wrench and manifold tube 3 4 wrench at the gas control valve thermostat Figure 22 NOTE L P Gas systems use reverse left hand threads on the manifold tube 5 Refer to Gas Piping Figure 3 and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat 6 To remove the gas control valve thermostat thread a 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use 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 Gas Control Valve Thermostat
44. nt openings to the outside or additional rooms within the building confined space 12 maximum All Air from Inside the Building When additional air is to be provided to the confined area from additional room s within the building the total volume of the room s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTU HR of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 5 Confined Permanent Openings 1 square inch 1000 BTU HR minimum 100 sq In Figure 5 All Air from Inside Building Confined Space Installation All Air from Outdoors Gable vent to outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The Install above ye insulation Ooo A fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Confined Outlet Ductwork must be of the same cross sectional area as HAS a the free area of the o
45. ntrol valve thermostat 4 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 Figure 3 Gas Piping Manual Gas Shut off Valven_ p z 5 Ground Joint gt Union Check with local _ Utility for minimum height R 3 Minimum tA Drip Leg Gas Pressure IMPORTANT The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s data plate The minimum supply pressure is for the purpose of input adjustment Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation e Ifthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water heater and its manual shut off valve must be disconnected from the gas supply piping system and the line capped e Ifthe gas lines are to be tested at a pressure less than 14 W C the water heater must be isolated from the gas supply piping system by closing its manual shut off valve U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial star
46. ostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is expected to be more than normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to the vacation VAC setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather 19 Operating the Temperature Control System Figure 19B Status Codes List of status codes are shown at top of gas control valve thermostat Water Temperature Adjustment The water temperature can be adjusted from 55 F to 155 F Turn the Gas Control Temperature Knob to the desired setting temperature NOTE Some models are certified for 180 F outlet temperatures See the Data Plate on the front of the water heater for the maximum outlet temperature Operating Modes and Settings e Standard Mode The controller adjusts the water heater to maintain the temperature set by the user e Vacation Setting The controller adjusts the water temperature to approximately 55 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the water heater down to a setting that prevents the water from freezing 20 Status Light Code Normal Flashes e 0QFlashes Indicates Control Off Pilo
47. pening to which they connect The 4000 BTU IR minimum dimension of rectangular air ducts cannot be less i Inlet air than three inches Alternate from he The size of each of the two openings is determined by the AINEL crawl method in which the air is to be provided Refer to Table 3 to calculate the minimum free area for each opening Figures 6 7 and 8 are typical examples of each method 1 sq inch per Ep j hA i 4000 BTU HR oundation Louvers and Grilles Vent i ilati i Figure 6 In paloulanng irae arga Tor venanen and combustion All Air from Outdoors Inlet Air from Ventilated air supply openings consideration must be given to the Crawl Space Outlet Air to Ventilated Attic blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may Cabie veni require larger openings to achieve the required minimum a t0 outdoors free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille neta nove is known it should be used in calculating the specified free a area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow SE i Outlet air 20 25 of free area while metal louvers and grilles will Confined to attic allow 60 75 of free area Space 1 Sq inch per 4000 BTU HR Louvers and grilles must be locked open or interconnected with the equipment so that they are opened autom
48. quired to properly install this venting system you should not proceed but get help from a qualified person Draft Hood Installation Align the legs of the draft hood with the slots provided Insert the legs and secure the draft hood to the water heater s top with the four screws provided as shown in Figure 9 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 10 Figure 9 Draft hood Installation Sheet Metal Screws four provided K Draft hood Install the draft hood with the four screws provided Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is required the vent transition connection must be made at the draft hood outlet Vent Connectors 1 Type B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and ma
49. r heater or on the inside of water heater panels e Remove exterior packaging and place installation com ponents aside e Inspect all parts for damage prior to installation and start up e Completely read all instructions before attempting to assemble and install this product e After installation dispose of recycle all packaging materials AWARNING Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Location Requirements AWARNING Carbon Monoxide Poisoning Hazard Do not install in a mobile home Doing so can result in death or carbon monoxide poisoning The Flame Lock Safety System is designed to reduce the risk of flammable vapor related fires The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame trap The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the Flame Lock Safety System disables the water heater by shutting off the gas supply to the water heater s burner and pilot preven
50. r faucet be opened for several minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the faucet as water begins to flow Do not smoke or have any open flame near the faucet at the time it is open The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the Act Table Of Contents Water Heater Safety Installing Your Gas Water Heater Unpacking the Water Heater Location Requirements Gas Supply Combustion Air Supply and Ventilation Water System Piping Temperature amp Pressure Relief Valve Special Applications Installation Checklist Operating Your Water Heater Lighting Instructions Operating the Temperature Control System Operational Conditions Maintenance of Your Water Heater Troubleshooting Charts Repair Parts Illustration INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufact
51. r 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 If the status light does not start blinking within 90 seconds repeat steps 2 through 5 up to THREE 3 times waiting 10 minutes between lighting attempts The circuitry in this advanced gas valve requires that you wait 10 minutes between lighting attempts If the status light turns solid red release the gas go to the next step control temperature knob and repeat steps 2 through 5 waiting 10 minutes before attempting to relight the pilot 4 Turn the gas control temperature knob clockwise A to PILOT If the status light does not start blinking after three lighting attempts turn the gas control temperature knob to OFF and call a qualified service technician or your gas supplier Thermopile Pilot TO TURN OFF GAS TO APPLIANCE 1 Turn the gas control temperature knob counterclockwise to the OFF setting The status light will stop blinking and stay on for a short time after the water heater is turned off 17 L P G Bottled Propane Models Liquefied petroleum gas is over 50 heavier than air and in the occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces skirted areas under mobile homes even when ventilated closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P
52. re and Pressure Relief Valve is required but may not be factory installed nique Flame Lock Safety System parts x Uni FI Lock Safety Syst rt Listed Parts Kits and Illustrations Item 12 Pilot assembly kit which contains the pilot assembly thermopile and retainer clip Natural Gas Item 12 Pilot assembly kit which contains the pilot assembly thermopile and retainer clip L P Gas Item 13 Burner Natural Gas L P Gas Item 13 Burner L P Gas Item 14 Manifold door assembly which contains the manifold tube gasket door pilot tube thermopile manifold component block with retainer clip thermal switch and pilot assembly Natural Gas Low Nox Item 14 Manifold door assembly which contains the manifold tube gasket door pilot tube thermopile manifold component block with retainer clip thermal switch and pilot assembly L P Gas Item 15 Contains manifold component block and retainer clip Item 16 Contains manifold door gasket Item 17 Contains viewport Item 12A Item 13A Item 13B Item 14A Item 14B Item 15 Item 17 31 Registered trademark TM Trademark of Whirlpool U S A 2010 Whirlpool Corporation All rights reserved Manufactured under license by American Water Heater Company Tennessee Warranty provided by Manufacturer
53. rner and the pilot if the flame is absent This unit is also equipped with a thermal switch designed to shut off the gas supply in the event the heater has been exposed to flammable vapors spilled gasoline or paint fumes for example poor combustion caused by a blocked vent or insufficient combustion air If the switch opens check the flame trap for signs of high temperature blue or black discoloration and inspect your installation for any problems with venting or combustion air See Pilot Light Troubleshooting Flowchart on page 29 Reset the switch by depressing the small button in the center of the switch IMPORTANT Correct any issues prior to resetting the switch Contact the Product Service and Support Department for service information at 1 877 817 6750 A temperature limit switch or ECO Energy Cut Off sensor located in the gas control valve thermostat is used to shut off the water heater if the water temperature exceeds 189 F 87 C for 155 F models or 199 F 93 C for 180 F models See the data plate for your model The Diagnostic Status Light will flash a code indicating an Overheat Failure 4 Flashes See Operating the Temperature Control System If the ECO has functioned the gas control valve thermostat should be replaced by a qualified person Contact your local dealer for service information Anode Rod Water Odor Each water heater contains at least one anode rod which will slowly deple
54. spection of the production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic Shut off Devices for Hot Water Supply Systems ANSI Z21 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the data plate 14 IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve e Must not be in contact with any electrical part e Must be connected to an adequate discharge line e Must not be rated higher than the working pressure shown on the data plate of the water heater The Discharge Line e Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line e Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adeq
55. substances are in use If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location e Select a location near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface Do not install in bathrooms bedrooms or any occupied room normally kept closed e Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows e Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the
56. t Customer Service at 1 877 817 6750 Refer to the Maintenance of manual for information on cleaning the flame trap and burner NOTE If you are still experiencing difficulties after Does we name ap Reassemble the heater press the thermal following the steps in sections A B and C please show signs of switch and attempt to return the heater to y discoloration service Does the pilot remain lit contact Customer Service at 1 877 817 6750 YES YES NO Shut off the gas supply to the water heater at the manual gas shut off valve and contact Customer Service at 1 877 817 6750 Figure 30 Thermal Switch Location NO Go to section C Set to desired temperature Does the diagnostic status light on the gas control valve thermostat give a two flash error code Refer to the Replacing the Pilot Assembly instructions in the manual Reassemble and restore to service 29 REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information 1 Model serial and product number 2 Type of gas 3 Item number 4 Parts description Repair Parts List Fal Parts Description e COLD WATERDIPTUBE SS Ysa LOCATED TOP OR SIDE o DRAINVALVE SOS with thermal switch wire lead PILOT THERMOPILE ASSEMBLY KIT Pictured on next page 30 LEGEND A Special anode rod see page 21 Temperatu
57. t Out e 1 Flash Indicates Normal Operation e Continuous Light indicates the gas control valve thermostat is shutting down Diagnostic Flashes If the water heater is not working look for the following diagnostic flashes after lighting the pilot 2 Flashes Indicates Thermopile Voltage Low 4 Flashes Indicates Overheat Failure 5 Flashes Indicates Sensor Failure 7 Flashes Indicates Electronic Control Failure 8 Flashes See Status Light Code Troubleshooting Chart Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces This will produce a sizzling or frying noise NOTE This condensation is normal and should not be confused with a leaking tank Condensation may increase or decrease at different times of the year High efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a large amount of hot water is being used NOTE Do not confuse this with a tank leak Once the water reaches a temperature of 120 F and the tank warms up usually 1 2 hours the condensation will stop IMPORTANT It is always recommended that a suitable metal drain pan be installed under the water heater to protect the area from water damage resulting from normal condensation production a leaking tank or piping
58. t edition Flue baffle properly positioned in the flue tube Check the vent system for restrictions obstructions and check the vent termination height Refer to the Air Supply and Ventilation section of this water heater manual for specific requirements Recheck for sufficient combustion air supply Water System Piping Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Mixing valve when applicable installed per manufacturer s instructions see Water Temperature Regulation section Gas Supply and Piping Gas type is the same as that listed on the water heater data plate Gas line equipped with shut off valve union and drip leg Adequate pipe size and approved pipe material An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks Correct any leak found TEFLON is a registered trademark of E I Du Pont De Nemours and Company OPERATING YOUR WATER HEATER AWARNING Explosion Hazard Lighting Instructions Read and understand these directions thoroughly before attempting to light or re light the pilot Make sure the vie
59. t of the water heater The water heater is certified for installation on a combustible floor e IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least three inches 76 2mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 2 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service Figure 2 Minimum Clearance Locations Jp Saek Sides Front a minimum Sides for service State of California NOTE The water heater must be braced anchored or strapped to avoid moving during an earthquake Contact local utilities for code requirements in your area visit http Awww dsa dgs ca gov or call 1 916 445 8100 and request instructions Gas Supply AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve Do not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Gas Requirements IMPORTANT Read the data plate to be sure the water heater is made for the type of gas you will be
60. t up The gas lines should be purged of air by a qualified person after installation of the gas piping system While purging the gas piping system of air make sure that the fuel is not spilled in the area of the water heater installation or any source of ignition If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL GAS instructions on the cover of this manual LP Gas Only AWARNING Explosion Hazard Have a qualified person make sure L P gas pressure does not exceed 13 water column Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Failure to do so can result in death explosion or fire Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Size in 10 20 30 40 50 60 Length of Pipe Feet 70 80 90 100 125 150 175 200 After the length of pipe has been determined select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the water heater By formula Cu Ft Per Hr Required Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT 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
61. tdoors Using a Single Permanent Opening Vent Pipe System This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation section This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z2223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere IMPORTANT The use of vent dampers is not recommended by the manufacturer of this water heater Although some vent dampers are certified by CSA International this certification applies to the vent damper device only and does not mean they are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations IMPORTANT If you lack the necessary skills re
62. te due to electrolysis prolonging the life of the water heater by protecting the glass lined tank from corrosion Adverse water quality hotter water temperatures high hot water usage hydronic heating devices and water softening methods can increase the rate of anode rod depletion Once the anode rod is depleted the tank will start to corrode eventually developing a leak Certain water conditions will cause a reaction between the anode rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfide gas dissolved in the water IMPORTANT Do not remove this rod permanently as it will void any warranties A special anode rod may be available if water odor or discoloration occurs NOTE This rod may reduce but not eliminate water odor problems The water supply system may require special filtration equipment from a water conditioning company to successfully eliminate all water odor problems 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 removed from the water heater tank every 3 years for inspection NOTE artificially softened water requires the anode rod to be inspected annually The following are typical but not all signs of a depleted anode rod
63. the Lighting Instructions on page 17 N 9 Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately 10 Replace the outer door Figure 28A Combustion Chamber Flame trap Door Gasket Figure 28B Close up inside view of Manifold Assembly C the combustion chamber gt 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 See Figure 29 Use only factory authorized piezoelectric igniter parts for replacement Figure 29 Gas Igniter Assembly iS K Thermopile Bracket Wire to Electrode Igniter Button 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 igniter if defective Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sa
64. ting 6 Install adequate heater 7 Correct piping dip tube must be in cold inlet 8 Advise customer 1 2 3 1 Replace thermostat 2 Replace thermostat Provide ventilation to water heater Check flue way flue baffle and burner 2 Clean locate source and correct 3 Provide fresh air ventilation 1 Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct 4 Replace thermostat Provide fresh air ventilation CONDENSATION 1 Temperature setting too low Increase the temperature setting 1 BURNER FLAME FLOATS AND LIFTS OFF PORTS Orifice too large High gas pressure Flue clogged 4 Cold drafts 2 3 5 6 Burner flame yellow lazy 2 3 Replace with correct orifice Check with gas utility company Clean flue and burner locate source and correct 4 Locate source and correct 2 3 5 6 See Burner Flame Yellow Lazy 2 3 1 1 1 BURNER FLAME TOO HIGH 1 Orifice too large Replace with correct orifice FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly 1 Replace thermostat 2 Low gas pressure 2 Check with gas utility company PILOT FLAME 1 Pilot line or orifice clogged TOO SMALL 2 Low gas pressure 1 Clean locate source and correct 2 Check with gas utility company 27 STATUS LIGHT CODE TROUBLESHOOTING CHART 0 FLASHES LED NOT LIT Pilot light is not lit Not enough Follow the
65. ting re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified person to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame trap and require replacement of the entire water 4 heater Note Not following these instructions and or an inadequate air supply can cause the Flame Lock Safety System to disable the water heater Please make required installation and venting air supply changes prior to resetting the system see Combustion Air Supply and Ventilation section IMPORTANT This water heater has a resettable thermal switch installed as part of the Flame Lock Safety System Do not attempt to disable or modify this feature in any way Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished Open the doors and windows for ventilation while flammable
66. tings IMPORTANT Always use a good grade of joint compound and be certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 13 Connect the cold water supply 3 4 NPT to the fitting marked C Connect the hot water supply 3 4 NPT to the fitting marked H IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 14 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 4 Ifinstalling the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion section 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 Atemperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the wat
67. uate drain inside the building e Must be capable of withstanding 250 F 121 C without distortion e Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation Some Models 1 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 15B 2 Locate the slit running the length of the T amp P relief valve insulation 3 Spread the slit open and fit the insulation over the T amp P relief valve See Figure 15B Apply gentle pressure to the insulation to ensure that it is fully seated on the T amp P Relief Valve Once seated secure the insulation with duct tape IMPORTANT The insulation or tape should not block or cover the T amp P relief valve drain opening Also the insulation or tape should not block or hinder access to the manual relief lever Figure 15B 4 Locate the hot water outlet amp cold water inlet pipes to the water heater 5 Locate the slit running the length of a section of pipe insulation 6 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape 7 Repeat steps 5 and 6 for the hot water outlet pipe 8 Add additional sect
68. ured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes Consumer Information This water heater is design certified by CSA International as a Category I non direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition This is available from the following CSA America Inc 8501 East Pleasant Valley Road Cleveland OH 44131 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 Check your phone listings for the local authorities having jurisdiction over your installation Consumer Responsibilities This manual has been prepared to acquaint you with the installation operation and maintenance of your gas water heater and provide important safety information in these areas Read all of the instructions thoroughly before attempting the installation or operation of this water heater Do not discard this manu
69. wport is not missing or damaged See Figure 23 Make sure the tank is completely filled with water before lighting the pilot Check the data plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the data plate If you have any questions or doubts consult your gas supplier or gas utility company Replace viewport if glass is missing or damaged Failure to do so can result in death explosion or fire FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion C Use only your hand to push in or turn the gas control A This appliance has a pilot which is lighted by a temperature knob Never use tools If the knob will not piezoelectric igniter When lighting the pilot follow these instructions exactly 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 WHAT TO DO IF YOU SMELL GAS push in or move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance Water heaters subjected to flood Do not try to light any appliance Do not touch any electrical switch do not us
70. y not pass through attic spaces crawl spaces or any confined or inaccessible location A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases e Install without dips or sags with an upward slope of at least 1 4 inch per foot e Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage e The length of the vent connector cannot exceed 75 of the vertical vent height The vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition e It is recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system to improve conditions for positive flow of venting gases IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing
71. ylene This water heater must not be installed using iron piping or PVC water piping e Use only pumps valves or fittings that are compatible with potable water e Use only full flow ball or gate valves The use of valves that may cause excessive restriction to water flow is not recommended e Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used e Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion As water is heated it expands thermal expansion In a closed system the volume of water will grow 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 discharg

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