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1. Pilot And Main Burner Flames Replacing The Manifold Burner Assembly Piezoelectric Igniter Testing The Igniter Removing And Replacing The Gas Control Valve Thermostat Removing The Manifold Burner Assembly Removing The Burner From The Manifold Burner Assembly Replacing The Pilot Thermopile Assembly Temperature amp Pressure Relief Valve Draining ee Cathodic Protection Drain Valve Washer Replacement Anode Rod Maintenance LEAKAGE CHECKPOINTS Service TROUBLESHOOTING GUIDELINES NOTES RESIDENTIAL GAS WARRANTY 21 21 21 22 22 22 22 24 24 24 24 25 25 25 25 26 27 27 28 28 28 28 28 30 30 31 33 34 INTRODUCTION Thank You for purchasing this water heater Properly installed and maintained it should give you years of trouble free service Abbreviations Found In This Instruction Manual e CSA Canadian Standards Association e ANSI American National Standards Institute NEPA National Fire Protection Association e ASME American Society of Mechanical Engineers e AHRI Air Conditioning Heating and Refrigeration Institute e LLC Low Lead Content This gas fired water heater is design certified by American Na tional Standard ANSI Z21 10 1 CSA 4 1 current edition
2. FIGURE 20 VENT RESTRICTER PLATE For short horizontal vent runs see Figure 16 place the restricter plate over the flue tube reducer before connecting the inner cor rugated tube to the flue tube reducer DO NOT use the restricter plate if the horizontal run is greater than 30 in UPPER AIR INLET BOX RESTRICTER FLUE TUBE REDUCER FIGURE 21 Pull and connect the inner corrugated tube to the water heater s flue tube reducer with hi temp red silicone included and gear clamp Make sure this connection is tight and leak proof The sealant between the inner corrugated tube and water heater s flue tube reducer must be hi temp red silicone or other material suitable for 600 F continuous service FIGURE 22 Apply hi temp red silicone included around the collar on air manifold box Pull corrugated vent tube all the way on to collar and secure with one sheet metal screw approx 3 4 in up from edge of vent tube Pull gear clamp past screw and tighten A ss gt FIGURE 23 CONDITION 1 Where a straight vent arrangement is impossible a horizontal 90 degree maximum bend can be made Use the water heater cas ing outer diameter as a template to form the corrugated tube gt S TOP VIEW FIGURE 24 CONDITION 2 Where floor joists impede venting a rise or drop to complete the vent termination is possible All insta
3. FIGURE 29 29 To replace the anode 1 Turn off gas supply to the water heater 2 Shut off the water supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 5 gallons of water from tank Refer to Draining and Flushing for proper procedures Close drain valve 4 Remove old anode rod 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open a nearby hot water faucet to purge air from water system Check for any leaks and imme diately correct any if found 7 Restart the water heater as directed in this manual See the Repair Parts Illustration for anode rod location LEAKAGE CHECKPOINTS SERVICE mmm If a condition persists or you are uncertain about the operation of the water heater contact a service agency Use this guide to check a Leaking water heater Many sus pected Leakers are not leaking tanks Often the source of the water can be found and corrected If you are not thoroughly familiar with gas codes your water heater and safety practices contact your gas supplier or quali fied installer to check the water heater Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water Never use this water heater unless it is completely filled with water To preve
4. CAUTION Improper installation and use may result in property damage Avoid water heater damage Install thermal expansion tank or device if necessary Contact qualified installer or service agency Water supply systems may because of such events as high line pressure frequent cut offs the effects of water hammer among others have installed devices such as pressure reducing valves check valves back flow preventers etc to control these types of problems When these devices are not equipped with an internal by pass and no other measures are taken the devices cause the water system to be closed As water is heated it expands thermal expansion and closed systems do not allow for the expansion of heated water 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 pre mature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up 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 in
5. Properly sized temperature relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Cancause serious injury or death This heater is provided with a properly certified combination temperature pressure relief valve by the manufacturer The valve is certified by a nationally recognized testing labora tory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 22 CSA 4 4 and the code requirements of ASME If replaced the valve must meet the requirements of local codes but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph The valve must be marked with a maximum set pressure not to ex ceed the marked hydrostatic working pressure of the water heater 150 psi 1 035 kPa and a discharge capacity not less than the water heater input rate as shown on the model rating plate For safe operation of the water heater the relief valve must not be removed from its designated opening nor plugged The temperature pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve Position the valve downward and provide tubing so that any dis charge will exit only within 6 in above or at any distance below the structural floor Be certain that no contact
6. PREPARING FOR THE INSTALLATION ____ 1 Read the General Safety section page 3 of this manual first and then the entire manual carefully If you don t follow the safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the water heater and your safety Since we cannot put every thing on the first few pages READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER 2 The installation must conform with these instructions and the local code authority having jurisdiction In the absence of lo cal codes installations shall comply with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA This publi cation is available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 3 If after reading this manual you have any questions or do not understand any portion of the instructions call the local gas utility or the manufacturer whose name appears on the rating plate 4 Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe instal lation are very important in prev
7. R KF a a a we ee x we rae Zy FIGURE 12 D gt LOCATING CLEARANCE HOLE FOR VENT Cut a clearance hole approximately 7 in in diameter through the exterior wall for the vent assembly The recommended height is 68 in for 40 gal models and 76 in for 50 gal 50 gal Hi Input and 75 gal models as measured from the hole center to bottom of water heater The maximum height recommended is 80 in or H in compliance with Figure 14 Where the wall is combustible and the wall thickness is over 14 in 1 in clearance to combustible surfaces around the vent ter minal is needed The first 14 in is zero clearance TO BOTTOM OF HEATER FIGURE 14 Minimum 9 in for appliances with ini i 10 000 btuh 3 Kw to 50 000 btuh Minim m 18 in 15 Kw inputs and 12 in for appliances greater than 50 000 btuh 15 Kw to 12in a window or door above grade or that may be opened anticipated snow level _ 12 from soffit ft Minimum Minimum 12 in 2 ft under veranda porch from outside deck or balcony corner see footnote 1 Minimum 3 ft above if within oft L horizontally to E a mechanical air supply inlet Minimum Minimum 9 in for appliances with 10 000 btuh 3 Kw id to 50 000 btuh 15 Kw inputs 12 in for appliances greater rom Sides anove OF than 50 000 btuh 15 Kw to
8. Contaminants in gas lines can cause fire or explosion Clean all installation gas piping before Install drip leg in accordance with NFPA54 A sediment trap dirt leg shall be installed as close to the inlet of the water heater as practical at the time of water heater installa tion The sediment trap dirt leg shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap dirt leg If a tee fitting is used it shall be installed in conformance with one of the methods of installation shown in Figures 7 and 8 Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a sediment trap dirt leg must be incorporated in the piping The sediment trap dirt leg must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 HOT WATER OUTLET COLD WATER INTLET SHUTOFF VALVE UNION TEMPERATURE AND PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG METAL DRAIN PAN DRAIN VALVE 6 MAXIMUM FLOOR DRAIN FIGURE 9 FILLING THE WATER HEATER CAUTION Avoid water heater damage Filltank with water b
9. WHETHER DIRECT OR INDIRECT AND WHETHER ARIS ING INCONTRACT OR IN TORT Should governmental regulations or industry standards pro hibit the Manufacturer from furnishing a comparable model replacement under this warranty the Owner will be furnished with the closest comparable water heater meeting the then current governmental regulations and industry standards A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards Model Number Serial Number INSTALLATION INFORMATION Date Installed Company s Name Street or P O Box City State and Zip Code Phone Number Plumber s Name A O Smith Water Heaters 500 Tennessee Waltz Parkway Ashland City TN 37015 Phone 800 433 2545 Fax 800 644 9306 Website www hotwater com A O Smith 500 TENNESSEE WALTZ PARKWAY ASHLAND CITY TN 37015 PHONE 1 800 433 2545 FAX 1 800 433 2515 www aosmithwaterheaters com email parts hotwater com 36
10. Lower the thermostat setting 4 Temperature setting too high 3 See Closed System Thermal Expansion 4 Decrease the temperature setting THERMOSTAT FAILS TO 1 Defective gas control thermostat 1 Replace gas control thermostat SHUT OFF 2 Improper calibration 2 Replace gas control thermostat 1 Insufficient secondary air 1 Provide ventilation to water heater Check 2 Flue clogged flue way flue baffle burner 3 Heater installed in a confined area 2 Clean locate source and correct 3 Provide fresh air ventilation COMBUSTION ODORS 1 Insufficient secondary air 1 Provide ventilation to water heater Check 2 Low gas pressure flue way flue baffle burner 3 Flue clogged 2 Check with gas utility company SMOKING AND CARBON FORMATION SOOTING 4 Defective gas control thermostat 3 Clean locate source and correct 5 Heater installed in a confined area 4 Replace gas control thermostat 6 Burner flame yellow lazy 5 Provide fresh air ventilation 6 See Burner Flame Yellow Lazy 1 Temperature setting too low 1 Increase the temperature setting CONDENSATION 2 Water heater too small 2 Install adequate size heater 1 Orifice too large 1 Replace with correct orifice 2 High gas pressure 2 Check with gas utility company 3 Flue clogged 3 Clean flue and burner locate source amp cor 4 Cold drafts rect 4 Locate source and correct BURNER FLAME TOO HIGH 1 Orifice too large 1 Replace with correct orifice 1 Def
11. dirt leg in gas line 4 Clean locate source and correct 5 Replace thermopile 6 Locate source and correct 7 Replace gas control thermostat 8 Replace igniter or pilot assembly 9 Check with gas utility company 1 Set temperature dial to lower setting 2 Drain Flush Provide water treatment if need ed 3 Install adequate size heater 4 Correct piping dip tube must be in cold inlet 5 Repair faucets 6 Check with utility repair at once 7 Advise customer 8 Insulate piping 9 Insulate piping 10 Check dip tube Replace if faulty Clean locate source and correct Check with gas utility company Replace pilot Turn temperature dial to desired setting Drain flush provide water treatment if need ed Install adequate size 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 Clean flue locate source and correct Check with gas utility company Replace gas control thermostat Turn temperature dial to desired setting Install adequate size heater Correct piping dip tube must be in cold inlet Advise customer ONOARWN PROBLEM POSSIBLE CAUSE S CORRECTION 1 Excessive water pressure 1 Use a pressure reducing valve and relief 2 Heater stacking valve DRIP FROM RELIEF VALVE 3 Closed water system 2
12. sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 25 AWARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace manifold component block if miss ing or removed Replace door gasket if damaged Failure to do so can result in death explosion or fire PIEZOELECTRIC IGNITER SYSTEM The piezoelectric igniter system consists of the igniter button electrode and wire The pilot is ignited by an electric spark gen erated when the igniter button is pressed See Figure 30 BRACKET WIRE TO ELECTRODE IGNITER BUTTON FIGURE 30 Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A vis ible 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
13. 12 Water Potable Heating And Space Heating 13 Closed Water 13 Gas RIDING soais eater ake eee noe Oe 14 Sediment 15 Filling The Water 15 Venting eee 15 High Altitude 1 lt lt 5 16 Combustion Air 16 Vent Terminal 16 DV Termination Safety 16 Vent lt 17 Locating Clearance Hole For 17 High Rise Vent Arrangement 17 Standard Vent 18 Vent Assembly 18 Securing Vent Termination Assembly To The Exterior sch ede de 18 Uncompressing The Corrugated Tubing 18 Vent Restricter 18 Offset Vent 19 TEMPERATURE REGULATION Temperature Operating The Temperature Control System FOR YOUR INFORMATION External Damage Start Up Operational MAINTENANCE Venting System 1 5
14. Heating All models are considered suitable for water potable heating and space heat ing ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes wash ing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requir ing a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as Mixing Valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores Consult a Qualified Installer or Service Agency Follow mixing valve manufacturer s inst
15. a non mechanical air supply inlet below permanantly into building or combustion air inlet to another appliance closed window or door V VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED 1 Permitted only if veranda porch deck or balcony is fully opened on a minimum of two sides beneath the floor 2 Avent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings FIGURE 15 17 lt 7 in MIN 3 6 in 26in 80 in MAX WALL P EA EEA POMEL GES ste lee TET EREE SLATES SALES PEREL RA SOCAL SLPS 44 2 1 in _4 7 47 LOST OT POLIS 4744 COPPELL LLALLERI FIGURE 16 If the horizontal distance is less than 30 in the restricter plate must be installed see Figure 21 NOTE The length of unstretched corrugated tube could cause the length of the vent run to exceed the minimum In this case cut off a piece of the corrugated tube to acheive the 17 in minimum vent length VENT ASSEMBLY The vent tube and terminal can be assembled as shown in Fig ure 17 There are springs fastened inside the corrugated tube When the vent tubes are pulled to a required length the springs will still be equally spaced FIGURE 17 SECURING VENT TERMINATION ASSEMBLY TO THE EXTERIOR WALL Some models are supplied with trim plates which may be us
16. are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting A WARNING Fire or Explosion Hazard Donotstore or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid allignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater AWARNING For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged A WARNING Explosion Hazard Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in opening provided A WARNING Breathing Hazard Carbon Monoxide Gas Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude orifice must be installed for operation above 7 700 feet not operate if soot is present Do not place chemical vapor emitting products near water heater e Gas and carbon monoxide detectors are available Breathing car
17. has not been altered defaced or removed except as required by the warrantor used in an open system or in a closed system with a properly sized and installed thermal expansion tank operated with properly installed sediment trap dirt leg in the gas supply line fired with the fuel for which it was factory built fired at the factory rated input operated with the inner and outer combustion chamber doors in place and all factory seals to combus tion chamber intact installed with no attempted nor actual modification or alteration of the water heater s design in any way includ ing but not limited to the attachment of non company approved appliances or equipment non corrosive non contaminated Any accident to the water heater or any part thereof includ ing freezing fire floods or lightning any misuse abuse or alteration of it any operation of it in a modified form any operation of the water heater on desalinated deionized water or any damage caused by attempts to repair tank leaks or parts will void this warranty This warranty does not cover water heaters replaced for cosmetic reasons or for reasons of noise taste odor discolored and or rusty water This warranty does not apply to water heaters used to heat pools whirlpools or hot tubs or used for space heating where its sizing does not conform with specifications of the heating component manufacturer This warranty gives you specific legal rights and you ma
18. is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 ft or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve see Figures 4 or 9 No valve or other obstruction is to be placed between the relief valve and the tank Do not connect tubing directly to discharge drain unless a 6 in max air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in quantities should circumstances demand If the discharge pipe is not connected to a drain or oth er suitable means the water flow may cause property damage CAUTION Temperature pressure relief valve discharge pipe must terminate at adequate drain The Discharge Pipe e Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall be plugged or blocked Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe e Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommend ed that the discharge pipe be terminated at an adequate drain inside the building e Shall not have any valve between the relief
19. or turn 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 contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced Gas Control amp Temperature Kriob FIGURE MAIN BURNER 120 F 120 120 Status f JX Mark Light A VAC OF POSITION PILOT POSITION GAS CONTROL CONTROL KNOB FIGURE D STOP It is imperative that you read all safety warnings before lighting the pilot 2 Turn the gas control temperature knob counterclockwise f to the OFF position Wait ten 10 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step Turn the gas control temperature knob clockwise N to PILOT See Figure B Press the gas control temperature knob all the way in and hold it in The knob should travel in about 6mm 1 4 inch if it is set to PILOT correctly While holding the gas control temperature knob in click the igniter button continuously about once a second for up to 90 seconds or until Status Light begins to blink When the status light starts blinking release the gas control temperature knob Set the gas control tem
20. the first time b Burning gas produces water vapor in water heaters par ticularly high efficiency models where flue temperatures are lower c Large amounts of hot water are used in a short time and the refill water in the tank is very cold Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a sizzling or frying noise Because of the suddenness and amount of water condensate water may be diagnosed as a tank leak After the water in the tank warms up about 1 2 hours the condition should disap pear Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up An undersized water heater will cause more condensation The water heater must be sized properly to meet the family s de mands for hot water including dishwashers washing machines and shower heads Excessive condensate may be noticed during the winter and early spring months when incoming water temperatures are at their lowest Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor SMOKE ODOR It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from metal parts and will disappear in a short while 22 THERMAL EXPANSION
21. valve and tank ADANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge The temperature pressure relief valve must be manually oper ated at least once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and re place the temperature pressure relief valve with a new one WATER POTABLE HEATING AND SPACE HEATING _ 1 All piping components connected to this unit for space heat ing applications shall be suitable for use with potable water 2 Toxic chemicals such as those used for boiler treatment shall NEVER be introduced into this system 3 This unit may NEVER be connected to any existing heating system or component s previously used with a non potable water heating appliance 4 When the system requires water for space heating at tem peratures higher than required for domestic water purposes a mixing valve must be installed see Figure 6 for suggested piping arrangement A WARNING not connect to non potable water system SHUT OFF VALV
22. who sold the heater or with any other dealer handling the warrantor s products If this is not practical the owner should contact A O Smith Water Heaters 500 Tennessee Waltz Parkway Ashland City Tennessee 37015 Phone 1 800 527 1953 or visit our website www hotwater com Replacement Parts may be ordered through authorized ser vicers or distributors Refer to your local Yellow Pages for where to call or contact A O Smith Water Heater Parts Full fillment 125 Southeast Parkway Franklin TN 37068 phone 1 800 433 2545 The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor Dealer replacements are made subject to in warranty valida tion by warrantor PROOF OF PURCHASE AND PROOF OF INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGINAL OWNER THIS FORM DOES NOT CONSTITUTE PROOF OF PURCHASE OR PROOF OF INSTALLATION DISCLAIMERS NO EXPRESSED WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RE SPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION OPERATION REPAIR OR REPLACE MENT OF THE HEATER OR PARTS THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CON SEQUENTIAL DAMAGE THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHER WISE FOR DAMAGE TO ANY PERSONS OR PROPERTY
23. D WATER INLET PIPE THERMAL TRIM PLATE EXPANSION TANK OUTSIDE TRIM PLATE INSIDE INLET VALVE VACUUM RELIEF INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALL PER INSTALLED IN A CLOSED INLET DIP LOCAL CODES SYSTEM TUBE HOT WATER OUTLET PIPE PILOT THERMOPILE TEMPERATURE AND PRESSURE RELIEF VALVE RETAINER CLIP MANIFOLD DOOR MANIFOLD s COMPONENT BURNER AND OTHER DISCHARGE PIPE BLOCK FITTINGS NOT SHOW DO NOT CAP OR FOR CLARITY PLUG GAS CONTROL VALVE THERMOSTAT MAIN MANUAL GAS SHUTOFF VALVE GROUND JOINT List of status codes are shown UNION geo at top of gas control valve thermostat DRAIN VALVE SEDIMENT Sl J ld TRAP DIRT OF METAL LEG i DRAIN PAN 6 MAXIMUM AIR GAP OUTER DOOR ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMER FIGURE 1 7 MIXING VALVE SUGGESTED PIPING ARRANGEMENT FOR TOP CONNECTIONS TO SUITABLE DRAIN SHUT OFF VALVE 18 COLD WATER INLET TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG CERTAIN MODELS ARE EQUIPPED WITH SIDE PLUMBING CONNECTIONS FOR SPACE HEATING DRAIN VALVE METAL DRAIN PAN 6 MAXIMUM AIR GAP FIGURE 2 This water heater has been design certified as complying with American National Standard CSA Standard for water heaters and is considered suitable for Water Potable Heating and Space
24. E MIXING VALVE 0 7 9 _ COLD WATER INLET SUGGESTED PIPING ARRANGEMENT FOR TOP CONDITIONS TEMPERED POTABLE WATER NON TEMPERED WATER SUPPLY NON TEMPERED WATER RETURN FIGURE 6 CLOSED WATER __ A closed system will exist if a back flow preventer check valve pressure reducing valve or other similar device is installed in the cold water line between the water heater and the street main or well Excessive pressure may develop due to the thermal ex pansion of heated water causing premature tank failure or inter mittent relief valve operation This type of failure is not covered by the limited warranty An expansion tank may be necessary in the cold water supply to alleviate this situation see Figure 1 Contact the local plumbing authority If the temperature and pressure relief valve on the appliance discharges periodically this may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE The water supply pressure should not exceed 80 psi If this oc curs 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 AWARNING Do not use water heater with any gas other than the gas shown on the r
25. ES THROUGH TOP THROUGH CENTER OF PASS THROUGH HOLE OF MANIFOLD MANIFOLD BOTTOM HOLE OF COMPONENT BLOCK COMPONENT BLOCK MANIFOLD LARGEST HOLE SMALLEST HOLE COMPONENT BLOCK FIGURE 27 10 Carefully bend the new pilot tube to match the bend of the manifold tube Note When bending DO NOT crimp or crease the pilot tube 11 Before you proceed to the next step install the new brass fer rule nut the gas control valve thermostat s pilot tube open ing HAND TIGHT ONLY 12 Install the manifold ourner assembly Refer to the Replacing the Manifold Burner Assembly section for instructions TEMPERATURE amp PRESSURE RELIEF VALVE At least once a year the temperature and pressure relief valve Figure 1 must be checked to ensure that it is in operating condi tion Lift the lever at the top of the valve several times until the valve seats properly and operates freely If water does not flow remove the valve and inspect for obstruc tions or corrosion Have a qualified service agent replace with a new valve of the recommended size as necessary Do not attempt to repair the valve as this could result in improper opera tion and a tank explosion In areas with poor water conditions it may be necessary to inspect the T amp P valve more frequently ADANGER Burn hazard Hot water discharge Keep clear of relief valve discharge outlet THE WATER PASSING OUT OF THE VALVE DURING THIS CHECKING OPERA
26. HE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED 1212 PART NO 321348 001 SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situ A DANGER ation which if not avoided will result in injury or death WARNING Indicates a potentially hazardous situ A WARNING ation which if not avoided could result in injury or death CAUTION Indicates a potentially hazardous situa A CAUTION tion which if not avoided could result in minor or moderate injury CAUTION used without the safety alert symbol CA UTION indicates a potentially hazardous situation which i
27. Important Be careful not to bend or alter the position of the pilot tube It will be used as a bending template for the new pilot assembly Note the placement order of the wires in the manifold component block 5 Lift the pilot thermopile assembly including the igniter wire from the manifold assembly PILOT THERMOPILE PILOT THERMOPILE TUBE CONNECTOR Oa SCREW IGNITER WIRE RETAINER CLIP MANIFOLD DOOR MANIFOLD AP BURNER AND OTHER BLOCK FITTINGS NOT SHOW FOR CLARITY FIGURE 25 6 Read this step carefully before proceeding 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 27 THERMOPILE CONNECTOR THERMOPILE PILOT THERMOPILE ASSEMBLY PILOT TUBE NOT SHOWN FOR CLARITY FIGURE 26 7 Route the new pilot tube igniter wire and thermopile wire through the opening in the manifold door See Figure 25 8 Using the pilot screw removed earlier attach the pilot thermopile assembly Reattach the burn er to the manifold using the screws removed earlier Note Make sure the burner scoop is oriented to the pilot side of the manifold tube Figure 24 9 Reinstall the manifold component block in the manifold door Ensure that the pilot tube and wires are positioned as shown in Figure 27 MANIFOLD COMPONENT PILOT TUBE PASSES IGNITER WIRE PASSES THERMOPILE WIR
28. Instruction Manual RESIDENTIAL GAS WATER HEATERS bh DIRECT VENT GAS MODELS GDV GDVT A O lt NOT FOR USE IN MANUFACTURED MOBILE HOMES 500 Tennessee Waltz Parkway Ashland City TN 37015 eet CERTIFIED www ahridirectory org WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Donottry to light any appliance AWA RNING e Do not touch any electrical switch do Read and understand instruction h buildi manual and safety messages notuse any p one in your building before installing operating or servicing this water heater e Immediately call your gas supplier f iqhbor s hone Follow the Failure to follow instructions and roma _ 8 safety messages could result in gas supplier s instructions death or serious injury Instruction manual must remain with e If you cannot reach your gas supplier water heater call the fire department Installation and service must be For Your Safety performed by a qualified installer AN ODORANT IS ADDED TO THE GAS USED service agency or the gas supplier BY THIS WATER HEATER ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM T
29. OF A LICENSED TRADESMAN IN THE FIELD INVOLVED PLUMBING AIR SUPPLY VENTING AND GAS SUPPLY ARE REQUIRED INSPECT SHIPMENT There may be hidden damage caused in transit Check to be cer tain all parts of the venting system as listed below are present CAUTION IF THERE ARE ANY DAMAGED PARTS DO NOT INSTALL THIS WATER HEATER REPORT ANY SHORTAGE TO YOUR DISTRIBUTOR OR DAMAGE TO YOUR CARRIER GENERAL The installation must conform to these instructions and the lo cal code authority having jurisdiction In the absence of local codes the installation must comply with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 The code is available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury A DANGER Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes wash ing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot wat
30. OO SMALL INSUFFICIENT HOT WATER SLOW HOT WATER RECOV ERY 1 Low gas pressure 2 Flue clogged 3 Main burner line clogged 4 Obstruction in main burner orifice 1 Air in gas line 2 No gas 3 Dirt in gas lines 4 Pilot line or orifice clogged 5 Defective thermopile 6 Cold drafts 7 Gas control thermostat ECO switch open 8 Defective igniter or electrode 9 Low gas pressure 1 Thermostat set too high 2 Sediment or lime in tank 3 Water heater too small for job 4 Wrong piping connections 5 Leaking faucets 6 Gas leaks 7 Wasted hot water 8 Long runs of exposed piping 9 Hot water piping in exposed wall 10 Leaks or cracks in dip tube Pilot line or orifice clogged Low gas pressure Defective pilot 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 Insufficient secondary air Flue clogged Low gas pressure Improper calibration Gas control thermostat set too low Water heater too small Wrong piping connections Wasted hot water 9 31 1 Check with gas utility company 2 Clean locate source and correct 3 Clean locate source and correct 4 Clean or replace orifice 1 Bleed the air from the gas line 2 Check with gas utility company 3 Notify utility install sediment trap
31. Please refer to Figure 2 for suggested piping arrangement Water supply systems may because of such events as high line pressure frequent cut offs the effects of water hammer among others have installed devices such as pressure reducing valves check valves back flow preventers etc to control these types of problems When these devices are not equipped with an internal by pass and no other measures are taken the devices cause the water system to be closed 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 pre mature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up 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 harmful effects of thermal expansion Contact a plumbing service agency or your retail sup plier regarding the installation of a thermal expansion tank NOTE To protect against untimely corrosion of hot and cold water fittings it is str
32. TION MAY BE EXTREMELY HOT AVOID CONTACT AND DISCHARGE SAFELY TO PREVENT WATER DAMAGE DRAINING It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during op eration The water heater 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 2 Open a nearby hot water faucet until the water is no longer hot 3 Close the cold water inlet valve 4 Connect a hose to the drain valve and terminate it to an ad equate drain or external to the building 5 Open the water heater drain valve and allow all of the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the 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 ADANGER Bumhazard Hot water discharge Keep hands clear of drain valve discharge 28 CATHODIC PROTECTION __ The anode rod within the tank is designed to be slowly consumed cathodically minimizing corrosion in the glass lined tank A hy drogen sulfide rotten egg odor may result if water contains high sulfate
33. ame characteris tics This can be done by removing the Outer Door and viewing the main burner operation through the Viewport on the Inner Door see Figure 1 The main burner should provide complete combustion of gas ignite rapidly give reasonably quiet opera tion and cause no excessive flame lifting from the burner ports If the proper flame characteristics are not evident see Figure 1 make sure that the flow of combustion and ventilation air is not blocked in the venting system You should also check for sooting Soot is not normal and will impair proper combustion A visual inspection of the main burner and pilot assembly should also be done at least once a year see Figure 1 Soot build up indicates a problem that requires correction be fore further use Turn OFF gas to water heater and leave off until repairs are made because failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage If proper flame characteristics are not evident check for accumu lation of lint or other foreign material that restricts or blocks the air openings in the heater or burner BURNER FLAMES gt Inspect the burner flames through the viewport and compare them to the drawings in Figure 27 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 be all yellow o
34. and or minerals Chlorinating the water supply should minimize the problem See EXTENDED NON USE PERIODS NOTE Anode must remain installed except for inspection to avoid shortening tank life See LIMITED WARRANTY Replace as necessary DRAIN VALVE WASHER REPLACEMENT See Figure 28 Turn OFF gas supply to water heater Follow Draining instructions Turning counterclockwise f remove the hex cap below the screw handle Remove the washer and put the new one in place Screw the handle and cap assembly back into the drain valve and retighten using a wrench DO NOT OVER TIGHT EN Follow instructions in the Filling The Water Heater section Check for leaks Follow the lighting instructions in the Lighting section to restart the water heater lt OND CAP ASSEMBLY WASHER FIGURE 28 CAUTION Avoid water heater damage Inspection and replacement of anode rod required Each water heater contains at least one anode rod which will slowly deplete 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 develop ing a leak Certain water conditions w
35. and then chlorinating the water heater tank and all water lines Contact the local water heater supplier or service agency for further information concerning an Anode Replacement Kit and this chlorination treatment If the smelly water persists after the anode replacement and chlorination treatment we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR IN HOT WATER FAUCETS A WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS 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 flam mable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for several minutes before any electri cal appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open HIGH WATER TEMPERATURE SHUT OFF SYSTEM This water heater is
36. ating plate Excessive pressure to gas control valve can cause serious injury or death Turn off gas installation Contact qualified service agency lines during installer or Make sure the gas supplied is the same type listed on the model rating plate The inlet gas pressure must not exceed 14 inch water column 3 5 kPa for natural and propane gas L P The minimum inlet gas pressure shown on the rating plate is that which will permit firing at rated input All gas piping must comply with local codes and ordinances or with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 whichever applies Copper and brass tubing and fittings except tin lined copper tubing shall not be used If the gas control valve is subjected to pressures exceeding 1 2 psi 3 5 kPa the damage to the gas control valve could result in a fire or explosion from leaking gas If the main gas line Shut off serving all gas appliances is used also turn the gas at each appliance Leave all gas appli ances shut off until the water heater installation is complete A gas line of sufficient size must be run to the water heater Consult the current edition of the National Fuel Gas Code ANSI 2223 1 54 and your gas supplier concerning pipe size There must be A readily accessible manual shut off valve the gas supply line serving the water heater and A sediment trap dirt leg ahead of the gas contro
37. bon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage Do not operate water heater if damaged Inspect and replace anode Installin location with drainage Filltank with water before operation Bealert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 2 IMPORTANT DEFINITIONS 2 GENERAL SAFETY 3 TABLE OF CONTENTS 4 INTRODUCTION 5 Preparing For The Installation 5 INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS 6 TYPICAL INSTALLATION 7 Get To Know Your Water 74 Replacement lt 7 Mixing Valve Usage 8 LOCATING THE NEW WATER HEATER 9 Facts To Consider About The Location 9 Insulation 10 Vent 10 INSTALLING THE NEW WATER HEATER 11 Required 11 Inspect Shipment 11 Generale csc yew tent kates Gt chins oe eS 11 Water Piping a eee eee eee 11 T amp P Valve And Pipe Insulation If Supplied 12 Temperature Pressure Relief Valve
38. d 2 Damage or deterioration which could cause improper venting or leakage of combustion products Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxia tion Obstructions and deteriorated vent systems may present serious health risk or asphyxiation Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical com pounds which are potentially corrosive If after inspection of the vent system you found sooting dete rioration something is wrong Call the local gas utility to correct the problem and clean or replace the flue and venting before resuming operation of the water heater PILOT AND MAIN BURNER _ _ _ _ ___ Flood damage to a water heater may not be readily visible or im mediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAM AGE Contact a qualified installer or service agency to replace 24 a flooded water heater Do not attempt to repair the unit It must be replaced At least once a year a visual inspection should be made of the main burner and the pilot assembly for proper fl
39. e Figures 3 amp 15 Minimum clearances between the water heater and combustible and noncombustible construction are 0 in from sides 0 in from back 4 in from front of jacket to closet door and 20 in from top of jacket to combustible and noncombustible material Minimum vent clearance 1 in Provide 3 ft front clearance for servicing and adequate clearance between the jacket top amp ceiling for servicing the flue vent area see Figure 3 This clearance 20 in is required only to accomodate the minimum vent radius Where the wall is combustible and the wall thickness is over 14 in 1 in clearance to combustible surfaces around the vent terminal is needed The first 14 in is zero clearance A WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Make certain the vent locations comply with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or lo cal codes There is some important information shown in Figure 15 For a second or more direct vent unit the distance between vent terminals must be a minimum of 12 in TOP VIEW OF CLOSET WITHOUT DOOR TOP VIEW OF CLOSET WITH DOOR To MIN FIGURE 3 INSTALLING THE NEW WATER HEATER REQUIRED ABILITY 0 INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT
40. e approximates The ac tual temperature of the heated water may vary OPERATING MODES AND SETTINGS Standard Mode The controller adjusts the water heater to main tain the temperature set by the user Vacation Setting The Vacation setting VAC sets the controller at approximately 55 F This setting is recommended when the water heater is not in use for a long period of time This effective ly turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy FOR YOUR INFORMATION EXTERNAL DAMAGE Do not operate the water heater until it has been fully checked out by a qualified technician if the water heater e Has been exposed to fire or damage e Displays evidence of sooting e Produces steam or unusually hot water If the water heater has been flooded it must be replaced START UP CONDITIONS 0 NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RE LIEF VALVE OPENING OF THE HEATER DO NOT ATTEMPT TO OPERATE HEATER WITH COLD WATER INLET VALVE CLOSED CONDENSATE Whenever the water heater is filled with cold water some con densate will form while the burner is on A water heater may appear to be leaking when in fact the water is condensate This usually happens when a Anew water heater is filled with cold water for
41. e manifold burner assembly to the combustion chamber See Figure 23 9 Carefully remove the manifold ourner assembly from the combustion chamber BE SURE NOT TO DAMAGE ANY INTERNAL PARTS GAS CONTROL ALVE THERMOSTAT Vi m AS CONTROL THERMOPILE PIEZO IGNITER BUTTON PILOT TUBE VIEWPORT MANIFOLD TUBE MANIFOLD SCREW 2 MANIFOLD DOOR OUTER DOOR NOT SHOWN MANIFOLD COMPONENT BLOCK FIGURE 23 REMOVING THE BURNER FROM THE MANIFOLD NATURAL GAS LOW NOX amp L P GAS BURNER 1 Take off the burner by removing the two 2 screws located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 24 Important DO NOT remove the orifice PILOT ASSEMBL BOTTOM VIEW FIGURE 24 REPLACING THE PILOT THERMOPILE ASSEMBLY 1 Remove the manifold door assembly as described in Remov ing the Manifold Burner Assembly section 2 Remove the burner to access the pilot thermopile assembly Remove and keep the screws securing the burner to the mani fold Figure 24 Important DO NOT remove the orifice 3 Remove the screw securing the pilot thermopile assembly to the pilot bracket and keep for reuse later Figure 25 4 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 Figure 25
42. e to follow instructions and sible water sources is made and necessary corrective steps safety messages could result in taken death or serious injury Instruction Manual must remain Leakage from other appliances water lines or ground seepage with water heater should also be checked To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow Draining instructions in the Periodic Maintenance section and then remove fitting Put pipe dope or Teflon tape on the threads and replace Then follow Filling the Water Heater instructions the Installing the New Water Heater section 30 TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE S CORRECTION BURNER WILL NOT IGNITE 1 Pilot not lit 2 Thermostat set too low 3 No gas 4 Dirt the gas lines 5 Pilot line clogged 6 Main burner line clogged 7 Defective thermopile 8 Defective gas control thermostat 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 gas control thermostat SMELLY WATER 1 Sulfur in the water 1 Replace the anode with a special anode BURNER FLAME YELLOW LAZY PILOT WILL NOT LIGHT OR REMAIN LIT HIGH OPERATION COSTS PILOT FLAME T
43. ective gas control thermostat 1 Replace gas control thermostat FLAME BURNS AT ORIFICE 2 Low gas pressure 2 Check with gas utility company 3 Orifice not properly installed 3 Reinstall the orifice BURNER FLAME FLOATS AND LIFTS OFF PORTS 32 33 A O Smith THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY in accordance with the warranty terms and conditions specified below The warrantor will furnish the ORIGINAL OWNER 1 a replacement water heater of equivalent size and cur rent model if the glass lined tank in this water heater leaks and 2 a replacement part for any component part which fails Sacrificial anode rods are consumable maintenance parts and are excluded from warranty coverage THE WATER HEATER REPLACEMENT MODEL OR PART WILL BE WARRANTED FOR ONLY THE UNEX PIRED PORTION OF THE ORIGINAL WARRANTY The warranty period will be determined by the original date of purchase of the water heater or in the absence of a Bill of Sale verifying said date from the date of manu facture indicated on rating plate affixed to this water heater This warranty is not transferable and applies to models listed below ProMax 10 Year Models XCV XCVL XCVH XVR 10 Year 6 Year XCVT XCVX ProMax 6 Year Models GCV GCVL GCVH GVR GCVT GCVX GCNH GNR When the water heater has been used for other than single family residential application GDV GDVT 1 The tank warranty shall be reduced to 1 year for 6 year mod
44. ed to cover the holes in the wall see Figures 1 and 18 Slide one trim plate if supplied over the outer corrugated tube then insert the outer corrugated tube through the clearance hole from exterior wall Secure the trim plate to the exterior wall then secure the vent terminal to the exterior wall with 4 screw anchors included appropriate for the type of wall construction Caulk the junction of the vent terminal base plate and the exterior wall with exterior type sealant not included Slide the trim plate inside over the outer corrugated tube and fasten the trim plate to the interior wall Caulk the junction of the outer corrugated tube and the trim plate inside with suitable sealant TRIM PLATE an ara 2699699595545 c N TRIM PLATE OUTSIDE FIGURE 18 UNCOMPRESSING THE CORRUGATED TUBING _ 1 Pull the inner corrugated tube towards the water heater and leave some length over the water heater s center for bend ing 2 Pull the outer corrugated tube toward the water heater and leave it 1 in shorter than the inner corrugated tube 3 Make sure there are two springs evenly spaced at the bend in the tube 4 Use metal hangers to keep venting level or with a slope up ward from the heater to terminal REDUCER FIGURE 19 Bend both the corrugated tubes toward the water heater s flue connection
45. eet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwell ing building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system c
46. efore operating Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water 1 Close the water heater drain valve by turning the handle clockwise CT The drain valve is on the lower front of the water heater 2 Open the cold water supply valve to the water heater NOTE The cold water supply valve must be left open when the water heater is in use 3 To insure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping 4 Check all water piping and connections for leaks Repair as needed VENTING _ NEVER OPERATE THE WATER HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION FIRE EXPLOSION OR ASPHYXIATION DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING AIR ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERATION HIGH ALTITUDE INSTALLATIONS Installations above 7 700 ft require replacement of the burner orifice in accordance with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Failure to replace the orifice could result in improper and inefficient operation of the app
47. els 2 The parts warranty anode rods excluded shall be reduced to 1 year for all models CONDITIONS AND EXCEPTIONS This warranty shall apply only when the water heater is in stalled and operated in accordance with 1 all local fire codes and plumbing codes ordinances and regulations 2 the printed instructions provided with it 3 good industry practic es and 4 proper safety practices such as but not limited to a properly sized drain pan if installed in an area where leakage from the tank or its connections would result in damage to the area adjacent to the heater In addition a new tempera ture and pressure relief valve certified by the Canadian Gas Association must have been properly installed and piped to the nearest drain 34 This warranty shall apply only when the heater is owned by the original purchaser e installed for indoor operation only e used at temperatures not exceeding the maximum calibrated setting of its thermostat used at water pressure not exceeding the working pressure shown on the heater filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits used in a atmosphere used with factory approved anode s installed in its original installation location in the United States its territories or possessions and Canada sized in accordance with proper sizing techniques for residential water heaters bearing a rating plate which
48. enting death from possible carbon monoxide poisoning and fires see Figures 1 and 2 Examine the location to ensure the water heater complies with the Locating the New Water Heater section in this manual 5 For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation proce dures Instructions may be obtained from California Office of the State Architect 400 P Street Sacramento CA 95814 6 Massachusetts Code requires this water heater to be in stalled in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 For more informa tion see next page INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated horizontally vented power vent direct vent and power direct vent gas fueled water heaters installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon mo
49. equipped with an automatic gas shut off system This system works when high water temperatures are present Turn OFF the entire gas supply to the water heater The high temperature shut off is built into the gas control valve It is non resettable If the high temperature shut off activates the gas control valve must be replaced Contact your gas supplier or service agency 23 MAINTENANCE FOR YOUR SAFETY AND SATISFACTORY OPERATION IT IS RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A YEAR BY A COMPETENT SERVICE PERSON USERS OF THIS WATER HEATER SHOULD BE AWARE THAT GAS COMPONENTS WEAR OUT OVER A PERIOD OF TIME THE GAS CARRYING COMPONENTS OF THIS WATER HEAT ER SHOULD BE INSPECTED FOR PROPER OPERATION PERIODICALLY BY A QUALIFIED SERVICE TECHNICIAN A WARNING Breathing Hazard Carbon Monoxide Gas e Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for 1 Obstructions which could cause improper venting The com bustion and ventilation air flow must not be obstructe
50. er than others These include the elderly children the infirm or physically men tally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the low est possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater see Figure 2 Valves for reducing point of use temperature by mixing cold and hot water are also available Consult a Qualified Installer or Service Agency Follow manufac turer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual 11 A WARNING Do not connect to non potable water system This water heater shall not be connected to any heating systems or component s used with a non potable water heating appli ance All piping components connected to this unit for space heating applications shall be suitable for use with potable water Toxic chemicals such as those used for boiler treatment shall not be introduced into this system When the system requires water for space heating at tempera tures higher than required for domestic water purposes a mixing valve must be installed
51. f not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury 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 water heater can cause low level exposure to some of the substances included in the Act Massachusetts Code requires this water heater to be installed In accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 This product is certified to comply with a maximum weighted average of 0 25 lead content as required in some areas IMPORTANT DEFINITIONS e Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified installer must also be familiar with the design features and use of flammable vapor ignition resistant water heaters and ha
52. ge may result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas control valve ther mostat may result REPLACING THE GAS CONTROL VALVE THERMOSTAT To replace the gas control valve thermostat reassemble in re verse 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 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 the tank Be sure to remove the pilot ferrule nut from the new gas control valve thermostat Turn the main gas supply on and check the gas supply connec tions for leaks Correct any leak found Next light the pilot and main burner then check the manifold tube and pilot tube connections for leaks Correct any leak found Use an approved noncorrosive leak detection solution If such a solution is not available use a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions on page 21 If additional information is required reference the number on the cover of this manual for se
53. he wa ter pressure differential between the cold water and hot water pipes connected to the water heater e Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply Also the water heater must be located and or protected so it is not subject to physical damage by a moving vehicle A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use 2 Read instruction manual before installing using or servicing water heater This water heater must not be installed directly on carpeting Carpeting must be protected by metal or wood panel beneath the water heater extending beyond the full width and depth of the water heater by at least 3 in in any direction or if the water heater is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in AWARNING For continued protection against risk of fire Do not install water heater carpeted floor Do not operate water heater if flood damaged INSULATION BLANKETS 00 Insulati
54. ill cause a reaction between the an ode rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfi de 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 prob lems 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 inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement 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 e The majority of the rods diameter is less than 3 8 in e Significant sections of the support wire approx 1 3 or more of the an ode rod s length are visible If the anode rod show signs of either or both it should be replaced NOTE Whether re installing or replacing ANODE the anode rod check for any leaks and R immediately correct if found
55. isk of scald injury Hot water can produce first degree burns within Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Time for 1st Degree Burn Less Severe Burns Water Tem perature F U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 21 AS CONTROL VALVE THERMOSTAT SETTINGS GAS CONTROL TEMPERATURE KNOB STATUS LIGHT 120 F MARK 130F 140 1507 1507 MARK MARK MARK MARK 91 F MARK IGNITER FIGURE 26 Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is ex pected 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 its lowest setting This will maintain the water at low tem peratures with minimum energy losses and prevent the tank from freezing during cold weather OPERATING THE TEMPERATURE CONTROL SYSTEM 00 WATER TEMPERATURE ADJUSTMENT The water temperature setting can be adjusted from 55 F to 155 F Turn the Gas Control Valve Temperature Knob to the desired setting temperature NOTE The temperatures indicated ar
56. l valve to help prevent dirt and foreign materials from entering the gas control valve A flexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit Be sure to check all the gas piping for leaks before lighting the water heater Use a soapy water solution not a match or open flame Rinse off soapy solution and wipe dry A WARNING e Flue gases may escape if vent pipe is not connected e Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual When installed at elevations above 7 700 feet input rating should be reduced at the rate of 4 percent for each 1 000 feet above sea level which requires replacement of the burner orifice in accordance with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Contact your local gas supplier for further information Failure to replace the standard orifice with a high altitude orifice when installed could result in improper and inefficient operation of the water heater producing carbon monoxide gas in excess of safe limits which could result in serious injury or death Con tact your gas supplier for any s
57. li ance producing carbon monoxide gas in excess of safe limits which could result in serious personal injury or death Contact your gas supplier for any specific changes which may be re quired in your area A WARNING High altitude orifice must be installed for operation above 7 700 ft Contact a qualified installer or service agency A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater When determining the installation location for a direct vent water heater snow accumulation and drifting should be considered in areas where applicable The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 as follows 12 MINIMUM ABOVE GRADE OR ANTICIPATED SNOW LEVEL f W YY Yy YY Wy Wy 4 TFA Wy YY WY FIGURE 10 Be sure venting is properly connected to prevent escape of dan gerous flue gases which could ca
58. llations require 1 in clearance to combustibles NOTE A The maximum horizontal vent length of 80 in minus wall thickness should be considered when installing an offset vent arrangement B Do not combine condition 1 Figure 24 with condition 2 Figure 25 in the same installation C The maximum allowable drop from vent center line to vent termination center line Figure 25 is 7 25 in gt 1 H WALL 10 in SEE REF CHART RECOMMENDED MODELS MINIMUM H 40 gal 68 in 50 gal 76 in 50 gal Hi INPUT 76 in 75 gal 76 in FIGURE 25 BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance has a pilot which is lit by a piezoelectric spark gas ignition system Do not open the inner door of the appliance and try to light the pilot by hand B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in
59. noxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the sidewall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided that during said thirty 80 day period a battery operated carbon monoxide detector with an alarm shall be installed APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and CSA certified SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 f
60. nt damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Water at the vent assembly is water vapor which has con densed out of the combustion products This is caused by a problem in the vent Contact the gas utility Condensation may be seen on pipes in humid weather or pipe connections may be leaking C The anode rod fitting may be leaking anode is located under the plastic plug and isulation D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pres sure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water vapor which can con dense on the cooler surfaces of the tank Droplets form and AWA RN G drip onto the burner or run on the floor This is common at the FIGURE 30 time of start up after installation and when incoming water is Read and understand instruction cold manual and safety messages Water in the water heater bottom or on the floor may be from before installing operating or condensation loose connections or the relief valve DO servicing his walen healer NOT replace the water heater until a full inspection of all pos Failur
61. 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 5 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 electrical tape or equivalent IMPORTANT The insulation and tape must not block the discharge opening or hinder access to the manual relief lever Figure 5 Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions in this manual 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 insula tion 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 electrical tape or equivalent 7 Repeat steps 5 and 6 for the hot water outlet pipe 8 Add additional sections of pipe insulation as needed T amp P Relief Valve Insulation Outlet opening on underside Manual Relief Lever T amp P Relief N T amp P Relief Valve Drain Line FIGURE 5 Explosion Hazard Temperature pressure relief valve must comply with ANSI 221 22 CSA 4 4 and ASME code
62. omponents and 2 Acomplete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instruc tions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equip ment at the completion of the installation that the discharge pipe be terminated at an adequate drain inside the building TYPICAL INSTALLATION REPLACEMENT PARTS _ Replacement parts may be ordered through authorized servicers or distributors When ordering parts provide complete model and serial numbers see rating plate quantity and name of part desired as listed in Figure 1 Standard hardware items may be purchased locally COL
63. on blankets available to the general public for external use on gas water heaters are not necessary with this product The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters Your Wa ter heater meets or exceeds the National Appliance Energy Con servation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary Should you choose to apply an insulation blanket to this heater you should follow these instructions See Figure 1 for identifica tion of components mentioned below Failure to follow these instructions can result in fire asphyxiation serious personal injury or death A WARNING Gas and carbon monoxide detectors are available Install water heater in accordance with the instruction manual Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Do not cover the outer door thermostat or temperature amp pressure relief valve Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Do obtain new warning and instruction labels from the manu facturer for placement on the blanket directly over the exist ing labels VENT __ Before installing water heater determine placement of vent ter mination Make certain to observe vent location limitations se
64. ongly recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe All gas piping must comply with local codes and ordinances or with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 whichever applies Copper and brass tubing and fittings except tin lined copper tubing shall not be used CAUTION Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to cold water inlet Contact qualified installer or service agency Bo COLD WATER INTLET SHUTOFF VALVE UNION HOT WATER OUTLET UNION 3 4 SWEAT FITTING 3 4 SWEAT FITTING TEMPERATURE AND PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG METAL DRAIN PAN DRAIN VALVE 6 MAXIMUM FLOOR DRAIN AIR GAP FIGURE 4 Figure 4 shows the typical attachment of the water piping to the water heater The water heater is equipped with 3 4 NPT water connections NOTE If using copper tubing solder tubing to an adapter before attaching the adapter to the cold water inlet connection Do not solder the cold water supply line directly to the cold water inlet It will harm the dip tube and damage the tank T amp P VALVE AND PIPE INSULATION IF PPLIED 1 Locate the temperature and pressure relief valve on the wa ter heater also known as a T amp P relief valve See Figure 5 2 Locate the slit running the length
65. pecific changes which may be required in your area A WARNING Use joint compound or tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or Teflon tape marked as being resis tant to the action of petroleum Propane L P gases The water heater and its gas connection must be leak tested before placing the water heater in operation The water heater and its individual Shut off valve shall be discon nected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 pound per square inch 3 5 kPa It shall be isolated from the gas sup ply piping system by closing its individual manual Shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 pound per square inch 3 5 kPa Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 7 and 8 Gas piping with flexible connector FLEX PIPE GROUND JOINT UNION OPTIONAL GAS CONTROL VALVE SEDIMENT TRAP DIRT LEG 3 MIN FIGURE 7 Gas piping with all black iron pipe to gas control BLACK PIPE GROUND JOINT UNION OPTIONAL GAS CONTROL VALVE SEDIMENT TRAP DIRT LEG FIGURE 8 AWARNING
66. perature knob to the desired setting See Figure C 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 control temperature knob and repeat steps 2 through 5 waiting 10 minutes before attempting to relight the pilot If the status light does not start blinking after three lighting attempts turn the gas control temperature knob to the OFF position and call a qualified service technician or your gas supplier DANGERS Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting information Turn the gas control temperature knob counterclockwise to the OFF position The status light will stop blinking and stay on for a short time after the water heater is turned off See Figure oi TEMPERATURE REGULATION Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury ADANGER Feel water before bathing or showering Temperature limiting valves are available Read ins
67. r have a sharp blue orange color Contaminated air may cause an orange col ored flame Contact a qualified service technician if the flame is not satisfactory TIPS MAY HAVE A YELLOW TINT ri YELLOW INNER dy CONES ARE SATISFACTORY INCORRECT FLAME LAZY YELLOW CORRECT FLAME SOFT BLUE FIGURE 27 A WARNING Flue gases may escape if vent pipe is not connected e Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual SOOT BUILD UP INDICATES A PROBLEM THAT REQUIRES CORRECTION BEFORE FURTHER USE CONSULT WITH A QUALIFIED SERVICE TECHNICIAN Should the main burner or burner air openings require cleaning turn the gas control knob to OFF position and allow the burner to cool Remove the burner and clean with a soft brush Clean main burner orifice with a suitable soft material A DANGER Do not use or store flammable vapor products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance Can cause serious injury or death A WARNING e Flue gases may escape if vent pipe is not connected Be alert for obstructed
68. ructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual LOCATING THE NEW WATER HEATER FACTS T NSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most eco nomical use of the appliance This water heater is not for use in manufactured mobile homes or outdoor installation CAUTION Improper installation and use may result in property damage Do not operate water heater if damaged Installin location with drainage Filltank with water before operation Bealert for thermal expansion Refer to instruction manual for installation and service Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed 1 Select a location indoors as close as practical to the vent terminal or location to which the water heater vent piping is going to be connected and as centralized with the water pip ing system as possible 2 Selected location must provide adequate clearances for ser vicing and proper operation of the water heater CAUTION Allwater heaters eventually leak Do not install without adequate drainage Installation of the water heater must be accompli
69. rvice information TEFLON is a registered trademark of E I Du Pont De Nemours and Company REMOVING THE MANIFOLD BURNER ASSEMBLY _ 1 Turn the gas control temperature knob to the OFF position Figure 22 2 Before performing any maintenance it is important to turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off Figure 3 3 With the unit shut off allow sufficient time for the water heater to cool before performing any maintenance 26 GAS CONTROL TEMPERATURE KNOB amp Sd Q IGNITER BUTTON oo IGNITER Al whare LEAD WIRE WIRE T PILOT IGNITER TUBE RED WIRE WIRE MANIFOLD TUBE FIGURE 22 4 Remove the outer door 5 Disconnect the following from the gas control valve thermo stat pilot tube 7 16 wrench igniter wire from the igniter lead wire and manifold tube 3 4 wrench See Figure 22 NOTE L P Gas systems use reverse left hand threads on the manifold tube 6 Use needle nose pliers to disconnect the thermopile wire from the gas control valve thermostat Figure 22 7 Grasp the manifold tube and push down slightly to free the manifold tube and pilot tube 8 Remove the screws 1 4 nut driver securing th
70. shed in such a manner that if the tank or any connections should leak the flow will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor When such locations cannot be avoided a metal drain pan should be installed under the water heater Metal drain pans are available at your local hardware store Such a metal drain pan must have a minimum length and width of at least 2 in greater that the water heater dimensions a maximum height of 1 75 in and must be piped to an adequate drain Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retail ers and detect and react to leakage in various ways e Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when leak age is detected Sensors mounted in the metal drain pan that turn off the wa ter supply to the entire home when water is detected in the metal drain pan e Water supply shut off devices that activate based on t
71. stalled on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail sup plier regarding the installation of a thermal expansion tank STRANGE SOUNDS Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not necessarily represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be consid ered normal See Condensate in this section OPERATIONAL CONDITIONS 0 SMELLY WATER In each water heater there is installed at least one anode rod see parts section for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell in the hot water The smell is a result of four factors which must all be present for the odor to develop a Aconcentration of sulfate in the supply water b Little or no dissolved oxygen in the water c Asulfate reducing bacteria which has accumulated within the water heater this harmless bacteria is nontoxic to humans d An excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active mate rial
72. truction manual for safe temperature setting TEMPERATURE ADJUSTMENT Valves for reducing the point of use temperature by mixing cold and hot water are available see Figure 2 Also available are inexpensive devices that attach to faucets to limit hot water temperatures Contact a licensed plumber or the local plumbing authority NOTE During low demand periods a lower thermostat 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 e g vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather 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 start ing point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 26 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 mark on the temperature dial will increase the r
73. use deadly asphyxiation A WARNING e Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater e Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual DV TERMINATION SAFETY VER A Safey cover see Figure 11 is available to prevent accidental contact with the vent terminal Contact your Customer Service Department for ordering information SM op SH Ly SEZ FIGURE 11 7 After the location for the vent terminal has been selected as peers outlined in Figures 3 amp 15 use the following illustrations for installation SEE TEXT NOT TO BE USED AS STORAGE AREA BOTTOM OF HEATER FIGURE 13 HIGH RISE VENT ARRANGEMENT When the height H From vent terminal center line to bottom of heater is over 80 in it is a high rise vent arrangement In this case the minimum distance D from the center of the water heater to the outside wall surface is 22 in and the maximum height of H is 12 ft LEFTIST RRR OR oY ore a a ky wz 2 LK ae ven
74. ve a thorough understanding of this instruction manual Service Agency A service agency also must have ability equivalent a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer e Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building 2 GENERAL SAFETY AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled
75. with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper REMOVING AND REPLACING THE GAS CONTROL __ Important This water heater has resettable thermal switch installed Do not attempt to disable or modify this feature in any way Use only factory authorized replacement parts 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 sup ply 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 nee dle nose pliers to disconnect the red and white thermopile wires Disconnectthe pilottube 7 16 wrench andmanifoldtube 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 a pipe wrench or equivalent to grip body Dama
76. y have other rights which vary under the laws of each state If any provision of this warranty is prohibited or invalid under applicable state law that provision shall be ineffective to the extent of the prohibition or invalidity without invalidating the remainder of the affected provision or the other provisions of this warranty SERVICE AND LABOR RESPONSIBILITY UNDER THIS LIMITED WARRANTY THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF THE OWNER IS RESPONSIBLE FOR ALL OTHER COSTS Such costs may include but are not limited to a Labor charges for service removal or reinstallation of the water heater or part thereof Shipping and delivery charges for forwarding the new wa ter heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor All cost necessary or incidental for handling and adminis trative charges and for any materials and or permits re quired for installation of the replacement heater or part LIMITATION ON IMPLIED WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts Some states do not allow limitations on how long an implied war ranty lasts so the above limitations may not apply to you CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer

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