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American Water Heater 319407-002 User's Manual

1. Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Check the vent system for restrictions obstructions and check the vent termination height Refer to the Air Supply and Ventilation section of this water heater manual for specific requirements NOTE This water heater utilizes an automatic flue damper that remains closed when the water heater is not operating Damper must be in open position when appliance main burner is operating Do not attempt to manually open operate the damper Damage to the flue damper may result Recheck for sufficient combustion air supply Water System Piping Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Mixing valve when applicable installed per manufacturer s instructions see Water Temperature Regulation section Gas Supply and Piping Gas type is the sam
2. 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 Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier INSTALLER AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER OWNER RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE REFERENCE RETAIN THE ORIGINAL RECEIPT AS PROOF OF PURCHASE Residential Gas Water Heater with the Flame Guard Safety System Installation Instructions and Use amp Care Guide Flammable Vapor Ignition Resistant NATURAL amp L P GAS MODELS To obtain technical warranty or service assistance during or after the installation of this water heater or call toll free 1 800 999 9515 When calling for assistance please have the following information ready IRN Model number 7 digit product number Serial number Date of installation Place of purchase Table of C ntents oo
3. Temperature and Pressure Relief Valve AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion Manually operate the temperature Temperature and Pressure and pressure relief Relief Valve valve at least once a year to make sure it is working properly To prevent water damage the valve must be properly connected to a discharge line which terminates at an adequate drain Standing clear of the outlet discharged water may be hot slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position If the valve fails to completely reset and continues to release water immediately shut off the manual gas control valve and the cold water inlet valve and call a qualified person Figure 26 Manual Relief r4 Valve Discharge line to drain 23 Replacement Parts IMPORTANT The following maintenance procedures are for the Flame Guard Safety System components and should be performed by a qualified person Replacement parts may be ordered through your plumber or the local distributor Parts will be shippe
4. HIGH OPERATION COSTS Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall 0 Flue Damper seal not functioning INSUFFICIENT HOT WATER Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure SLOW HOT WATER RECOVERY Insufficient secondary air Flue clogged Low gas pressure 4 Improper calibration Water heater too small Wasted hot water DRIP FROM RELIEF VALVE Excessive water pressure Use a pressure reducing valve and relief valve Heater stacking Lower the thermostat setting Closed water system See Closed System Thermal Expansion 2 3 5 6 Wrong piping connections 7 1 2 3 THERMOSTAT FAILS TO 1 Thermostat not functioning properly SHUT OFF 2 Improper calibration COMBUSTION ODORS Insufficient secondary air 2 Flue clogged 3 Heater installed in a confined area SMOKING AND CARBON 1 Insufficient secondary air FORMATION SOOTING Low gas pressure Flue clogged 4 Thermostat not functioning properly Heater installed in a confined area Provide ventilation to water heater Check with gas utility company Clean locate source and correct Cycle gas control valve thermostat OFF then ON If
5. cecceceeeccseeeeseeeeeeeeeeeeeeaees 2 LOW LEAD CONTENT 319407 002 April 2013 WATER HEATER SAFETY Your safety and the safety of others are very important We have provided many important safety messages in this manual and on your appliance Always read and obey all safety messages This is the safety alert symbol This symbol alerts you to potential hazards that can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING These words mean A indicates an imminently hazardous situation which If DAN G E R not avoided will result in death or injury indicates apotentially hazardous situation which if not WARN l NG avoided could result in death or injury All safety messages will tell you what the potential hazard is tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed Important Instructions e Do not use this appliance if any part has been under water Immediately call a qualified person Water heaters sub jected to flood conditions or any time the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame To preven
6. do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not depend upon this odorant as an indication of leaking gas Gas Piping The gas piping must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Tables 1 and 2 on page 7 provides a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials Refer to Figure 5 NOTE When installing gas piping apply approved pipe joint compound 1 Install a readily accessible manual shut off valve in the gas supply line as recommended by the local utility Know the location of this valve and how to turn off the gas to this unit 2 Install a sediment trap if not already incorporated as part of the water heater as shown The sediment trap must be no less than three inches long for the accumulation of dirt foreign material and water droplets 3 Install a ground joint union between the gas control valve thermostat and the manual shut off valve This is to allow easy removal of the gas control valve thermostat 4 Turn the gas supply on and check for leaks Test all connections by brushing on an approved noncorrosive leak detection solution Bubbles will s
7. Harness Pilot Tube Viewport FV Sensor Manifold Tube Thermal Switch Manifold Door Manifold Component Block Manifold Screw 2 Removing the Burner from the Manifold Assembly Natural Gas Burner Low Nox amp L P Burner 1 Take off the burner by removing the two 2 screws lo cated 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 29 Figure 29 Natural gas Low NOx and L P Burner Assembly Manifold Door Assembly Thermal Switch Manifold Component Block e Tube Igniter Wire Viewport Pilot Tube ne Bumer Manifold Tube Pilot Igniter Flame Sensor Assembly Sorks Manifold Door Assembly Replacing the Pilot Igniter Flame Sensor Assembly 1 Remove the manifold assembly as directed previously 2 Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 30 Figure 30 Manifold Component Block Assembly Pilot Igniter Flame Sensor Assembly Pilot Tube Igniter Wire Manifold Component Block 3 Using a 7 16 wrench loosen the nut sec
8. Natural Gas L P Gas Burner L P Gas Burner assembly which contains the manifold tube gasket door pilot igniter flame sensor assembly manifold component block with retainer clip thermal switch and pilot tube Natural Gas Low Nox Burner assembly which contains the manifold tube gasket door pilot igniter flame sensor assembly manifold component block with retainer clip thermal switch and pilot tube L P Gas Contains manifold component block and retainer clip Contains manifold door gasket Contains viewport Item 13A Item 13B QU L P BURNER Item 15 Item 17 NOTES 36 Copyright 2013 American Water Heater Company All rights reserved
9. Single Opening 1 sq in per 3000 BTU HR Figure 11 Example A water heater with an input rate of 50 000 BTU HR using horizontal ducts would require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTU HR x 1 sq in 2000 BTU HR 25 Sq Inches These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements Gable vent to outdoors Install above J insulation A Outlet air to attic 1 Sq inch per 4000 BTU HR Confined Space Inlet air from the crawl Alternate Air Inlet 1 sq inch per 4000 BTU HR RS Vent Figure 8 All Air from Outdoors Inlet Air from Ventilated Crawl Space Outlet Air to Ventilated Attic Gable vent aw to outdoors Install above ae insulation Confined ILS Space Figure 9 All Air from Outdoors Through Ventilated Attic 1 Sq inch per 4000 BTU HR Inlet air duct 1 sq inch per 4000 BTU HR 12 maximum 1 sq inch per 2000 BTU HR Confined Outdoor Air Ducts 1 sq Inch per 2000 BTU HR Figure 10 All Air from Outdoors Using Horizontal Ducts Alternative Opening Location Confined Space Figure 11 All Air from Outdoors Using a Single Permanent Opening Vent Pipe System This water heater uses a non direct single pipe vent system to remov
10. normal shower temp pain threshold 35 minutes 1 minute 5 seconds 2 seconds 45 minutes 5 minutes 25 seconds 5 seconds 149 1 second 2 seconds 154 instantaneous 1 second U S Government Memorandum C PS C Peter L Armstrong Sept 15 1978 Figure 22 Gas Control Valve Thermostat 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 expected to be more than normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to the vacation VAC setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather 19 Electrical Connections Before plugging in the water heater always make sure e The Voltage and frequency correspond to that specified on the water heater The electrical outlet has the proper overload fuse or breaker protection Water heater to be located within 6 feet of 120VAC outlet Unit is to connect to a 120VAC electrical supply outlet extension cord is not allowed The water heater and the outlet are properly grounded Installed in accordance with prevailing provisions of local codes or in the absence of such National Electric Code ANSI NFPS 70 current edition Completely fill th
11. 6 4 flash error code See Corrective Action Table page 31 REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information 1 Model serial and product number 2 Type of gas 3 Item number 4 Parts description Repair Parts List Fa Parts Description 6 fconwarervrnse ao LOCATED ON SIDE o oranye ooo STP SPARK TO PILOT PILOT ASSEMBLY KIT L P x BURNER Natural Gas Low Nox BURNER L P gt 14A 14B 15 16 17 18 AQ 20 21 22 23 BURNER ASSEMBLY BURNER ASSEMBLY L P Burner MANIFOLD COMPONENT BLOCK MANIFOLD DOOR GASKET VIEWPORT ASSEMBLY TRANSFORMER ASSEMBLY KIT FV SENSOR KIT FV SENSOR KIT WITH BRACKET FV WIRE HARNESS MAIN WIRE HARNESS GAS CONTROL VALVE THERMOSTAT CONTROL MODULE Pictured on next page Not shown LEGEND A Special anode rod see page 21 Temperature and Pressure Relief Valve is required but may not be factory installed Unique Flame Guard Safety System parts 33 Listed Item 12A Item 12B Item 13A Item 13B Item 14A Item 14B Item 15 Item 16 Item 17 34 Parts Kits and Illustrations Pilot Igniter Flame Sensor assembly kit which contains the pilot igniter flame sensor and retainer clip Natural Gas Pilot Igniter Flame Sensor assembly kit which contains the pilot igniter flame sensor and retainer clip L P Gas Burner
12. Heater Location Water heater location is important and can affect system performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located with the water piping system Located as close to the gas piping and vent pipe system as possible Water heater must be located within 6 feet of 120VAC outlet Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the flame arrestor located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the flame trap Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a
13. air is to be provided to the confined area from additional room s within the building the total volume of the room s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTU HR of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 7 Confined Space Permanent Openings 1 square inch 1000 BTU HR minimum 100 sq In Figure 7 All Air from Inside Building Confined Space Installation All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is determined by the method in which the air is to be provided Refer to Table
14. any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 4 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service Figure 4 Minimum Clearance Locations gees i Sides for service Front 24 minimum Sides Ve State of California NOTE For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake Correct installation procedure instructions may be obtained from California s Office of the State Architect 1102 Q street Suite 5100 Sacramento CA 95811 Instructions can also be downloaded to your computer at www dsa dgs ca gov Pubs Gas Supply AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve Do not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Gas Requirements IMPORTANT Read the data plate to be sure the water heater is made for the type of gas you will be using in your home This information will be found on the data plate located near the gas control valve thermostat If the information does not agree with the type of gas available
15. chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTU HR of the total input for all gas using appliances Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1 000 BTU HR of the total input for all gas appliances The table below shows a few examples of the minimum square footage area required for various BTU HR inputs Table 3 Minimum Square Feet with 8 Ceiling 30 000 188 9 x 21 657 750 844 BTU HR Input Typical Room with 8 Ceiling 105 000 20 x 33 120 000 25 x 30 135 000 28 x 30 IMPORTANT The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for sto
16. combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Figure 20 Draft Hood 18 Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 21 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 or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified person if the flame is not satisfactory Figure 21 Flame Characteristics Water Temperature Stacking Stacking occurs when a series of short draws of hot water 3 gallons or less are taken from the water heater tank This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet This water heater s temperature control has been designed to accurately regulate the water temperature However under certain operating conditions the water temperature may temporarily exceed the dial setting Consequently in addition to setting the temperature no higher than 120 F we recommend the installation of a mixing valve or an anti scald device in the hot water supply line or at the point of use to further redu
17. connections found If any connections are found to be damaged consult the replacement parts list for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 16 If the problem persists proceed to step 3 Check condition of the base ring filter and flame trap If they are clogged follow the instructions for cleaning on page 24 If parts are not clogged proceed to step 4 After cleaning follow instructions for lighting on page 16 If problem persists proceed to step 4 Follow the instructions on page 23 to remove the burner assembly Once the burner assembly has been removed inspect the manifold tube and burner see figure 29 for any obstructions If any clogs or obstructions are present clear them Inspect the electrode flame sense rod see figure 35 for corrosion buildup degradation or damage If there is evidence of any damage to the electrode flame sense rod replace the igniter pilot assembly Follow the directions on page 25 to re install the burner assembly into the combustion chamber Follow the instructions for lighting on page 16 If the problem persists contact a certified service representative Two Flash three second pause End Switch Failed Closed Look at the top of water heater to see if the damper is open see figure 20 If the damper is open insure there is no obstruction that would prevent the damper from closing If there are any obstructions t
18. early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortable with making the repair a qualified person should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Locate the water heater near an adequate indoor drain The discharge pipe must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Outside drains are subject to freezing temperatures which can obstruct the drain line The piping should be at least 3 4 ID and pitched for proper drainage Under no circumstances will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your failure to follow these instructions Figure 2 Drain Pan Installation DISCHARGE PIPE DO NOT CAP OR PLUG i AT LEAST 2 GREATER THAN THE DIAMETER OF THE WATER HEATER PIPED TO AN e The water heater should be located in an area not subject to freezing temperatures Water heaters located in uncon
19. gas Scat supply pipe Figure 5 e Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on 2 Move the ON OFF switch on the gas control valve the back of the gas control valve that screws into tank thermostat to the OFF position to turn off the water Be sure to remove the pilot ferrule nut from the new gas heater and unplug from the wall outlet Figure 22 control valve thermostat 3 Drain the water heater Refer to the section of Draining Turn the gas supply on and check for leaks Test the and Flushing and follow the procedure water heater by brushing on an approved noncorrosive 4 Disconnect the wire harness flammable vapor sensor leak detection solution Bubbles forming indicate a leak wires and igniter wire from the gas control valve Correct any leak found thermostat Disconnect pilot tube 7 16 wrench and e Be sure tank is completely filled with water before manifold tube 3 4 wrench at the gas control valve lighting and activating the water heater Follow the thermostat Figure 27 NOTE L P Gas systems use Lighting Instructions on page 16 reverse left hand threads on the manifold tube With the burner lit check the gas control valve 5 Refer to Gas Piping Figure 5 and disconnect the thermostat supply line manifold component block ground joint union in the gas piping Disconnect the manifold tube and pilot tube connections for remaining
20. gasoline paint paint thinners varnish or cleaners that could emit flammable vapors Remove anything that can potentially emit flammable vapors from the area and store it properly in a different location i Contact a certified service representative for inspection Eight One Flash three second pause Flammable Vapor Sensor FVS Fault Detected Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas valve Eight Two Flash three second pause Temperature Sensor Fault Detected Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas valve Eight Three Flash three second pause Electronic Fault Detected Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas valve Eight Four Flash three second pause Gas Control Valve Thermostat Fault Detected Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas valve 31 SEQUENCE
21. proper electrical contact If no connection problems are found replace the damper Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list on pages 31 32 for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 16 If the problem persists replace the damper Six Three Flash three second pause Soft Lockout Recycle Limit Flame Lost Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the power outlet 1 Check the incoming gas line pressure to ensure adequate supply to the water heater If incoming gas supply pressure is adequate proceed to step 2 Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact If no connection problems are found proceed to step 3 Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 16 If the problem persists proceed to step 3 Check condition of the base ring filter and flame arrestor If they are clogged follow the instruc tions for cleaning on page If parts are not clogged proceed to step 4 After cleaning follow instructions for ligh
22. the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified person to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame trap and require replacement of the entire water heater NOTE Not following these instructions and or an inadequate air supply can cause the Flame Guard Safety System to disable the water heater Please make required installation and venting air supply changes prior to resetting the system see Combustion Air Supply and Ventilation section IMPORTANT This water heater has a resettable thermal switch installed as part of the Flame Guard Safety System Do not attempt to disable or modify this feature in any way Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished Open the doors and windows for ventilation while flammable substances are in use If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to c
23. thermal switch on the door assembly to trip Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Location Requirements section of this water heater manual for specific requirements Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air Conditioning amp Refrigeration HVAC R authorized service provider 16 Fresh air supply free of corrosive elements and flammable vapors Fresh air openings sized correctly with consideration given to the blocking effect of louvers and grilles Ductwork is the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following
24. using iron piping or PVC water piping e Use only pumps valves or fittings that are compatible with potable water e Use only full flow ball or gate valves The use of valves that may cause excessive restriction to water flow is not recommended e Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used e Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system e This water heater is suitable for combination water potable heating and space heating and not suitable for space heating applications only Closed System Thermal Expansion AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Ther
25. will cause a reaction between the anode rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfide gas dissolved in the water IMPORTANT Do not remove this rod permanently as it will void any warranties A special anode rod may be available if water odor or discoloration occurs NOTE This rod may reduce but not eliminate water odor problems The water supply system may require special filtration equipment from a water conditioning company to successfully eliminate all water odor problems Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water softener may decrease the life of the water heater tank The anode rod should be 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 e Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod show signs of either or both it should be replaced NOTE Whether re installing or replacing the anode rod check for any leaks and immediately correct if found In rep
26. 2 3 4 5 6 7 8 9 1 1 FV Senor Lockout Flue Damper not functioning Non functioning gas control valve thermostat Heater installed in a confined area Non functioning Pilot lgniter Flame Sensor See PILOT WILL NOT LIGHT OR REMAIN LIT Turn temp dial to desired temperature Check with gas utility company Notify utility install trap in gas line Clean locate source and correct Clean locate source and correct Replace gas control valve thermostat Provide fresh air ventilation Cycle power to the water heater off and on If problem persists replace the flue damper CDN OO RS N See Status Light Code Troubleshooting Table section See Pilot Light Troubleshooting Flowchart section Seat connector firmly in socket Bleed the air from the gas line Check with gas utility company Check with gas utility company Notify utility install dirt trap in gas line Locate source and correct Replace thermostat Clean locate source and correct See maintenance section for inspection and cleaning of flame trap Contact a qualified person to reset the sensor Cycle power to the water heater off and on If problem persists replace the flue damper 230NOm8S N PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION BURNER FLAME YELLOW Insufficient secondary air LAZY Low gas pressure Flue clogged Flue damper partially open Main burner line clogged Heater installed in a confined area Obstruction in main burner orifice
27. 4 to calculate the minimum free area for each opening Figures 8 9 and 10 are typical examples of each method Louvers and Grilles In calculating free area for ventilation and combustion air supply openings consideration must be given to the blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may require larger openings to achieve the required minimum free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 25 of free area while metal louvers and grilles will allow 60 75 of free area Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions Table 4 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on the total BTU HR input rating for all utilizing equip ment within the confined space Minimum Free Area Reference Opening Source Per Opening sq in Drawing Direct to outdoors 1 sq in per 4000 BTU HR Vertical ducts 1 sq in per 4000 BTUHR Horizontal ducts 1 sq in per 2000 BTU HR Figure 10
28. CLEARANCE SUPPORT MAINTAIN CLEARANCE VENT CONNECTOR CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM UNUSED CHIMNEY Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections 11 Water System Piping Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 16 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures IMPORTANT Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings IMPORTANT Always use a good grade of joint compound and be ce
29. OF OPERATION CHART 32 Apply Power to Appliance Is there a Call for Heat Y Will not attempt to light 2 flash error code See Corrective Action Table Is Damper Closed on page 30 Damper Energizes Is Damper Open Pilot Valve Energizes Gas Valve attempts to open damper for 30 seconds then waits 2 mintues 3 flash error code See Corrective Action Table page 30 Does Pilot Valve Open Will not light 8 4 flash error code See Corrective Action Table on page 31 Spark Electrode is Energized Is Pilot Flame Sensed Within 1 5 min Will not light 8 4 flash error code See Corrective Action Table on page 31 Main Valve Energized Does Main Valve Open Will not light 8 4 flash error code See Corrective Action Table on page 31 Is Main Flame Sensed Will not light 8 4 flash error code See Corrective Action Table on page 31 Is Demand for Heat Satisfied Will not light 8 4 flash error code See Corrective Action Table on page 31 AA Pilot amp Main Valve De Energize y Damper Energizes and Closes A Wait for flame lost 5 flash error code See Corrective Action Table page 31 cc Damper closes 20 minute lockout
30. OR BK 120VAC Dmi 120VAC BK 24VAC HOT FLAME SENSOR IGNITER You must provide all wiring of the proper size outside of the water heater You must obey local codes and electric utility requirements when you install this wiring This appliance must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA No 70 current edition and or THE CSA C22 1 ELECTRICAL CODE CURRENT EDITION Note If any of the original wire as supplied with the appliance must be replaced it must be replaced with 105 C wire or its equivalent Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Operating the Temperature Control System Figure 24 Status Codes Water Temperature Adjustment The water temperature setting can be adjusted from 70 F Status to 160 F Turn the Gas Control Temperature Knob to the desired setting temperature Operating Modes and Settings e Standard Mode The controller adjusts the water heater to maintain the temperature set by the user e Vacation Setting The Vacation Setting VAC sets the controller at approximately 70 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezin
31. P Relief Valve Follow the instructions under Temperature and Pressure Relief Valve section 12 7 After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any ex cess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks Figure 16 Water Piping Installation In a closed system use a thermal expansion tank ES Cold Water Hot Water D wie to Fixtures Cue t 1 5 lt Main water supply Pressure reducing valve with bypass 4 Cold Water Inlet Valve Temperature and Pressure Relief Valve Discharge Pipe Do Not Cap or Plug Drain line 3 4 ID minimum 6 Maximum 1 minimum gt Massachussetts Install a vacuum relief in cold water line per section 19 MGL 142 Metal Drain Pan 1 3 4 depth maximum YF Floor Drain Figure 17 Typical Mixing Valve Installation Follow the mixing valve manufacturer s instructions Tempered water to fixtures Mixing valve Set to 120 F Please note the following e The system should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybutylene This water heater must not be installed
32. RTS Orifice too large High gas pressure Flue clogged 4 Cold drafts 2 3 5 6 Burner flame yellow lazy 2 3 Replace with correct orifice Check with gas utility company Clean flue and burner locate source and correct 4 Locate source and correct 2 3 5 6 See Burner Flame Yellow Lazy 2 3 1 1 1 BURNER FLAME TOO HIGH 1 Orifice too large Replace with correct orifice FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly 1 Replace thermostat 2 Low gas pressure 2 Check with gas utility company PILOT FLAME 1 Pilot line or orifice clogged 1 Clean locate source and correct TOO SMALL 2 Low gas pressure 2 Check with gas utility company SMELLY WATER 1 Sulfides in the water 1 Replace the anode with a special anode 29 STATUS LIGHT CODE TROUBLESHOOTING TABLE Status Light Code LED FLASH CONTROL STATUS CORRECTIVE ACTION SEQUENCE One Flash three second pause Low Flame Signal control continues to oper Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the ate power outlet Ac Check the incoming gas line pressure to ensure adequate supply to the water heater If incoming gas supply pressure is adequate proceed to step 2 Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact If no connection problems are found proceed to step 3 Firmly seat any loose
33. anty Department at 1 877 817 6750 Failure to install and clean the air filter assembly properly can allow dust and lint to restrict the air supply to the water heater If that occurs the pilot light could go out or the thermal switch could shut the water heater off A service call could be needed to clean the flame trap These condi tions are not defects and are not covered by the warranty Figure 32A Air Filter Assembly Installation Air Filter assembly Filter Clip Install the air filter assembly as described below and clean as needed Replace the air filter assembly with a new one if it is damaged 1 Before installing the air filter assembly remove any dust lint or debris including any packaging materials or tape from under the water heater For existing installations a visual inspection of the flame trap is recommended Refer to External Inspection amp Cleaning of the Flame trap 2 Wrap the filter around the base of the water heater Cut to fit around a sensor if present Trim excess filter material with scissors but allow filter material to overlap a few inches Figure 32B 3 The filter should fit snugly against the base of the water heater with no gaps The filter must fit flush against the bottom of the drain pan and or floor Hold the filter in place then stretch the filter clip over the overlapped joint and hook in place Figure 32B 4 Check the filter at least every three months and clean as
34. ce the risk of scald injury These devices can be obtained from a plumbing service agency or your retail supplier Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified person Water Temperature Regulation A WARNING Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded Feel water before bathing or showering Temperature limiting valves are available The thermostat is adjusted to the pilot position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 22 There is a hot water scald potential if the thermostat is set too high NOTE Temperatures shown on the gas control valve thermostat are approximates The actual temperature of the heated water may vary IMPORTANT Adjusting the thermostat past the 120 F bar on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within Table 5 Time for Permanent Burns 2nd amp 3rd Degree Most Severe Bums Time for 1st Degree Burn Less Severe Bums Water Temperature F 110 116 116 122 131 140
35. d at prevailing prices and billed accordingly When ordering replacement parts always have the following information ready 1 model serial and product number 2 type of gas 3 item number 4 parts description See pages 31 32 for a list of available repair parts Removing the Manifold Assembly 1 Turn off the gas to the water heater at the manual shut off valve Figure 5 2 Move the ON OFF switch on the gas control valve thermostat to the OFF position to turn off the water heater Figure 22 3 Remove the outer door Remove the two screws 1 4 nut driver securing the manifold door assembly to the combustion chamber Figure 28 5 Disconnect the pilot tube 7 16 wrench the igniter wire and manifold tube 3 4 wrench at the gas control valve thermostat Also use needle nose pliers to disconnect the yellow TCO wire leads from the thermal switch on the manifold door NOTE L P Gas systems use reverse left hand threads on the manifold tube 6 Grasp the manifold tube and push down slightly to free the manifold and pilot tube 7 Carefully remove the manifold assembly from the burner compartment NOTE Be sure not to damage internal parts Figure 27 Gas Control Valve Pilot a Tube Tbe Wiring Harness Igniter Wire Figure 28 Burner Assembly Removal Gas Control Valve __ Thermostat Wiring
36. d terminate it to an adequate 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 Routine Preventative Maintenance At least annually a visual inspection should be made of the venting and air supply system piping systems main burner pilot burner and Flame trap Check the water heater for the following e Obstructions damage or deterioration in the venting system Make sure the ventilation and combustion air supplies are not obstructed e Build up of soot and carbon on the main burner and pilot burner Check for a soft blue flame e Leaking or damaged water and gas piping Presence of flammable or corrosive materials in the installation area e Presence of combustible materials near the water heater e After servicing this water heater check to make sure it is working properly See Operating Your Water Heater section of this manual IMPORTANT If you lack the necessary skills required to properly perform this visual inspection you should not proceed but get help from a qualified person
37. ditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the data plate e Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling e Ifthe water heater is located in an area that is subjected to lint dirt and oil it may be necessary to periodically clean the flame trap see External Inspection amp Cleaning of the Flame trap section Figure 3 Air moving Devices Exhaust Fan L Reverse flow of gases Clearances and Accessibility NOTE Minimum clearances from combustible surfaces are stated on the data plate adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor e IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least three inches 76 2mm in
38. e TCO door switch button does not depress proceed to step 2 Follow the lighting instructions on page 16 Observe the damper during initial startup If there is a call for heat and the damper opens allow the unit to continue to perform and monitor any change in status If there is a call for heat and the damper does not open proceed to step 3 Check all wiring connections to insure all harness and wire connections are seated firmly and provide proper electrical contact If no connection problems are found replace the damper Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list on page 31 32 for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 17 If the problem persists replace the damper Four Flash three second pause ECO Limit Lockout r Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas control valve Five Flash three second pause Flame Out of Sequence Turn the power switch on the gas control valve to the OFF position Wait 10 minutes then fol lighting instructions on page If the problem persists replace the gas control valve Six One Flash three second pause Soft Lockout Retry Limit Failed TFI Turn the power switch
39. e as that listed on the water heater data plate Gas line equipped with shut off valve union and sediment trap Adequate pipe size and approved pipe material An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks Correct any leak found TEFLON is a registered trademark of E I Du Pont De Nemours and Company OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to start or re start the water heater Make sure the viewport is not missing or damaged See Figure 28 Make sure the tank is completely filled with water before turning the power switch on Check the data plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the data plate If you have any questions or doubts consult your gas supplier or gas utility company AWARNING Explosion Hazard Replace viewport if glass is missing or damaged Failure to do so can result in death explosion or fire FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to th
40. e exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation section This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere IMPORTANT The use of vent dampers is not recommended by the manufacturer of this water heater Although some vent dampers are certified by CSA International this certification applies to the vent damper device only and does not mean they are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations IMPORTANT If you lack the necessary skills required to properly install this venting system you should not proceed but get help from a qualified person Draft Hood Installat
41. e floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control temperature knob Never use tools If the knob will not move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance Water heaters subjected to flood conditions or anytime the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater DO NOT USE THIS APPLIANCE IF THERE HAS BEENAN IGNITION OF VAPORS Immediately call a qualified service technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid bottom of combustion chamber and require replacement of the entire water heater LIGHTING INSTRUCTIONS STOP It is imperative that you read all the safety warnings above on this label Remove the outer door Move the ON OFF switch on the Gas Control Valve Thermostat
42. e fuel is not spilled in the area of the water heater installation or any source of ignition If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL GAS instructions on the cover of this manual LP Gas Only AWARNING Explosion Hazard Have a qualified person make sure L P gas pressure does not exceed 13 water column Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Failure to do so can result in death explosion or fire Table 1 i Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Size in 10 20 30 40 50 60 1600 1100 Length of Pipe Feet 70 80 90 100 125 150 175 200 After the length of pipe has been determined select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the water heater By formula Cu Ft Per Hr Required Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Table 2 f LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted
43. e tank with water and check all connections for leaks Open the nearest hot water faucet and let it run for three 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank The Electrical power may then be turned on Verify proper operation after servicing AWARNING Electric Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock Figure 23 Wiring Diagram a LBK 120VAC _w 120vac TRANSFORMER l YL 24 VAC g gt A a ae f gt A zZ a v24vac DAMPER l o lt i 5 TEMPERATURE CUT OFF SWITCH BK 24 VAC H WH 24 VAC N a 5 GAS CONTROL VALVE l THERMOSTAT jie Saai es zl m IGNITER FLAME SENSOR FV SENSOR ON OFF SWITCH WARNING x Electric Shock Hazard Plug into a grounded 3 prong oulet Do not remove ground prong Do not use an adapter Do not use an extension cord Failure to follow these instructions can result in death fire or electrical shock BN 24VAC V 24VAC i l s FLUE DAMPER l BK 24VAC HOT WH 24VAC NEUTRAL l 1 l AC gt vl ain END SWITCH YL 24VAC YL 24VAC J L TRANSFORMER Vg VE TEMPERATURE CUT OFF SWITCH WH 24VAC NEUTRAL i 5 D FV SENS
44. e trap section instructions Figure 33A Flame trap visual inspection Flashlight Cleaning the Combustion Chamber and Flame trap 1 Follow procedure outlined in Removing the Manifold Assembly 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 33B Use compressed air to clear any dust or debris that may have accumulated in the flame trap 3 Reassemble following the procedure under Replacing the Manifold Assembly Figure 33B Combustion Chamber Flame trap Door Gasket Replacing the Manifold Assembly A WARNING 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 two piece wire connector if missing or removed Replace door gasket if damaged Failure to follow these instructions can result in death explosion or fire 1 Check the door gasket for damage or imbedded debris prior to installation 2 Inspect the viewport for damage and replace as required 3 Insert the manifold assembly into the burner compartment making sure that the tab of the manifold tube engages in the slot of the bracket inside the combustion chamber Figure 34 4 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion cha
45. ections for leaks Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately 11 Replace the outer door Figure 34 Manifold Assembly Close up Close up inside view of the combustion chamber Burner Igniter System The STP Spark to Pilot igniter system consists of the pilot electrode and wire The pilot is ignited by an electric spark generated when the gas control valve thermostat sends an electrical signal to the electrode Use only factory authorized STP igniter parts for replacement Figure 35 Gas Igniter Assembly Igniter Wire Pilot Igniter Flame Sensor Bracket 27 objects into the inlet or outlet connections Damage to the gas control valve thermostat may result Gas Control Valve Thermostat To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat clockwise Removing and Replacing the Gas Control Valve Thermostat IMPORTANT The gas control valve thermostat is a standard valve with wire leads that connect to a thermal switch flue damper igniter and flammable vapor sensor Removing the Gas Control Valve Thermostat DO NOT OVER TIGHTEN damage may result 1 Turn off the gas at the manual shut off valve on the
46. f your gas water heater and provide important safety information in these areas Read all of the instructions thoroughly before attempting the installation or operation of this water heater Do not discard this manual You or future users of this water heater will need it for future reference Service to the Flame Guard Safety System should only be performed by a qualified person Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel IMPORTANT The manufacturer and seller of this water heater will not be liable for any damages injuries or deaths caused by failure to comply with the installation and operating instructions outlined in this manual If you lack the necessary skills required to properly install this water heater or you have difficulty following the instructions you should not proceed but have a qualified person perform the installation of this water heater Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2 00 and 5 00 A data plate identifying your water heater can be found next to the gas control valve thermostat When referring to your water heater always have the information listed on the data plate readily available Retain your original receipt as proof of purchase Unpacking the Water Heater AWARNING Excessive Weight Hazard Use two or m
47. following 1 Normal expansion and contraction of metal parts during periods of heat up and cool down 2 Condensation causes sizzling and popping within the burner area and should be considered normal 3 Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure Drain and flush the tank as directed under Draining and Flushing Smoke Odor The water heater may give off a small amount of smoke and odor during the initial start up of the unit This is due to the burning off of oil from metal parts of a new unit and will disappear after a few minutes of operation Safety Shut off This water heater is designed to automatically shut off in the event of the following 1 The water temperature exceeds 189 F 87 C for 160 F models 3 Excessive combustion chamber temperatures 4 The presence of flammable vapors This unit is equipped with a flammable vapor sensor designed to shut off the gas supply in the event the heater has been exposed to flammable vapors spilled gasoline or paint fumes for example IMPORTANT If the flammable vapor sensor activates a qualified service person must be contacted to reset the water heater This unit is also equipped with a thermal switch designed to shut off the gas control valve thermostat in the event the water heater has poor combustion caused by a blocked vent or insufficient combustion air If the switch opens check the flame tra
48. g while still conserving energy CONTROL STATUS IDLE No call for heat no fault conditions Call for Heat No fault conditions 21 Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces This will produce a sizzling or frying noise NOTE This condensation is normal and should not be confused with a leaking tank Condensation may increase or decrease at different times of the year High efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a large amount of hot water is being used NOTE Do not confuse this with a tank leak Once the water reaches a temperature of 120 F and the tank warms up usually 1 2 hours the condensation will stop IMPORTANT It is always recommended that a suitable metal drain pan be installed under the water heater to protect the area from water damage resulting from normal condensation production a leaking tank or piping connections Refer to Location Requirements on page 4 Under no circumstances is the manufacturer to be held responsible for any water damage in connection with this water heater Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard These noises are common and may result from the
49. how a leak Correct any leak found Figure 5 Gas Piping Manual Gas Shut off ee Ground Joint gt Union Check with local utility for minimum height l 3 Minimum Sediment Trap Gas Pressure IMPORTANT The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s data plate The minimum supply pressure is for the purpose of input adjustment Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation e Ifthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water heater and its manual shut off valve must be disconnected from the gas supply piping system and the line capped e Ifthe gas lines are to be tested at a pressure less than 14 W C the water heater must be isolated from the gas supply piping system by closing its manual shut off valve U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified person after installation of the gas piping system While purging the gas piping system of air make sure that th
50. ion Align the legs of the draft hood with the slots provided Insert the draft hood leg tips into slots on the flue dampers flange as shown in Figure 12 Secure the draft hood by twisting or bending the leg tips See Figure 12 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the new draft hood supplied with the water heater 10 Figure 12 Draft hood Installation Draft hood Flue Damper Draft hood Leg Tips Twist or bend the leg tips to secure the draft hood to the flue damper Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is required the vent transition connection must be made at the draft hood outlet Vent Connectors 1 Type B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces crawl spaces or any c
51. it the risk of scald injury Pumps valves piping and fittings must be compatible with potable water e A properly installed flow control valve is required to pre vent thermosiphoning Thermosiphoning is the result of a continuous flow of water through the air handler circuit during the off cycle Weeping blow off of the temperature and pressure relief valve T amp P or higher than normal water temperatures are the first signs of thermosiphoning e The domestic hot water line from the water heater should be vertical past any mixing valve or supply line to the air handler to remove air bubbles from the sys tem Otherwise these bubbles will be trapped in the air handler heat exchanger coil reducing the efficiency e Donot connect the water heater to any system or components previously used with non potable water heating appliances when used to supply potable water Some jurisdictions may require a backflow preventer in the incoming cold water line This may cause the temperature and pressure relief valve on the water heater to discharge or weep due to expansion of the heated water A diaphragm type expansion tank suitable for potable water will normally eliminate this weeping condition Please read and follow the manufacturer s instructions for the installation of such tanks Also see Water System Piping section for additional instructions on the proper installation and operation of this water heater Figure 16 T
52. k and fire can cause death or serious burns to anyone in the area Figure 1 FV Sensor This heater is equipped with an FV sensor for detecting the presence of flammable vapors When the sensor detects those vapors the unit will shut down and not operate Should this happen please refer to the troubleshooting guide Even though this water heater is a flammable vapors 4 ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance In the event the FVIR system does not prevent the ignition of flammable vapors the Flame Guard Safety System is designed to reduce the risk of flammable vapor related fires The patented Flame Guard Safety System protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame trap The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the Flame Guard Safety System disables the water heater by shutting off the gas supply to the water heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter activates and flammable vapors have accumulated in
53. l Conditions Maintenance of Your Water Heater Troubleshooting Charts Repair Parts Illustration INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes Consumer Information This water heater is design certified by CSA International as a Category I non direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition This is available from the following CSA America Inc 8501 East Pleasant Valley Road Cleveland OH 44131 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 Check your phone listings for the local authorities having jurisdiction over your installation Consumer Responsibilities This manual has been prepared to acquaint you with the installation operation and maintenance o
54. lacing the anode Figure 25 1 Turn off gas supply to the water heater node Rod Depletion 2 Shut off the water supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 5 gallons of water from tank Refer to Draining and Flushing for proper procedures Close drain valve 4 Remove old anode rod 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open a nearby hot water faucet to purge air from water system 7 Check for any leaks and immediately correct any if found 8 Restart the water heater as directed in this manual See the Repair Parts Illustration for anode rod location TEFLON is a registered trademark of E I Du Pont De Nemours and Company Exposed Support Wire MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation 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 1 Move the switch on the gas control valve thermostat to the OFF position to turn off the water heater 2 Open a nearby hot water faucet until the water is no longer hot Close the cold water inlet valve Connect a hose to the drain valve an
55. lean the spill until all ignition sources have been extinguished Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location e Select a location near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface Do not install in bathrooms bedrooms or any occupied room normally kept closed e Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows e Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure Due to the normal corrosive action of the water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause
56. liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Size in 10 20 30 40 50 1 2 275 3 4 576 1 1071 1 1 4 2205 Example Length of Pipe Feet 60 70 80 90 100 125 150 Input BTU requirement of the water heater 100 000 BTU HR Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI Z223 1 Combustion Air Supply and Ventilation WARNING Carbon Monoxide Hazard Water heater must be vented to outdoors Vent must be installed by a qualified person using the installation instructions Examples of a qualified person include gas technicians authorized gas company personnel and authorized service persons Failure to follow these instructions can result in death or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air e beauty shops photo processing labs e buildings with indoor pools e water heaters installed in laundry hobby or craft rooms e water heaters installed near
57. mal 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 effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank 13 Temperature and Pressure Relief Valve WARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion Figure 18 Temperature and Pressure Relief Valve Installation Temperature and p Pressure Relief Valve Discharge Pipe Do not cap or plug Drain Line 3 4 ID minimum Maximum Air Gap Floor 5S Drain Metal Drain Pan For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE see Figure 18 This valve must be design certified by a na
58. mber 5 Replace the two screws which secure the manifold assembly door to the combustion chamber and tighten securely There should be no space between the gasket part of the manifold door and combustion chamber IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber 6 Reconnect the yellow wire leads to the thermal switch Figure 27 the manifold tubing 3 4 wrench and pilot tubing 7 16 wrench to the gas control valve thermostat Do not cross thread or apply any thread sealant to the fittings NOTE L P Gas systems use reverse left hand threads on the manifold tube 7 If replacing the pilot tube install ferrule nut supplied with kit into the gas valve at the pilot tube location hand tight only Insert pilot tube into ferrule nut until tube bottoms out then tighten nut with a 7 16 wrench until crimp connection seals to pilot tube Continue to tighten until the nut is tight in gas valve 8 Reconnect the igniter wire to the gas control valve thermostat 9 Turn the gas supply on and check for leaks Test the water heater by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found 10 Refer to the Lighting Instructions on page 16 With the burner lit check the gas control valve thermostat supply line manifold component block manifold tube and pilot tube conn
59. necessary After installation the filter may be cleaned by using a vacuum cleaner with a brush attachment to remove lint and dust NOTE Because the amount of dust and lint in the air can vary your filter may need to be inspected cleaned more often In some instances the filter may need to be removed and washed using mild hand soap and water to remove any oily residue After washing allow to dry and properly reinstall Never operate the water heater without a clean air filter 25 Figure 32B Installing Air Filter Assembly Trim excess material making sure there is enough to overlap by 4 menes 100 mm If the water heater has a E gt sensor the air filter must be YS trimmed around sensor Discard piece after trimming Filter clip end on the air filter assembly OVERLAP 4 100 mm Attach the filter clip as 5a shown holding the air filter assembly in place Fit around sensor if present then wrap the air filter assembly around the bottom of the water heater NOTE Clip on top edge Flush fit against bottom of drain pan and or floor Drain pan removed for clarilty 26 External Inspection amp Cleaning of the Flame trap Although not likely to occur if debris collects on the flame trap use a vacuum compressed air or a soft bristle brush to remove it NOTE If unable to inspect or clean the flame trap from underneath follow the Cleaning the Combustion Chamber and Flam
60. odes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases e The connector must be firmly attached and sealed to prevent it from falling out e To aid in removing the connector a thimble or slip joint may be used e The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 13 Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with U L listed type B vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 14 and 15 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry encl
61. on the gas control valve to the OFF position and unplug the power cord from the power outlet A Check the incoming gas line pressure to ensure adequate supply to the water heater If incoming gas supply pressure is adequate proceed to step 2 Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact If no connection problems are found proceed to step 3 Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page If the problem persists proceed to step 3 Check condition of the base ring filter and flame arrestor If they are clogged follow the instructions for cleaning on page 24 If parts are not clogged proceed to step 4 After cleaning follow instructions for lighting on page 16 If problem persists proceed to step 4 30 STATUS LIGHT CODE TROUBLESHOOTING TABLE Status Light Code LED FLASH CONTROL STATUS CORRECTIVE ACTION SEQUENCE Six Two Flash three second pause Soft Lockout Recycle Limit Flame Lost Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the END Switch Fails power outlet ls Check all wiring connections to insure all harness and wire connections are seated firmly and provide
62. onfined or inaccessible location A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases e Install without dips or sags with an upward slope of at least 1 4 inch per foot e Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage e The length of the vent connector cannot exceed 75 of the vertical vent height e The vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition e It is recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system to improve conditions for positive flow of venting gases IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state c
63. ore people to move and install water heater Failure to do so can result in back or other injury IMPORTANT Do not remove any permanent instructions labels or the data label from either the outside of the water heater or on the inside of water heater panels e Remove exterior packaging and place installation com ponents aside e Inspect all parts for damage prior to installation and start up e Completely read all instructions before attempting to assemble and install this product e After installation dispose of recycle all packaging materials WARNING e eo N y Y y Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Location Requirements AWARNING Carbon Monoxide Poisoning Hazard Do not install in a mobile home Doing so can result in death or carbon monoxide poisoning The FVIR System is designed to reduce the risk of flammable vapor related fires Flammable liquids such as gasoline solvents propane etc emit flammable vapors which can be ignited by a gas water heater s spark igniter or main burner The resulting flashbac
64. osure may be used as a passageway for the installation of a gas vent Figure 15 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation IMPORTANT Do not common vent this water heater with any power vented appliance Figures 13 15 are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI Z223 1 current edition and the guidelines set forth by prevailing local codes Listed Lined f Chimney a Figure 13 Chimney Termination Vent System c 2 ft minimum above any object within10 ft horizontally 3 ft minimum Maintain e EST ame SEEI AH AHH UHH Do not extend vent beyond edge of chimney T TH z HHH HHH Vent Connector Figure 14 Vertical Gas Vent System With Type B Double Wall Vent Pipe NT Listed Vent Cap mi 2 ft minimum above any 3 ft minimum object within10 ft EX horizontally Maintain Support Strap clearance lt __ Type B Double Wall Vent Pipe j A Maintain Vent specified connector clearance slope up 1 4 in per ft minimum Figure 15 Venting LIL EEE MANUFACTURER S a Chimney SPECIFIED MINIMUM CLEARANCE with Type B Double Wall Vent Pipe fmm LISTED VENT CAP lt _ lt MAINTAIN SPECIFIED
65. p for signs of high temperature blue or black discoloration and inspect your installation for any problems with venting or combustion air See Troubleshooting Flowchart on page 29 Reset the thermal switch by depressing the small button in the center of the switch IMPORTANT Correct any issues prior to resetting the switch Contact the Product Service and Support Department for service information at 1 877 817 6750 22 A temperature limit switch or ECO Energy Cut Off sensor located in the gas control valve thermostat is used to shut off the water heater if the water temperature exceeds 189 F 87 C The Diagnostic Status Light will flash a code indicating an Overheat Failure 4 Flashes See Operating the Temperature Control System If the gas control valve thermostat has an ECO Lockout the gas control valve thermostat must be replaced by a qualified person Contact your local dealer for service information Anode Rod Water Odor Each water heater contains at least one anode rod which will slowly 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 developing a leak Certain water conditions
66. 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 Figure 19 T amp P Relief Valve Insulation T amp P Relief Valve Insulation Manual Relief Lever T amp P Relief Valve T amp P Relief Valve Drain Line Special Applications Combination Space Heating Potable Water System Some water heater models are equipped with inlet outlet connections for use in space heating applications Note this water heater Suitable for combination water potable heating and space heating and not suitable for space heating_ applications only If this water heater is to be used to supply both space heating and potable drinking water the instructions listed below must be followed e Be sure to follow the manual s shipped with the air handler system e This water heater is not to be used as a replacement for an existing boiler installation e Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping e Ifthe space heating system requires water tempera tures in excess of 120 F a mixing valve or an anti scald device should be installed per its manufacturer s instructions in the domestic potable hot water supply to lim
67. pipe from the gas control valve thermostat leaks Check for leaks by brushing on an approved 6 To remove the gas control valve thermostat thread a 4 noncorrosive leak detection solution Bubbles forming section of gas pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use pipe wrench or equivalent to grip body Damage may result causing leaks Do not insert any sharp indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately If additional information is required contact the Service Department at 1 877 817 6750 Flame Guard Safety System Operational Checklist 1 Manifold gasket properly sealed 5 No leaks at pilot and manifold connection 2 Viewport not damaged or cracked 6 Manifold door screws securely tightened 3 Flame trap free of debris and undamaged 7 Depress the button on the thermal switch 4 Manifold component block properly installed TROUBLESHOOTING CHART BURNER WILL NOT IGNITE PILOT WILL NOT LIGHT OR Pilot will not light Thermostat set too low No gas Dirt in the gas lines Pilot line clogged Main burner line clogged CONDOR WN Flue Damper not functioning REMAIN LIT 28 The thermal switch tripped Igniter wire connection loose Air in gas line Low gas pressure No gas Dirt in gas lines Cold drafts Thermostat ECO switch open Pilot line or orifice clogged Air for combustion obstructed
68. problem persists replace damper Clean locate source and correct Proper fresh air ventilation Clean or replace orifice Set temperature dial to lower setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping 0 Replace the flue damper Turn temperature dial to desired setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Advise customer Insulate piping Insulate piping Check with gas utility company Provide ventilation to water heater Check flue way flue baffle and burner 2 Clean flue locate source and correct 3 Check with gas utility company 4 Replace thermostat 5 Install adequate heater 6 Correct piping dip tube must be in cold inlet 7 Advise customer 1 2 3 1 PE thermostat 2 PE thermostat 1 Provide ventilation to water heater Check flue way flue baffle and burner 2 Clean locate source and correct 3 Provide fresh air ventilation 1 Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct 4 Replace thermostat Provide fresh air ventilation CONDENSATION 1 Temperature setting too low Increase the temperature setting 1 BURNER FLAME FLOATS AND LIFTS OFF PO
69. rage or contain large objects may not be suitable for water heater installation e Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space e Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 6 The size of each opening free area is determined by the total BTU HR input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTU HR input can be found on the water heater data plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors Figure 6 Opening Locations Confined Spaces 12 maximum Permanent openings to the outside or additional rooms within the building confined space 12 maximum All Air from Inside the Building When additional
70. rtain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 16 Connect the cold water supply 3 4 NPT to the fitting marked C Connect the hot water supply 3 4 NPT to the fitting marked H IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 17 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 4 Ifinstalling the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion section 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 Atemperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp
71. s it is recommended that the discharge pipe be terminated at an adequate drain inside the building e Must be capable of withstanding 250 F 121 C without distortion e Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation some Models 1 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 18 2 Locate the slit running the length of the T amp P relief valve insulation 3 Spread the slit open and fit the insulation over the T amp P relief valve See Figure 19 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 or tape should not block or cover the T amp P relief valve drain opening Also the insulation or tape should not block or hinder access to the manual relief lever Figure 19 Ensure that 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 insulation 6 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the
72. t the possibility of injury under these conditions we recommend the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the faucet as water begins to flow Do not smoke or have any open flame near the faucet at the time it is open The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm e This appliance can cause low level exposure to some of the substances listed in the act This product is certified to comply with a maximum weighted average of 0 25 lead content as required in some areas Table Of Contents Water Heater Safety Installing Your Gas Water Heater Unpacking the Water Heater Location Requirements Gas Supply Combustion Air Supply and Ventilation Water System Piping Temperature amp Pressure Relief Valve Special Applications Installation Checklist Operating Your Water Heater Lighting Instructions Electrical Connections Operating the Temperature Control System Operationa
73. ting on page 16 If problem persists proceed to step 4 Follow the instructions on page to remove the burner assembly Once the burner assembly has been removed inspect the manifold tube and burner see figure 29 for any obstructions If any clogs or obstructions are present clear them Inspect the electrode flame sense rod see figure for corrosion buildup degradation or damage If there is evidence of any damage to the electrode flame sense rod replace the igniter pilot assembly Follow the directions on page 25 to re install the burner assembly into the combustion chamber Follow the instructions for lighting on page 16 If the problem persists contact a certified service representative Six Four Flash three second pause Soft Lockout Flame out of Sequence Sensed Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the power outlet Wait 10 minutes then follow the lighting instructions on page 16 If the problem persists replace the gas control valve Seven Flash three second pause Flammable Vapor Sensor FVS Lockout Do not touch any electrical switch do not use any phone in the building and do not try to light any appliance Smell around the water heater to ensure there are no gas leaks at the gas control valve or in the supply gas line or for any other type of flammable vapors in the area Carefully inspect the area surrounding the water heater for any substances such as
74. tionally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic Shut off Devices for Hot Water Supply Systems ANSI Z21 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the data plate 14 IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve e Must not be in contact with any electrical part e Must be connected to an adequate discharge line e Must not be rated higher than the working pressure shown on the data plate of the water heater The Discharge Line e Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line e Must terminate a maximum of six inches above a floor drain or external to the building In cold climate
75. to the OFF position On Off Switch Status Light e C a 120 F pe Position HOT Gas Control Temperature Knob To clear any gas that may have accumulated wait ten 10 minutes If you then smell gas STOP Follow B in the safety warning above If you do not smell gas go to the next step Turn on all electric power to the appliance Connect to a grounded 110 120 volt power outlet Move the ON OFF switch on the Gas Control Valve Thermostat to the ON position 7 Turn the gas control temperature knob to the LOW temperature setting As shown above 8 This appliance is equipped with a device that automatically lights the pilot DO NOT TRY TO LIGHT THE PILOT BY HAND When the pilot is lit the status light should blink a heartbeat bright dim bright dim etc If the status light does not start blinking repeat steps 3 7 The pilot can be located by looking through the glass view port If the pilot is lit you will see the pilot flame through the glass view port IMPORTANT If the appliance pilot fails to light after several tries follow the instructions To Turn Off Gas to Appliance and call a qualified service technician or gas supplier Record any status light flash codes Electrode 10 Set the gas control temperature knob to the desired setting 11 Replace the outer door TO TURN OFF GAS TO APPLIANCE 1 Turn off the gas to the water heater at the manual shut off
76. uring the pilot tube to the pilot assembly NOTE To prevent any bending of the pilot bracket use pliers to hold the pilot assembly bracket while loosening the pilot nut 4 Pull the pilot tube from the pilot assembly Figure 31 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components Figure 31 Pilot Thermopile Assembly Pilot Tube Pilot Ignitor Flame Sensor Igniter Wire Assembly 5 Use a screwdriver to remove the screws securing the Pilot Igniter Flame Sensor Assembly Keep the screws for reattachment 6 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 Push the new pilot tube and igniter wire through the hole in the manifold door See Figure 30 Reconnect the pilot tube and tighten the nut securing it to the pilot assembly IMPORTANT Keep the pilot orifice in the pilot when making the connection DO NOT operate the water heater without the pilot orifice installed Reattach the pilot assembly to the manifold Be sure the igniter wire is positioned through the bottom opening of the manifold component block See Replacing Manifold Assembly section Filter Installation and Cleaning IMPORTANT It is essential that the filter be installed properly If you encounter difficulty installing the filter or have a question please call the Service amp Warr
77. urn the power switch on the gas valve to the OFF position remove the obstruction if the damper closes turn the power switch on the gas valve to the ON position If there are no obstructions present turn the power switch on the gas valve to the OFF position Observe the damper to see if the damper closes If the damper does not close unplug the power cord from the power outlet and proceed to step 1 If the damper closes turn the power switch on the gas valve to the ON position 1 Check all wiring connections to insure all harness and wire connections are seated firmly and provide proper electrical contact If no connection problems are found replace the damper Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list on page for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 16 If the problem persists replace the damper Three Flash three second pause End Switch Failed Open or TCO Limit Lockout Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the power outlet t Attempt to depress the TCO door switch button see figure If the TCO door switch button depresses follow the instructions for cleaning the filter and flame arrestor on page 24 After cleaning is completed follow the lighting instructions on page If th
78. valve Move the ON OFF switch on the Gas Control Valve Thermostat to the OFF position 3 Turn off all electric power to the appliance Disconnect from a grounded 110 120 volt power outlet 17 L P G Bottled Propane Models Liquefied petroleum gas is over 50 heavier than air and in the occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces skirted areas under mobile homes even when ventilated closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P gas water heater smell all around the appliance at floor level If you smell gas follow the instructions as given in the warning on the front page When your L P tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions Checking the Draft AWARNING Burn Hazard Do not touch vent AT Doing so can result in burns After successfully lighting the water heater allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the drafthood A steady flame drawn into the opening indicates proper draft If the flame flutters or is blown out
79. ypical Mixing Valve Installation Combination Space Heating Potable Water Heating System Domestic Must be vertical to Hot n remove air bubbles x A Cold Water Inlet Flow Control p Valve ump ot To Air Handler Do Not Cap or Plug Shut off Valve D 6 Maximum Air Gap Massachusetts code does not allow this type installation Metal Drain Pan Floor Drain Solar Installation If this water heater is used as a solar storage heater or as a backup for the solar system the water supply temperatures to the water heater tank may be in excess of 120 F A mixing valve or other temperature limiting valve must be installed in the water supply line to limit the supply temperature to 120 F The unit must be set to Standard Mode See Operating the Temperature Control System section NOTE Solar water heating systems can often supply water with temperatures exceeding 180 F and may result in water heater malfunction 15 Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident The new technology used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make any required installation upgrades or changes Questions Call 1 877 817 6750 Installation Checklist Water

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