Home

A.O. Smith GAHH-50 Technical Documents

1. 25 Removing the Burner from the Manifold Burner Assembly 2 nennen enne 25 Replacing the Flame Sense Hot Surface Igniter Assembly 26 External Inspection amp Cleaning of the Air Intake Chamber Louvers 26 Cleaning the Combustion Chamber andAir Diverter Assembly 26 Replacing the Manifold Burner Assembly 2 nennen nennen nene enne enini 26 27 Removing and Replacing the Gas Control Valve Thermostat 2 27 FVIR System Operational Checklist de ee Eg o 28 Troubleshooting e 28 29 Control Display Troubleshooting seen eem nennen 30 33 Repair Parts lIllustration uon eee eee e Jes onan e ed peer ue edad enge doe Ea iia 34 Listed Parts Kits and Illustrations cete eterne d qned or een se eo sse desee didt 35 eene en enema eerte ete e e deret MEER E RUM OR ERU de tt REPRE MIRROR 36 38 E c 39 40 SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and i
2. FIGURE 19 Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the heater s manual gas control valve and the electrical power Call a qualified technician Water Temperature Regulation Water temperature over 125 F 52 C can cause servere burns instantly resulting in severe injury or death ADANGER Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs showers sink etc HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precauti
3. ITEM 15 ITEM 16 ITEM 17 35 NOTES 36 NOTES 37 NOTES 38 LIMITED RESIDENTIAL GAS WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY in accordance with the warranty terms and conditions specified below The warrantor will furnish the ORIGINAL OWNER 1 a replacement water heater of equivalent size and current model if the glass lined tank in this water heater leaks and 2 a replacement part for any component part which fails THE WATER HEATER REPLACEMENT MODEL OR PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY The warranty period will be determined by the original date of purchase of the water heater or in the absence of a Bill of Sale verifying said date from the date of manufacture indicated on rating plate affixed to this water heater This warranty is not transferable and applies to models listed below TANK PARTS When the water heater has been used for other than single family residential application 1 The tank warranty shall be reduced to 1 year for 6 year models and to 3 years for 10 year models 6 Year Models GAHH The parts warranty shall be reduced to 1 year for all models CONDITIONS AND EXCEPTIONS This warranty shall apply only when the water heater is installed and operated in accordance with 1 all local fire codes and plumbing codes ordinances and regulations 2 the printed instructions prov
4. for 1 tons together and holding for 1 second Then press second Then press the COOLER Q button to the HOTTER 5 button until the desired setting the lowest setting is reached 5 Set the ON OFF switch on the gas control to the OFF position A DANGER Hotter water increases the 6 This appliance is equipped with a device risk scald injury Consult the instruction which automatically lights the burner manual before changing temperature DO NOT TRY TO LIGHT THE BURNER BY HAND 10 If the appliance will not operate follow the instruc 7 Wait five 5 minutes to clear out any gas tions TO TURN OFF GAS TO APPLIANCE and If you then smell gas STOP Follow B in call your technician or gas supplier the safety information above on this label If you WARNING OFF ALL don t smell gas go to the next step ELECTRIC POWER BEFORE SERVICING TO TURN OFF GAS APPLIANCE ass 1 Set the Electronic Display to the lowest setting by first 2 i pressing the COOLER HOTTER 1 switch the gas control to the Q an ons together and holding for 1 second Therrpress the COOLER button to the lowest setting 3 Turn off all electrical power to the appliance if service is to be performed Water Heater Operation Figure 17 below shows the water heater s sequence of operation when a call for heat is initiated The ignition control module will attempt to light the burner three times If
5. 1 Min Drain line 3 4 1 Min Metal Drain _ T 1 37 Ad T 6 Min Depth Max Typical water piping installation FIGURE 13 Mixed Water Unmixed Hot Water D To Fixtures T Cold Water Hot Water Outlet Mixing Valve Set To 120 F Follow The Mixing Valve Manufacturer s Instructions FIGURE 14 Please note the following 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 using iron piping or PVC water piping Use only pumps valves or fittings that are compatible with potable water tis recommend that only full flow ball or gate valves are used in water piping installations The use of valves that may cause excessive restriction to water flow is not recommended Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used 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 16 Closed System Thermal Expansion CAUTION All water heaters eventually leak Donotinstall without adequate drainage As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water
6. 34 31 64 1600 1100 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 Min 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 LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Length of Pipe Feet Size in i 114 103 237 217 448 409 913 834 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI 2223 1 10 COMBUSTION AIR amp VENTILATION AWARNING Carbon Monoxide Warning Water heater must be vented to outdoors Vent must be installed by a qualified technician using the installation instructions Examples of a qualified technican include gas technicians authorized gas company personel and authorized service persons Failure to so do can result in death or carbon monoxide poisoning IMPORTANT Air for combustio
7. This part of the control cannot be replaced or serviced If the error code cannot be cleared the lower control must be replaced Turn power off for 10 to 20 seconds then on again to clear this error code This part of the control cannot be replaced or serviced If the error code cannot be cleared the lower control must be replaced Press and release each of the temperature adjustment buttons If the above action does not clear the error the control will continue to regulate the water temperature at the last setting However settings will no longer be adjustable the upper control should be replaced Checkthe wire that runs from the power anode to the upper control Check the wire for damage and to ensure that the connectors are fully seated into the mating connectors on both ends Check that the tank is full of water Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater Cycle power to the water heater OFF and ON to reset Turn the power off for 10 to 20 seconds then on again to clear the error code If the error code persists or cannot be cleared replace the upper control TROUBLESHOOTING FLOWCHART APPLY POWER TO APPLIANCE NO REQUEST FOR HEAT PRESENT MINUTE AUTOM
8. Temperature limiting valves are available AWARNING Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in opening provided Read instruction manual for safe temperature setting AWARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell Natural or LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use A Read instruction manual before installing using or servicing Install vent system in accordance with codes Do not operate water heater if flood damaged Heater should not be installed for High Altitude operation above 10 100 feet 3 078 m Do not operate if soot buildup Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are available water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage Do not operate water heater if flood damaged Inspect and replace anode Install
9. Time for 1st Degree Burn Less Severe Burns U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 FIGURE 20 Pressing the COOLER button decreases temperature and pressing the HOTTER button increases the temperature 45 minutes 5 minutes 25 seconds 5 seconds 2 seconds 110 116 116 122 131 140 149 154 1 second To avoid any unintentional changes in water temperature settings the control has a tamper resistant feature for changing the temperature setting To change the temperature setting follow these instructions 1 Wake Up the temperature indicators by holding down both COOLER HOTTER temperature adjust ment buttons at the same time for one second See Figure 19 The display will light up The display will only remain on for 30 seconds if no further buttons are pressed After 30 seconds the control will go back to Sleep mode Release both of the temperature adjustment buttons A To decrease the temperature press and release the COOLER button until the desired setting is reached B To increase the temperature press and release the HOTTER button until the desired setting is reached NOTE Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and
10. cinere einer ede erae reed 17 Combination Space Heating Potable Water System 17 18 oolar Installatiori e ote tore ERE ERREUR SER 18 Electrical Connections and Wiring Diagram 18 Important Information About this Water Heater 19 Operating Your Water Heater 20 25 Gas Valve Thermostat Lighting Instructions 20 Checking the Draft tette eese Lie eio exeo desee 21 Burner Flames c EE 22 Emergency Shutdown pede 22 Water Tembperature Regulatlori 3 eee te EG eet e E Ne Pr p M Re 22 23 Operational ConditiOris eren rne decease a ep eee In tede dde de dete tede d nde de dne Etpe deduce 23 24 Routine Preventive Maintenances ueteri rette ee UR E ARR pua STU ne Imma o See SEE NE RUE Xue ex 24 Temperature and Pressure Relief Valve 25 Maintenance of Your Water Heater 25 27 Replacement PariS E
11. 6 min at Single Wall gt 4 Vent Pipe 12 min Top to Ceiling 0 min Sides 0 e Air Inlet Chamber 5 min Front Top View Minimum Clearance Locations FIGURE 2A State of California NOTE The water heater must be braced anchored or strapped to avoid moving during an earthquake Contact local utilities for code requirements in your area visit http www dsa dgs ca gov or call 1 916 445 8100 and request instructions GAS SUPPLY WARNING 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 rating 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 rating plate located near the gas control valve thermostat If the information does not agree with the type of gas available do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not
12. If this occurs a pressure reducing valve with a bypass may need to 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 certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 13 Connect the cold water supply 3 4 NPT to the cold water inlet fitting Connect the hot water piping 3 4 NPT to the hot water outlet fitting 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 e The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 14 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use gt If installing the water heater closed water system
13. LOCAL CODES CONNECTOR DISPLay ANODE CONNECTOR NATURAL GAS BURNER ASSEMBLY MANIFOLD DOOR GASKET MANIFOLD COMPONENT X MANIFOLD DOOR ASSEMBLY N BLOCK W RETAINER CLIP BURNER IGNITER FLAME SENSE W CONNECTOR WIRE FLAME SENSE fi 3 DISCHARGE PIPE 7 DO NOT CAP OR PLUG MANIFOLD TUBE IGNITER FLAME SENSE CONNECTOR WIRE 6 MAXIMUM AIR GAP BURNER FLOOR DRAIN VIEW PORT IMPORTANT DO NOT USE AN EXTENSION CORD TO CONNECT THE WATER HEATER TO AN ELECTRICAL OUTLET FIGURE 1 5 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 outs
14. blocked Thermostat not functioning properly Heater installed in a confined area Burner flame yellow lazy 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 Thermostat not functioning properly Improper calibration Excessive water pressure Heater stacking Closed water system 29 CONDO RWN gt Tighten threaded connections Inspect other appliances near water heater See OPERATIONAL CONDITIONS section Use a pressure reducing valve and relief valve Lower the thermostat setting See Closed System Thermal Expansion Install thermal expansion tank DO NOT plug T amp P valve Check relief valve for proper operation DO NOT plug T amp P valve Drain and flushing heater thoroughly then refill Chlorinate water supply See START UP CONDITIONS section See DRAINING AND FLUSHING section Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct Replace thermostat Provide fresh air ventilation See Burner Flame Yellow Lazy Set temperature 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
15. 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 water heater 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 condi tions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling Figure 2 The water heater is to be located as close as possible to a 120VAC outlet NOTE all electrical wiring should be in accordance to the NEC and all local state electrical codes extension cord is not allowed 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 and the National Electrical Code ANSI NFPS 70 current edition CAUTION All water heaters eventually leak Donotinstall without adequate drainage 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 water the tank will
16. grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Temperature and Pressure Relief Valve AWARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death Temperature and Pressure Relief Valve T amp P Discharge line 3 4 Min Do not cap or plug Metal Drain Pan FIGURE 15A For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE see Figure 15A This val
17. 50 cubic feet for each 1 000 BTUH of the total input for all gas appliances The table below shows a few examples of the minimum square footage area required for various BTUH inputs Minimum Square Feet with Typical Room with 8 Ceiling BTUH Input 30 000 45 000 60 000 75 000 90 000 105 000 120 000 135 000 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 storage or contain large objects may not be suitable for water heater installation Water heaters installed in open spaces in buildings with unusually tight construction may still require out door air to function properly In this situation outside air openings should be sized the same as for a con fined space Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 4 The size of each opening free area is determined by the total BTUH input of all gas utilization equipment i e water he
18. Connector Clearance Slope Up 1 4 Inch Venting Gas Vent System With Type B Double Wall Vent Pipe FIGURE 11 Listed Vent Cap Maintain Manufacturer s Specified Minimum Clearance Maintain Support Strap Specified Clearance Maintain p Clearance TA Vent t ent Connector d Vent Connector Slope Up Unused Chimney 1 4 Inch Per Foot po Masca Enclosure Minimum Venting Through Chimney With Type B Double Wall Vent Pipe FIGURE 12 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 15 WATER SYSTEM PIPING Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 13 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation The water supply pressure should not exceed 80 psi
19. Electrical Code ANSI NFPS 70 current edition OPERATING YOUR WATER HEATER Operating Instructions Read and understand these directions thoroughly before AWARN NG attempting to operate the water heater Make sure the view port is not missing or damaged See Figure 25 Make Explosion Hazard sure the tank is completely filled with water before operating the water heater The gas control valve thermostat has a On Off Switch and needs to be turned Replace view port if glass is missing or damaged on before water heater is operational Check the label on Failure to do so can result in death the front of heater 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 label If you have any explosion or fire questions or doubts consult your gas supplier or gas utility company FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion result causing property damage personal injury or loss of life FLAMMABLE BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance does not have a pilot It is equipped with e If you cannot reach your gas supplier call the an ignition device that will automatically light the fire department burner Do not try to light the burner by hand C Use only your hand
20. GOntined Space ya c EE 11 All Air from lriside the Building eon cocer rte cene cete perte ec stp de Logros eee 12 All Air from Outdoors eor ioi Pee Cn 12 Rel EE Renta LEE 12 13 Ment PIpe SyStetm ute e phate del ewige 13 Draft Hood Installation perte e se EET on p eed E E TEN ee 13 14 2 6 eens Hae 14 8 14 Chimney Connection noses ein ry a deer sere de EE gu deve 14 Vertical Exhaust Gas c secesdver dewene RE ESE 14 15 Water System 1 eoe eer aan E dna eee xg Va sages 15 18 Piping Installation n ecrire rette roce e Slee ad een re ae 15 16 Closed System Thermal Expansion n er e ide ir pese px ede tie neget coni 16 Temperature amp Pressure Relief Valve 1 12110 00 0000000 enne nn net EEES EEEE EEES EEEn EEEE Eneste EEEE sen eterne rss sinn 16 17 T amp P Relief Valve and Pipe Installation
21. TION Thermostat set too low Settemperature control higher Thermostat defective Replace thermostat Heater undersized Reduce hot water use Low gas pressure Contact dealer Incoming water is unusually cold Allow more time for heater to reheat Leaking hot water pipes or fixtures Have plumber check and repair leaks INSUFFICIENT HOT WATER Low gas pressure Check with gas utility company Improper calibration Replace thermostat Thermostat set too low Turn temperature dial to desired setting SLOW HOT WATER Water heater too small Install adequate heater RECOVERY Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Advise customer WATER TOO HOT Thermostat set too high Settemperature control lower see WATER TEMPERATURE REGULATION section Turn off heater and gas clean burner head Check intake venting arrangements for obstruc tions Check intake venting arrangements for obsruc tions Clean locate source and correct Clean or replace orifice Check orifice and replace if necessary Replace thermostat Dirt in burner ports Combustion air path restricted BURNER FLAME YELLOW LAZY Not enough dilution air for proper com bustion Main burner line clogged Obstruction in main burner orifice Burner flame too high Flame burns at orifice thermostat not functioning properly Low gas pressure NOTRe 1 2
22. USED BY THIS WATER HEATER 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 ALL TECHNICAL AND WARRANTY QUESTIONS SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED IF YOU ARE UNSUCCESSFUL CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1 800 527 1953 OR WWW HOTWATER COM PRINTED IN THE U S A 0810 PART NO 315456 004 TABLE OF CONTENTS Water Heater Satety 1 4 Safe Installation Use and Service inisa 3 Safety Precautions ete deam ede ee EQ eite dt ido ecu ire dede Rouges sed 3 4 Typical Installation eor ER Ee en Rer en Eee E REED ENTER ER e eas ERR es BER Ce ti roS RE here 5 Installing Your Gas Water Heater 6 8 Important
23. con nections 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 Control Display CAUTION DO NOT USE AN EXTENSION CORD TO CONNECT THE TRANSFORMER TO AN ELECTRICAL OUTLET Power Supply LABEL ALL WIRES PRIOR TO Transformer DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 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 Contact Residential Technical Assistance by referencing the phone number on the front of the Installation Instructions and Use amp Care Guide Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located with the water piping system For new installations Located as close to the gas pipi
24. 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 2223 1 54 current edition Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials NOTE Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum gases See Figure 3 1 Install a readily accessible manual shut off valve in the gas supply line as recommended by the local utility Know the location of this valve and how to turn off the gas to this unit 2 Install a drip leg if not already incorporated as part of the water heater as shown The drip leg must be no less than three inches long for the accumulation of dirt foreign material and water droplets 3 Install a ground joint union between the gas control valve thermostat and the manual shut off valve This is to allow easy removal of the gas 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 show a leak Correct any leak found Manual Gas Shut Off Valve Install a readily sible manual shut off valve in the gas supply line a
25. due to water running down the flue tube onto the main burner Because of the suddenness and amount of water condensation water may be diagnosed as a tank leak After the water in the tank warms up about 1 2 hours the condition should disappear Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up An undersized water heater will cause more condensation The water heater must be sized properly to meet the family s demands for hot water including dishwashers washing machines and shower heads Excessive condensation may be noticed during the winter and early spring months when incoming water temperatures are at their lowest 23 Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor CAUTION All water heaters eventually leak Do notinstall without adequate drainage 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 the Location Requirements section Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard These noises are common and may result from the following 1 Normal expansion and contraction of metal parts during periods of heat up and co
26. eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortable with making the repair a qualified technician 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 Locate the water heater near a suitable indoor drain 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 At least 2 greater than the water heater Water heater life depends upon water quality water usage water temperature and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to
27. flame is steady Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean the flame sensor Turn the power off for 10 20 seconds then on again to clear this error code Replace the lower control if the error code persists P SW and SHORT Flashing IGN Flashing FV SENSE Flashing 1 The air pressure switch contacts remain open longer than 11 seconds after the combustion fan is energized The air pressure switch contacts remain closed for more than 5 seconds when they should be open Open ignitor circuit Flammable Vapor Sensor has detected the presence of flammable vapors and is in lockout 31 Clean the screen on the combustion air intake chamber Turn the power OFF for 10 to 20 seconds then ON again to clear the error code If the problem persists Ensure the pressure switch sensing tube is in good condition and securely connected at both ends Ensure the inner door to the combustion chamber is secure and the gasket is properly sealing Check operation of the air intake chamber fan and pressure switch A Turn off power to the water heater B Remove the tubing from the pressure switch and the wires from both terminals of the pressure switch Connect a digital manometer to the open end of the tubing from the air intake chamber Turn on the power to the water heater and when the fan turns on measure the pressure
28. 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 NOTE Solar water heating systems can often supply water with temperatures exceeding 180 F and may result in water heater malfunction Wiring Diagram Gas Control Air Intak a ieu Valve Thermostat Pressure Switch Igniter Flame Sense Connector Electrical Connections 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 Before plugging in the water heater always make sure Voltage and frequency correspond to that specified on the water heater electrical outlet has the proper overload fuse or breaker protection Unit is to connect to a 120VAC electrical supply outlet extension cord is not allowed IMPORTANT Do not use an extension cord to connect the water heater to an electrical outlet 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 the tank with water and check all
29. install an expansion tank in the cold water line as specified under Closed System Thermal Expansion Install 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 A temperature 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 P Relief Valve Follow the instructions under Temperature and Pressure Relief Valve 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 excess 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 In a closed system use a thermal expansion tank Cold Water Pressure Reducing Inlet vag Valve with Bypass ot Water m Outlet fe Cold Water Supply to Fixture Main Water Supply Temperature and Pressure T amp P 7 Relief Valve Optional Top Relief Valve Not Shown Massachusetts Install a vacuum relief in cold water line per section 19 MGL 142 Discharge line Do Not Cap or Plug
30. off power for 10 seconds and then back on If this error code will not clear and the ignitor resistance is within specifications replace the lower control 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 gas oline 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 different location continued next page FV SENSE Flashing Continued from previous page LDO SW OPEN and CLEAN SCREEN Flashing FV SENSE and OPEN Flashing FV SENSE and SHORT Flashing THMSTR and OPEN Flashing THMSTR and SHORT Flashing All Segments Flashing P ANODE OPEN Flashing P ANODE Flashing The air pressure switch contacts remain open longer than 5 seconds after the combustion fan is energized Flammable Vapor Sensor is open Flammable Vapor Sensor is shorted The self diagnostic test has detected the temperature sensor thermistor inside the immersion probe is open The self diagnostic test has detected the temperature
31. operating and all doors windows are closed when performing the draft test Pass a match flame or smoke around the relief opening of the draft hood A steady flame or smoke drawn into the opening indicates proper draft Flue Products Vented to Ouside of Building Dilution Air Draft Hood Dilution Air Relief Opening Air is drawn in for combustion Keep area clean and free from combustibles and flammable vapors 6 Maximum Floor Drain Outer Door The water heater must be installed according to all local and state codes or in the adsence of local and state codes the National Fuel Code ANSI Z223 1 NFPA 54 current edition FIGURE 18 If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 19 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 technician if the flame is not satisfactory
32. reading in the tubing If the pressure reading reaches the 22 WC make point of the pressure switch turn off power to the water heater and reconnect tubing to the pressure switch If pressure reading does not reach the 22 WC make point check the system and tubing for restrictions and cleanliness Attach leads of ohmmeter or continuity tester to the terminals of the pressure switch Turn on power to the water heater and when the air intake fan comes on check for continuity across the pressure switch contacts If switch contacts remain open no continuity while the fan is in operation replace the pressure switch Turn off power to the water heater Locate the pressure switch wiring ensure pressure switch wiring is correct and not jumped Remove wires to both terminals on pressure switch Check pressure switch contacts with an ohmmeter for continuity A If pressure switch contacts show continuity closed circuit replace the pressure switch If pressure switch contacts show open circuit and all wiring is correct replace the lower control Check all wiring to the hot surface ignitor Check the 3 pin Molex ignitor assembly plug and receptacle on the lower control for a good connection Repair or replace parts if necessary Check resistance of the ignitor with an ohmmeter on the ignitor assembly plug Replace ignitor if resistance is not within 1 72 and 2 40 ohms If above checks are good turn
33. should be purged of air by a qualified technician after installation of the gas piping system While purging the gas piping system of air insure that the fuel is not spilled in the area of the water heater installation or any source of ignition NOTE spilled fuel may trip the FV Sensor preventing heater from starting 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 Gas Pipe Capacity Table WARNING 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 A WARNING Explosion Hazard Gas leaks can not always be detected by smell Gas suppliers recommend that you use a gas detector approved by UL or CSA For more information contact your gas supplier If a gas leak is detected follow the What to do if you smell gas instructions on the cover of this manual Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90 100 125 150 175 200
34. to push in the electronic display BEFORE OPERATING smell all around the appliance buttons and gas control switch Never use tools area for gas Be sure to smell next to the floor because If the control buttons will not push in don t try to some gas is heavier than air and will settle on the floor repair them call a qualified service technician Force WHAT TO DO IF YOU SMELL GAS or attempted repair may result in a fire or explosion Do not try to light any appliance D Do not use this appliance if any part has been Do not touch any electric switch under water Immediately contact a qualified do not use any phone in your building installer or service agency to replace a flooded Immediately call your gas supplier from a neighbors water heater Do not attempt to repair the unit phone Follow the gas supplier s instructions It must be replaced OPERATING INSTRUCTIONS OFF lesse 50 pem ON OFF SWITCH GAS CONTROL ELECTRONIC DISPLAY 1 D STOP Read the safety information above on the label 2 Turn on all electrical power to the appliance Set the ON OFF switch on the gas control to the Set the ON OFF switch on the gas control to the ON postition ON position UM Set the Electronic Display to the lowest Setthe Electronic Display to the desired setting by first setting by first pressing the COOLER Q and pressing the COOLER and HOTTER but HOTT R buttons together and
35. 3 4 5 6 7 8 Check with gas utility company Orifice too large wrong orifice Replace with correct orifice High gas pressure Check with gas utility company Water heater flue or vent system Clean flue and burner locate source and correct blocked Cold drafts Locate source and correct BURNER FLAME FLOATS AND LIFTS OFF PORTS Insufficient secondary air Provide ventilation to water heater Check flue Water heater flue or vent system Clean locate source and correct blocked Heater installed in a confined area Provide fresh air ventilation COMBUSTION ODORS 28 continued PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION WATER LEAKS LEAKING T amp P HOT WATER ODORS WATER HEATER SOUNDS SIZZLING RUMBLING SMOKING AND CARBON FORMATION SOOTING HIGH OPERATION COSTS THERMOSTAT FAILS TO SHUT OFF DRIP FROM RELIEF VALVE CONDO RWN gt Improperly sealed hot or cold supply connections relief valve drain valve or thermostat threads Leakage from other appliances or water lines Condensation of flue products Excessive water pressure Heater stacking Closed water system Thermal expansion in closed water system Improperly seated valve High sulfate or mineral content in water supply Bacteria in water supply Condensation dripping on burner Sediment at bottom of heater tank Insufficient secondary air Low gas pressure Water heater flue or vent system
36. ATIC RESET YES TIME DELAY Is WAIT FOR PRESSURE PRESSURE SWITCH SWITCH TO OPEN PROVEN OPEN WITHIN DISPLAY ERROR 5 SECONDS NUMBER 7 YES COMBUSTION FAN ON Is WAIT FOR PRESSURE PRESSURE SWITCH SWITCH TO OPEN PROVEN OPEN WITHIN DISPLAY ERROR 5 SECONDS NUMBER 7 Is PRESSURE SWITCH PROVEN CLOSED WITHIN 11 SECONDS NO WAIT FOR PRESSURE YES SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 ONE HOUR AUTOMATIC RESTART YES TIME DELAY PREPURGE COMBUSTION FAN OFF TURN OFF NO COMBUSTION FAN Is IGNITOR OKAY DISPLAY ERROR CODE NUMBER 8 YES GNITOR ON FOR TURN OFF COMBUSTION COMBUSTION AFTER POST PURGE FAN OFF DISPLAY ERROR 3 GAS VALVE OPENS Is PRESSURE SWITCH PROVEN CLOSED WITHIN 5 SECONDS WAIT FOR PRESSURE SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 COMBUSTION FAN ON BURNER LIGHTS YES AND IS SENSED DURING TRIAL FOR IGNITION NO LESS THAN 3 TRIES OR IGNITION 7 GAS VALVE CLOSES YES NO INTERPURGE YES LOST LESS THAN 4 TIMES YES GAS VALVE CLOSES NO Is PRESSURE SWITCH PROVEN CLOSED WITHIN 5 SECONDS NO WAIT FOR PRESSURE SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 Please Note YES The control continually monitors internal circuits and external sensors Error codes noted above and thos
37. Information About Your Water Heater 6 Consumer nformallon 2 rer 6 Gonsumer Responsibilities 3 Eo RON Ute a Ra Rte 6 eee qt Hon tente ure eb ee etate dea 6 Location Requirements moimi iirde ede secura ebd ec dee eg 7 Site LOCATIONS mM c p M 7 Clearances and Accessibility QE ete Ie Se o eig ede Lee eee ei o pudore ete Donee den 8 Stateof California E 8 50 9 10 Gas BRequir mienits 9 Gas Piping Gas Pressure 5 6 Eme 9 Ga s Pip Table T d 10 Combustion Air and Ventilation 11 15 Unconfiried Spaces ist ir evertit ie nd Du ta s on o M lr I Mer Ee A ID NL Nr Ades 11
38. Installation Instructions and Use amp Care Guide f Smith HIGH EFFICIENCY ATMOSPHERIC VENT GAS WATER HEATER FLAMMABLE VAPOR IGNITION RESISTANT FOR SPACE HEATING AND POTABLE WATER HEATING ONLY NOT FOR USE IN MOBILE HOMES This water heater complies with ANSI Z21 10 1 current edition regarding the accidental or unintended ignition of flammable vapors such as those emitted by gasoline AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater Care and Maintenance Troubleshooting Parts List Safety Instructions Installation Operation INSTALLER 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 WARNING Gas leaks can not always be detected by smell Gas suppliers recommend that you use a gas detector approved by UL or CSA For more information contact the your gas supplier If a gas leak is detected follow the WHAT TO DO IF YOU SMELL GAS instructions ENERGY STAR RESIDENTIAL GAS WATER HEATERS d Mu 2 2 00656 THU For Your Safety AN ODORANT IS ADDED TO THE GAS
39. MPORTANT Do Not splash solution onto the electrical connections Bubbles forming indicate a leak Correct any leak found 6 Check the operation of the burner by following the lighting instructions on the front of the water heater With the burner lit check the gas control valve thermostat supply line manifold tube connections for leaks 7 Verify proper operation and then replace the outer door 8 If additional information is required contact Residential Technical Assistance by referencing the phone number on the water heater or on the front cover of this manual TEFLON is registered trademark of E I Du Pont De Nemours and Company Pressurized Combustion Chamber System Operational Checklist Manifold gasket properly sealed 5 No leaks at manifold connection Viewport not damaged or cracked 6 Manifold door screws securely tightened Combustion chamber free of debris and undamaged Manifold component block properly installed gt TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION Transformer unplugged Plug transformer back into 120 VAC outlet No power at outlet Repair service to outlet NO HOT WATER Thermostat defective Replace Thermostat Air Intake Chamber Fan defective Replace Air Intake Chamber Fan Assembly Pressure Switch defective Replace Pressure Switch Assembly Gas Valve Thermostat Switch in OFF Move Gas Valve Thermostat Switch to ON POSI POSITION
40. S Vent All Air From Outdoors Inlet Air From Ventilated Crawl Space Outlet Air To Ventilated Attic FIGURE 6 Gable Vent to Outdoors Install Above r Insulation ca xn I I TT Confined Space to the Attic b Outlet Air 1 sq in per 4000 BTUH Inlet Air Duct 1 sq in per 4000 BTUH Aia Max y All Air from Outdoors Through Ventilated Attic FIGURE 7 1 sq in per 2000 BTUH Confined Space Outlet Outdoor Air Ducts Inlet v 1 sq in per 2000 BTUH All Air From Outdoors Using Horizontal Ducts FIGURE 8A 13 Alternative Opening Location um gt 1 sq in per Confined ds Space eR 3000 BTUH All Air From Outdoors Using A Single Permanent Opening FIGURE 8B Vent Pipe System This water heater uses a non direct single pipe vent System to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe s
41. apors which can be ignited by a gas water heater s hot surface igniter or main burner The resulting flashback and fire can cause death or serious burns to anyone in the area 1 MC i FIGURE 1A 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 on pages 31 32 numbers 9 11 12 Even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flamm able 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 WARNING FIRE AND EXPLOSION HAZARD T 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 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
42. at once Advise customer Insulate piping Insulate piping Replace thermostat Replace thermostat Use a pressure reducing valve and relief valve Lower the thermostat setting See CLOSED SYSTEM THERMAL EXPAN SION section POWER VAG SCREEN E ECO LDO SW THMSTR P SW OPEN SHORT ELECTRONIC CONTROL DISPLAY ELECTRONIC CONTROL DISPLAY TROUBLESHOOTING IGN HEATING CLEAN LOCK CHECK Please check guidelines below For your safety water heater service should be performed only by a qualified service person Read the GENERAL SAFETY INFORMATION supplied by the water heater manufacturer CONTROL DISPLAY STATUS PROBLEM POWER Flashing HEATING and SHORT Flashing HEATING and OPEN Flashing HEATING OPEN and SHORT Flashing ECO and OPEN Flashing Communication Error The system has detected a communication error between the upper and lower controls The self diagnostic tests have found a problem with an internal circuit Ignition flame failure The water heater has reached the maximum number of retries and is currently locked out for one hour Cycle the power to the water heater off and on to reset Weak flame sensor current Water temperature in the tank has exceeded 185 F 85 C and has activated the ECO 30 SOLUTION Checkthe 5 conductor data cable that runs between the upp
43. aters furnaces clothes dryers etc and the method by which the air is provided The BTUH input can be found on the water heater rating plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors gt Permanent d openings to Closet the outside or or other additional confined rooms within space the building 12 Max FIGURE 4 All Air from Inside the Building When additional air is to be provided to the confined area from additional room s within the building the total volume of the room s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTUH of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 5 Confined Space Permanent Openings eun m 1 Square inch 1000 BTUH min 100 sq in SS FIGURE 5 All Air from Outdoors Outdoor fre
44. ch substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the Act IMPORTANT DEFINITIONS Qualified Technician A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified technician must also be familiar with the design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this instruction manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the
45. e for YES COMBUSTION FAN self diagnostic faults can be found on GAS VALVE OFF OFF AFTER POST PURGE DELAY pages 30 through 32 Is REQUEST FOR HEAT SATISFIED NO 33 REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information 1 Model serial and product number 2 Type of gas 3 number 4 Parts description Repair Parts List ES Parts Description 6 coia water contol X o Ar itake Charmer bem Natural Gas Burner Manifold Door Gasket Viewport Assembly Special anode rod see Anode Rod Water Odor LEGEND B Temperature and Pressure Relief Valve is required but may not be factory installed Electrical Transformer Unique FVIR System parts Pressure Switch Pictured on next page 34 Listed Parts Kits and Illustrations Item 12 Burner Natural Gas Item 13 Flame Sense Hot Surface Igniter Assembly Item 14 Manifold door assembly which contains the manifold tube gasket manifold door manifold component block with retainer clip and flame sense hot surface igniter assembly Natural Gas Item 15 Contains manifold component block with retainer clip Item 16 Contains manifold door gasket Item 17 Contains viewport ITEM 12
46. e vent system for restrictions obstructions and check the vent termination height Refer to the Combustion Air and Ventilation section of this water heater manual for specific requirements Recheck for sufficient combustion air supply Water System Piping Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Mixing valve when applicable installed per manufacturer s instructions See Water Temperature Regulation section Gas Supply and Piping Gas type is the same as that listed on the water heater rating plate Gas line equipped with shut off valve union and drip leg Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum gases 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 Electrical Supply Water heater to be located as close as possible to a 120VAC outlet extension cord is not allowed Electrical supply installed according to all local and state codes or in the absence of local and state codes MCN
47. ed by a qualified technician Contact your local dealer for service information Powered Anode Operation To protect the glass lined water tank from corrosion through electrolysis this water heater is equipped with a non sacrificial powered anode rod The powered anode rod is non sacrificial and should not need to be replaced unless damaged If the powered anode rod has been damaged then the powered anode rod should be removed and replaced from the water heater tank IMPORTANT If the damaged powered anode rod has not been replaced but has been remove permanently this will void any warranties Powered Anode System To ensure a long trouble free operating life this water heater is equipped with a powered anode system Powered The powered anode rod is of a permanent design and does not need replacing unless damaged NOTE Whether re installing or replacing the powered anode rod check for any leaks and immediately correct if found FIGURE 22 In replacing the powered anode 1 off electrical supply and gas supply to the water heater Shut off the water supply and open a nearby hot water faucet to depressurize the water tank Drain approximately 5 gallons of water from tank Refer to the Draining and Flushing section for proper procedures Close drain valve Remove the wiring connection on the top of the powered anode and remove the old powered anode rod Figure 22 Use Teflon
48. emaining pipe from the gas control valve thermostat 7 To remove the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use pipe wrench or equivalent to grip body Damage may result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas control valve thermostat may result Replacing the Gas Valve 1 To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas valve clockwise DO NOT OVER TIGHTEN or damage may result NOTE Use an approved TEFLON tape or pipe compound only on the threaded section of the gas control valve thermostat that screws into the tank 2 Reconnect the gas piping to the gas control valve thermostat NOTE Use an approved Teflon tape or pipe compound on the gas piping connections 3 Reconnect the manifold tube flame sense hot surface igniter wire power supply transformer pressure switch fan and display connector wires Figure 24 4 Fill the tank completely with water NOTE To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained 5 Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection solution I
49. emoving the two 2 screws located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 25 4 Scoop side to be Manifold Door Assembly on the same side as View Port ___ View Port Screws Igniter Flame Sense Connector Burner Bottom View FIGURE 25 Replacing the Flame Sense Hot Surface igniter Assembly 1 Remove the manifold burner assembly See Removing the Manifold Burner Assembly 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 26 Remove and keep the screw securing the flame sense hot surface igniter assembly Figure 26 Remove and discard the old flame sense hot surface igniter assembly Route the new flame sense hot surface igniter con nector wire through manifold burner door opening as shown in figure 26 Secure assembly to bracket using screw removed earlier Flame Sense Hot Surface Igniter Assembly FIGURE 26 6 Reposition the manifold component block in the mani fold door opening and secure it with the retainer clip 7 See Replacing the Manifold Burner Assembly External Inspection amp Cleaning of the Air Intake Chamber Screen 1 Atleast twice annuall
50. emperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly To prevent water damage the valve must be pro perly 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 See Figure 23 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 technician TEMPERATURE AND PRESSURE RELIEF VALVE MANUAL RELIEF x VALVE DISCHARGE LINE TO DRAIN FIGURE 23 MAINTENANCE OF YOUR WATER HEATER Replacement Parts IMPORTANT The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician Replacement parts may be ordered through your plumber or the local distributor Parts will be shipped at prevailing prices and billed accordingly When ordering replacement parts always have the following information ready 1 model serial and product number 2 type of gas 3 item number 4 parts description See R
51. epair Parts Section for a list of available repair parts Removing the Manifold Burner Assembly 1 Turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off Figure 3 Disconnect power supply to the heater Remove the outer door Remove the 2 screw securing the manifold door assembly to the skirt Disconnect all wiring connectors from the gas control valve thermostat Figure 24 Disconnect the manifold tube at the gas control valve thermostat Grasp the manifold tube and push down slightly to free the manifold from the gas control valve thermostat Carefully remove the manifold assembly from the burner compartment NOTE Be sure not to damage internal parts Figure 28 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water 25 Gas Control Valve Thermostat 1 i Manifold Tube gt r pra 0 EU mE Power Supply 25 J ES x 7 Transformer A i Connector Igniter Flame I Sense I Connector W ray Pressure 1 Switch Fan Sensor Connector Control Display Anode Rod Connector FIGURE 24 Removing the Burner from the Manifold Burner Assembly Natural Gas Burner 1 Take off the burner by r
52. er Flue feat b Edi SE Top Slot Y Slot Install The Draft Hood With The Four Screws Provided FIGURE 9 Slot Slot Install The Draft Hood With The Four Screws Provided 40 Gal Water Heater Align the reducer flue over top of baffle as shown in Figure 9 NOTE reducer flue must be installed on 40 gal water heater above elevation 5 400 Ft 1 646 m from sea level 40 amp 50 Gal Water Heaters Align the legs of the draft hood with the slots provided Insert the legs and secure the draft hood to the water heater s top with the four screws provided as shown in Figure 9 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the draft hood supplied with this water heater 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 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 fr
53. er and lower controls Check that the wiring is not broken and the connectors on both ends are properly seated in the mating connectors Replace the upper control if the error code does not clear cycle power to the water heater Off and On to reset Replace the lower control if the problem persists Turn the power off for 10 to 20 seconds then on again to clear the error code If the error code persists or cannot be cleared replace the lower control Gas supply is turned off pressure too low Ensure supply and manifold gas pressures are within requirements in the installation manual Manifold gas pressure is non adjustable if pressure is off by more than 0 3 W C 75 Pa replace the lower control Low supply voltage should be 115 125 VAC Ensure flame sensor is making good contact with the burner flame ensure flame is steady Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean the flame sensor Ensure the hot surface ignitor is positioned to provide consistent ignition Checkfor any cracks in the ignitor assembly ceramic insulators replace ignitor assembly if damaged Check resistance of the ignitor at room temperature 77 F 25 C at the plug end Replace ignitor if the resistance is not within 1 72 to 2 4 ohms at room temperature Ensure flame sensor is making good contact with the burner flame ensure
54. hould not proceed but have a qualified technician 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 rating plate identifying your water heater can be found on the front of your water heater When referring to your water heater always have the information listed on the rating plate readily available Retain your original receipt as proof of purchase Unpacking the Water Heater A WARNING Excessive Weight Hazard Use two or more people to move and install the water heater Failure to do so can result in injury including back 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 Inspect all parts for damage prior to installation and start up Completely read all instructions before attempting to assemble and install this product After installation dispose of recycle all packaging materials Location Requirements A WARNING Do not install in a mobile home Doing so can result in carbon monoxide poisoning and death The FVIR System is designed to reduce the risk of flammable vapor related fires Flammable liquids such as gasoline solvents propane etc emit flammable v
55. ide 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 Agency 1 Batterymarch Park Quincy MA 02269 Check your phone listings for the local authorities having jurisdiction over your installation Consumer Responsibilities This manual has been prepared to acquaint you with the installation operation and maintenance of your gas water heater and provide important safety information in these areas Read all of the instructions thoroughly before attempting the installation or operation of this water heater Do not discard this manual You or future users of this water heater will need it for future reference Service to the FVIR System should only be performed by a qualified technician Examples of a qualified technician 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 s
56. ided with it 3 good industry practices and 4 proper safety practices such as but not limited to a properly sized drain pan if installed in an area where leakage from the tank or its connections would result in damage to the area adjacent to the heater In addition a new temperature and pressure relief valve certified by the Canadian Gas Association must have been properly installed and piped to the nearest drain This warranty shall apply only when the heater is e owned by the original purchaser installed for indoor operation only used at temperatures not exceeding the maximum calibrated setting of its thermostat used at water pressure not exceeding the working pressure shown on the heater filled with potable water free to circulate at all times and with the tank free of damaging water sediment or scale deposits used in a non corrosive and non contaminated atmosphere used with factory approved anode s installed 39 its original installation location in the United States its territories or possessions and Canada sized in accordance with proper sizing techniques for residential water heaters bearing a rating plate which has not been altered defaced or removed except as required by the warrantor used in an open system or in a closed system with a properly sized and installed thermal expansion tank operated with properly installed drip leg in the gas supply line fired with the fuel for
57. in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS Vent Pipe K Outer door U Main Burner B Draft hood L Union V Flue C Anode Not Shown M Inlet Water Shut off Valve W Suitable Metal Drain Pan D Hot Water Outlet N Cold Water Inlet X Control Display E Insulation O Inlet Dip Tube Y Power Supply Transformer F Gas Supply Piping P Temperature amp Pressure Relief Valve Shown detached from Heater G Manual Gas Shut off Valve Q Rating Plate YY Pressure Switch H Ground Joint Union R Flue Baffle Shown detached from Heater Drip Leg Sediment Trap Gas Control Valve Thermostat 2 Air Intake Chamber J Inner Door T Drain Valve ZZ FV Sensor Shown without Bracket INSTALL IN ACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES du aims Sneed S GAS CONTROL VALVE THERMOSTAT TO BE SUPPLIED BY CUSTOMERS TO VENT TERMINATION ON ROOF A INSTALL THERMAL EXPANSION TANK IF WATER HEATER 15 INSTALLED IN A CLOSED IMPORTANT WATER SYSTEM WHEN BRUSHING ON AN k APPROVED NONCORROSIVE LEAK DETECTION SOLUTION DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NECTIONS SEE PAGE 27 PRESSURE 2 SWITCHIFAN MANIFOLD TUBE Z VACUUM RELIEF POWER SUPPLY 3 IGNITE NY ace ABER TRANSFORMER
58. inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building SAFETY PRECAUTIONS AWARNING e FIRE AND EXPLOSION HAZARD Can result in serious injury or death y 4 Y fA j 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 Flammable Vapors vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater AWARNING Fire Hazard For continued protection against risk of fire not install water heater on carpeted floor Do not operate water heater if flood damaged ADANGER Water temperature over 125 F 52 can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically mentally disabled are at highest risk forscald injury Feel water before bathing or showering
59. is recommended that the discharge pipe be terminated at an adequate drain inside the building Must be capable of withstanding 250 F 121 C without distortion Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation 1 Locate the temperature and relief valve on the water heater also known as a Relief Valve Figure 15B Locate the slit running the length of the insulation Spread this slit open and slip it up under the T amp P Relief Valve See Figure 15B Apply gentle pressure to the insulation to ensure it is fully seated on the T amp P Relief Valve Once sealed secure the insulation with a section of duct tape electrical tape or equivalent IMPORTANT The insulation or tape must not block the discharge opening or hinder access to the manual relief lever Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions manual Locate the hot water outlet amp cold water inlet pipes to the water heater Locate the slit running the length of a section of pipe insulation 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 it is fully seated around the 2 3 17 pipe Also ensure that the base of insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape or equi
60. is water heater manual for specific requirements Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans dryers 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 Fresh air supply free of corrosive elements and flammable vapors Provisions made to protect the area from water damage Ductwork is the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Flue baffle properly positioned in the flue tube Check th
61. lash solution onto the electrical connections Bubbles forming indicate a leak Correct any leak found All leaks must be fixed immediately 10 Replace the outer door see item K page 5 3 Door Gasket Burner Min Ne DAN Viewport Manifold Tab FIGURE 29 Removing and Replacing the Gas Control Valve Thermostat IMPORTANT Use only factory authorized replacement parts Removing the Gas Control Valve Thermostat 1 Set the gas control valve thermostat to its lowest setting by first depressing the COOLER D and HOTTER D buttons together and hold for 1 second Then press the COOLER button until the lowest setting appears Figure 21 2 Unplug the electrical transformer from the wall outlet 3 Turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off Figure 3 4 Drain the water heater Refer to the section of Draining and Flushing section and follow the procedure 5 Disconnect the the flame sense hot surface igniter wire power supply transformer pressure switch fan and display connector wires from the thermostat Figure 24 Disconnect the manifould tube at the thermostat Figure 24 6 Refer to Gas Piping section Figure 3 and disconnect the ground joint union in the gas piping Disconnect the r
62. leakage in various ways e Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the metal drain pan e Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply EXHAUST FAN _ REVERSE FLOW OF GASES FIGURE 2 Clearances and Accessibility NOTE Minimum clearances from combustible materials are stated on the label on the front of the heater 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 five inches 127mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 2A be used as a reference guide to locate the specific clearance locations A minimum of 5 inch es of front clearance should be provided for inspection and service
63. 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 total BTUH input rating for all utilizing equipment within the confined space Minimum Free Area Opening Source Per Opening sq in Reference Drawing Direct to outdoors 1 sq in per 4000 BTUH Horizontal Ducts 1 sq in per 2000 BTUH Figure 8A 1 sq in per 3000 BTUH Figure 8B Example A water heater with an input rating of 50 000 BTUH using horizontal ducts would require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 sq in Vertical Ducts 1 sq in per 4000 BTUH Single Opening 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 x Install Above BELA Insulation Confined Space S H Outlet Air to the Attic 1 sq in per gd 4000 BTUH Inlet Air from the Alternative 5 Air Inlet di A 1 sq in per Open 4000 BTUH PO ndath
64. 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 Set the electronic control display tem perature COOLER D button to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather Gas Control Valve Thermostat Settings POWER IGN HEATING LOCK CHECK CLEAN SCREEN e a m Electronic Control Display FIGURE 21 HOTTER COOLER Operational Conditions Condensation Whenever the water heater is filled with cold water some condensate will form while the burner is on A water heater may appear to be leaking when in fact the water is condensation This usually happens when a Anew water heater is filled with cold water for the first time b Burning gas produces water vapor in water heaters par ticularly high efficiency models where flue temperatures are lower c Large amounts of hot water are used in a short time and the refill water in the tank is very cold Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a sizzling or frying noise Excessive condensation can cause burner flame problems
65. n 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 buildings with indoor pools e water heaters installed in laundry hobby or craft rooms e water heaters installed near chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTUH 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
66. ng vent pipe system and 120VAC outlet as possible 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 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 air intake chamber louvers located on the side of the water heater will need to be cleaned periodically Refer to the maintenance section of your water heater s manual for information on cleaning the Air Intake Chamber Louvers Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in a inferior burner flame yellow lazy thereby allowing smoking and carbon formation sooting to build up in the combustion chamber 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 th
67. nstructions have been provided in this manual and on your water heater to warn you and others of a potential hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will A DANGER result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could A WARN l NG result in death or injury CAUTION indicates a potentially hazardous situation which if not avoided could A CAUTION result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTI ON situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury 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 su
68. nting 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 codes 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 The connector must be firmly attached and sealed to prevent it from falling out To aid in removing the connector a thimble or slip joint may be used The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 10 e 2 FT Minimum Above Any Object Within 10 FT Horizontally 3 Minimum Support Strap Maintain I MM Connector Slope Up 1 4 Inch Per Foot Minimum Seal Sa Do Not Extend Vent Beyond Edge Of Chimney Chimney Termination Vent System FIGURE 10 Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with ULL listed type B vent pipe according to the vent manufacturer s instr
69. ol down Condensation causes sizzling and popping within the burner area and should be considered normal 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 the Draining and Flushing section 2 3 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 brief period of operation Safety Shut off This water heater is designed to automatically shut off in the event of the following 1 The burner flame is extinguished for any reason 2 water temperature exceeds 195 F 91 C 3 Excessive build up of dust on the louvers of the air intake chamber See Maintenance of your Water Heater Section This unit is also equipped with a flammable vapor sensor FV Sensor designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors e g spilled gasoline A high temperature limit switch or ECO Energy Cut Off in the tank is used to shut off the unit if the water temperature exceeds 195 F 91 C The ECO is a single use switch which if activated requires complete replacement of the entire gas control valve thermostat If the ECO should activate the water heater cannot be used until the gas control valve thermostat is replac
70. om 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 confined or inaccessible location A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following See Figures 10 12 Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases Install without dips or sags with an upward slope of at least 1 4 inch per foot 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 The length of the vent connector cannot exceed 75 of the vertical vent height The vent connector must be accessible for cleaning inspection and replacement Vent connectors cannot pass through any ceiling floor firewall or fire partition 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 e 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 14 used for ve
71. ons In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water 22 heater Mixing valves are available at plumbing supply or hardware stores see Figure 14 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figures 20 and 21 Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub or shower NOTE A water temperature range of 120 F 140 F 49 C 60 C is recommended by most dishwasher manufacturers The thermostat of this water heater has been factory set at its lowest position It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury The electronic control display temperature should be set at approximately 120 F 49 C and this is the pre ferred starting point see Figure 20 Some states have a requirement for a lower setting If you need hotter water follow directions for temperature adjustment but beware of the warnings in this section Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Water Temperature F
72. pressure relief valve T amp P or higher than normal water temperatures are the first signs of thermosiphoning 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 system Otherwise these bubbles will be trapped in the air handler heat exchanger coil reducing the efficiency Do not 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 Must Be Vertical To Remove Air Bubbles Domestic Hot Water Expansion Tank Out Cold Water Inlet Mixing Valve Ne Flow Control MASSACHUSETTS CODE DOES NOT ALLOW THIS TYPE OF INSTALLATION Typical Mixing Valve Installation Combination Space Heating Potable Water Heating System FIGURE 16 Also see Water System Piping for additional instructions on the safe and correct installation and operation of this water heater Solar Installation If this water
73. s recommended by the local utility Ground Joint Union 00 Discharge Pipe Do Not plug or cap Check with local utility for minimum height 3 Minimum Y Drip Leg 5 an o Max Air Gap W Suitable Drain FIGURE 3 Gas Pressure A WARNING Explosion Hazard Gas leaks can not always be detected by smell Gas suppliers recommend that you use a gas detector approved by UL or CSA For more information contact your gas supplier If a gas leak is detected follow the What to do if you smell gas instructions on the cover of this manual IMPORTANT The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s rating 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 code requires the gas lines to be tested at 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 NOTE Air may be present in the gas lines and could prevent the burner from lighting on initial start up The gas lines
74. sensor thermistor inside the immersion probe is shorted The self diagnostic check has detected one or both of the temperature adjustment buttons are stuck No current to Power Anode Power Anode circuit failure System must be manually reset by entering a special FVS reset sequence into the Electronic Control Display Contact a service agency to determine the cause and instructions on the reset sequence Clean the screen on the combustion air intake chamber retest If the problem persists Cycle power to the water heater OFF and ON to reset Checkall wiring to the flammable vapor sensor Remove the connectors from the flammable vapor sensor and measure the resistance of the sensor with an ohmmeter A Ifthe reading taken is more than 1 7 million ohms replace the flammable vapor sensor B If the reading taken is less than 1 7 million ohms and the wiring from the control to the sensor is good replace the lower control Checkall wiring to the flammable vapor sensor Remove the connectors from the flammable vapor sensor and measure the resistance of the sensor with an ohmmeter A If the reading taken is less than 2000 ohms replace the flammable vapor sensor B Ifthe reading taken is more than 2000 ohms and the wiring from the control to the sensor is good replace the lower control Turn power off for 10 to 20 seconds then on again to clear this error code
75. sh 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 12 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 4 to calculate the minimum free area for each opening Figures 6 7 8A and 8B 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
76. tape or approved pipe sealant on threads and install new anode rod Turn on water supply and open nearby hot water faucet to purge air from water system Check for any leaks and immediately correct any if found Turn on electrical and gas supplies Restart the water heater as directed under the Operating Your Water Heater See the Repair Parts Illustration section for anode rod location TEFLON is a registered trademark of E l Du Pont De Nemours and Company 24 Draining and Flushing ADANGER Hot water discharge burn hazard Keep clear of relief valve discharge unit Temperature limiting valves are available Read instruction manual for safe temperature setting 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 and turn off the electrical power to the gas control thermostat valve 2 Open a nearby hot water faucet until the water is not longer hot 3 Close the cold water inlet valve 4 Connect a hose to the drain valve and terminate it to an adequate drain or external to the building 5 Open the water heater drain valve and allow all the water to drain from the tank Flush the tank with water as needed
77. the remainder of the affected provision or the other provisions of this warranty SERVICE AND LABOR RESPONSIBILITY UNDER THIS LIMITED WARRANTY THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF THE OWNER IS RESPONSIBLE FOR ALL OTHER COSTS Such costs may include but are not limited to a Labor charges for service removal or reinstallation of the water heater or part thereof Shipping and delivery charges for forwarding the new water heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor All cost necessary or incidental for handling and administrative charges and for any materials and or permits required for installation of the replacement heater or part b LIMITATION ON IMPLIED WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the heater or with any other dealer handling the warrantor s products If this is not practical the owner should contact A O Smith Water Heaters 500 Tennessee Waltz Parkway Ashland City Tennessee 37015 Phone 1 800 527 1953 or visit o
78. the closest comparable water heater meeting the then current governmental regulations and industry standards A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards IMPORTANT INFORMATION Model Number Serial Number INSTALLATION INFORMATION Date Installed Company s Name Street or P O Box City State and Zip Code Phone Number Plumber s Name
79. the ignition control does not detect ignition it will enter lockout mode indicated by display flashing status code see status code 3 page 30 and or status code 8 page 31 SEQUENCE OF OPERATION Call for heat indicated by flashing of display screen status codes Gas valve thermostat will open for 4 second trial for ignition and fan will turn on Gas valve thermostat will do a relay check relay clicks will be heard Display will show temperature set point during call for heat Draft Blower is energized System will verify pressure switch operation and start a 5 second pre purge then air intake fan will turn off Main burner flame is detected by flame sense rod Air intake fan and main burner will continue to operate until water temperature inside the tank reaches temperature set point Gas valve thermostat is de energized and air intake fan continues for a post purge time of approximately 5 seconds Water heater returns to standby mode Ignitor will start a 12 second warm up period IGN will show on display FIGURE 17 21 Checking the Draft Burn Hazard Do not touch vent Doing so result in burns After successfully lighting the water heater allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft Figure 18 Make sure all other appliances in the area are
80. to installation 2 Inspect the view port for damage and replace as required 3 Insert the manifold burner assembly into the burner compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber Figure 29 4 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber 5 Replace the two screws which secure the manifold burner assembly door to the combustion chamber and tighten securely Once the manifold burner assembly door is tightened visually inspect the door gasket between the manifold burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber 6 During the following procedure do not cross thread or apply any thread sealant to any of the fittings listed below First reconnect the manifold tubing to the gas control valve thermostat 7 Reconnect the flame sense hot surface igniter wire to the gas control valve thermostat Figure 24 8 Turn gas supply on and refer to the Lighting Instructions 9 With the burner lit check the gas control valve thermostat supply line two piece wire connector and manifold tube connections for leaks Check for leaks by brushing on an approved noncorrosive leak detection solution IMPORTANT Do Not sp
81. 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 Preventive Maintenance At least annually a visual inspection should be made of the venting and air supply system piping systems and main burner 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 Clean any dust or debris from the louvers of the air intake chamber Soot and or carbon on the main burner Contact a qualified technician Leaking or damaged water and gas piping Presence of flammable or corrosive materials in the installation area Presence of combustible materials near the water heater 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 technician Temperature and Pressure Relief Valve Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized t
82. uctions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 11 and 12 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 12 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation CAUTION DO NOT common vent this water heater with any power vented appliance Figures 10 12 are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI Z223 1 current edition and the guidelines set forth by prevailing local codes 2 FT Minimum Above Y Any Object Within 3FT A 10 FT Horizontally Minimum e y Support Strap x21 Maintain cc ISO Clearance Type B Double NI Wall Vent Pipe Maintain Vent Specified
83. ur website www hotwater com Replacement Parts may be ordered through authorized servicers or distributors Refer to your local Yellow Pages for where to call or contact A O Smith Water Heater Parts Fullfillment 125 Southeast Parkway Franklin TN 37068 phone 1 800 433 2545 The warrantor will only honor replacement with identical or similar water heater or parts thereof which are manufactured or distributed by the warrantor Dealer replacements are made subject to in warranty validation by warrantor PROOF OF PURCHASE AND PROOF OF INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGINAL OWNER THIS FORM DOES NOT CONSTITUTE PROOF OF PURCHASE OR PROOF OF INSTALLATION DISCLAIMERS NO EXPRESSED WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE HEATER OR PARTS THE WARRANTOR SHALL 40 NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN CONTRACT OR IN TORT Should governmental regulations or industry standards prohibit the Manufacturer from furnishing a comparable model replacement under this warranty the Owner will be furnished with
84. valent Repeat steps 5 through 6 for the hot water outlet pipe Add additional sections of pipe insulation as needed Manual Relief Lever AMA CC T amp P Relief Valve 1 T amp P Relief Valve Drain Line T amp P Relief Valve Insulation FIGURE 15B Combination Space Heating Potable Water System Some water heater models are equipped with inlet outlet connections for use with space heating applications If this water heater is to be used to supply both space heating and domestic potable drinking water the instructions listed below must be followed e Be sure to follow the manual s shipped with the air handler system This water heater is not to be used as a replacement for an existing boiler installation Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping space heating system requires water temperatures in excess of 120 F a mixing valve or an anti scald device should be installed per its manufacturer s instructions in the domestic potable hot water supply to limit the risk of scald injury Pumps valves piping and fittings must be compatible with potable water properly installed flow control valve is required to prevent 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
85. ve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 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 rating plate 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 Must be connected to an adequate discharge line Must not be rated higher than the working pressure shown on the rating plate of the water heater The Discharge Line Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it
86. which it was factory built fired at the factory rated input operated with the inner and outer combustion chamber doors in place and all factory seals to combustion chamber intact installed with no attempted nor actual modification or alteration of the water heater s design in any way including but not limited to the attachment of non company approved appliances or equipment including any additional aftermarket equipment introduced into the sealed system Any accident to the water heater or any part thereof including freezing fire floods or lightning any misuse abuse or alteration of it any operation of it in a modified form any operation of the water heater on desalinated deionized water or any damage caused by attempts to repair tank leaks or parts will void this warranty This warranty does not cover water heaters replaced for cosmetic reasons or for reasons of noise taste odor discolored and or rusty water This warranty does not apply to water heaters used to heat pools whirlpools or hot tubs or used for space heating where its sizing does not conform with specifications of the heating component manufacturer This warranty gives you specific legal rights and you may have other rights which vary under the laws of each state If any provision of this warranty is prohibited or invalid under applicable state law that provision shall be ineffective to the extent of the prohibition or invalidity without invalidating
87. 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 clean the spill until all ignition sources have been extinguished Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location 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 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 water heater should be located in an area not subject to freezing temperatures Water heaters located in unconditioned spaces i e attics basements
88. y inspect the air intake chamber screen Figure 27 for any dust or debris that may have accumulated on the louvers NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the air intake chamber screen more frequently Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the screen Air Intake Chamber Screen FIGURE 27 26 Cleaning the Combustion Chamber and Air Diverter Assembly 1 Follow procedure outlined in Removing the Manifold Burner Assembly 2 Use vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 28 Use compressed air to clear any dust or debris that may have accumulated on the air diverter assembly ae Diverter Combustion 2 Assembly Chamber K Manifold Door Gasket NS bs FIGURE 28 3 Reassemble following the procedure under Replacing the Manifold Burner Assembly Replacing the Manifold Burner Assembly AWARNING Explosion Hazard 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 Tighten both manifold door screws securely Failure to follow these instructions can result in death explosion or fire 1 Check the door gasket for damage or imbedded debris prior
89. ystem 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 technician Draft Hood Installation 50 GAL UNIT 40 GAL UNIT Flat BERT Of Hood Next Connections Installation above elevation 5 400 ft 1 646 from sea level Reducer Flue must be installed on ef 40 gallon unit Flat Side Of Hood Next To Water Connections A Legs Draft Hood eg ure Hood a SEWA Reduc

A.O. Smith GAHH-50 Technical Documents

Contents

Download Pdf Manuals

Related Search

Related Contents