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State Industries 186489-002 Water Heater User Manual

1. Check the water heater for a Flammable Vapor FV event Note it may be necessary to remove the manifold door assembly to visually inspect the water heater Reference the Maintenance of your Water Heater section of this manual for removal instructions THERMAL SWITCH z of discoloration and YES or debris YES Shut off the gas supply to the water heater at the manual gas shut off valve then contact Residential Technical Assistance by referencing the phone FIGURE 33 Is the igniter wire insulation burnt or NO Is the pilot tube NO Does the flame show signs of discoloration damaged arrestor show signs YES number on the front of the Installation Instructions and Use Care Guide 31 REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information 1 Model serial and product number 2 Type of gas 3 Item number 4 Parts description LOCATION FOR Repair Parts List TOP HOT OUTLET 5 ANODE COMBO Parts Description DRAFT HOOD REDUCER RING SOME MODELS FLUE BAFFLE HEAT TRAP NIPPLES COLD SOME MODELS HEAT TRAP NIPPLES HOT SOME MODELS 6 COLD WATER DIP TUBE 7 ANODE ROD 10 11 TEMPERATURE 8 PRESSURE RELIEF VALVE gg LOCATED TOP OR SIDE DRAIN VALVE 10 GAS CONTROL VALVE THERMOSTAT with wire leads y 11 OUTER DOOR MANIFOLD DOOR ASSEMBLY Natural Gas Low Nox k W
2. e To aid in removing the connector a thimble or slip joint may be used e The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 10 LISTED LINED So 27 2 FT MINIMUM ABOVE ANY OBJECT 3 FT MINIMUM AA WITHIN 10FT HORIZONTALLY O he aay SUPPORT STRAP e MAINTAIN CLEARANCE DO NOT EXTEND VENT BEYOND EDGE OF CHIMNEY CONNECTOR 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 U L listed type B vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 11 and 12 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be
3. suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame arrestor and require replacement of the entire water heater 4 WARNING E 4 ed Y j D Flammable Vapors FIRE AND EXPLOSION HAZARD Y 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 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 sour
4. 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 Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion CAUTION All water heaters eventually leak Do notinstall without adequate drainage Periodic discharge of the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system The water utility supply meter may contain a check valve backflow preventer or water pressure reducing valve This will create a closed water system During the heating cycle of the water heater the water expands causing pressure inside the water heater to increase This may cause the temperature and pressure relief valve to discharge small quantities of hot water To prevent this it is recommended that a diaphragm type expansion tank Suitable for potable water be installed on the cold water supply line The expansion tank must have a minimum capacity of 1 5 U S gallons for every 50 gallons of stored water Contact the local water supplier or plumbing inspector for information on other methods to control this situation Temperature and Pressure Relief Valve A WARNING e Temperature pressure relief valve must comply with
5. which create resistance to the flow of vent gases e Install without dips or sags with an upward slope of at least 1 4 inch per foot e Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage e The length of the vent connector cannot exceed 75 of the vertical vent height e The vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition e It is recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition 14 e The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases e The connector must be firmly attached and sealed to prevent it from falling out
6. Before performing any maintenance it is important to turn the temperature dial on the gas control valve thermostat to its lowest setting SAE COMBUS TON CUAMBES 3 On top of the gas control valve thermostat turn the gas control knob to the OFF position NOTE On the White Rodgers gas control valve thermostat the knob stop must first be depressed before turning the gas control knob See Lighting Instructions on the water heater 4 Drain the water heater Refer to the section of FLAME ARRESTOR BRACKET ES SUEZ ee gt SD TIP BRACKET MANIFOLD TUBE Draining and Flushing section and follow the procedure did 5 Disconnect the piezo igniter wire from the piezo igniter Piezoelectric Igniter System button NOTE There are two types of igniters If you have the square igniter slide the igniter bracket backwards away from the gas valve to remove it If you have the round igniter first remove the igniter from the bracket by depressing front and rear holding tabs and lift Next remove igniter bracket from the The piezoelectric igniter system consists of the igniter button electrode and wire The pilot is ignited by an electric spark generated when the igniter button is pressed The spark gap of 0 125 inch is set when the gas valve Disconnect the thermocouple pilot tube electrode is installed at the factory Figure 32 Use the two connectors attached to the thermal switch only facto
7. On the White manifold pilot tube and thermocouple Rodgers gas control valve thermostat the knob stop must O Disconnect the thermocouple right hand thread pilot tube the igniter wire from the igniter button the two connectors attached to the thermal switch and manifold tube at the gas control valve thermostat Figures 22 amp 23 NOTE L P Gas systems use reverse left hand threads on the manifold tube first be depressed before turning the gas control knob 8 Carefully remove the AiO ones assembly from the See Lighting Instructions on the water heater Figure 19 burner compartment NOTE Be sure not to damage internal parts WHITE RODGERS GAS VALVE ROBERTSHAW GAS VALVE el YT DA O psa Key Removing the Burner from the Manifold dl Heel Burner Assembly TUBE THERMOCOUPLE MANIFOLD TUBE TT THERMOCOUPLE MANIFOLD TUBE Natural Gas Low Nox amp L P Gas Burner 1 Take off the burner by removing the two 2 screws FIGURE 22 located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 24 o o 2 BURNER BOTTOM VIEW FIGURE 24 Replacing the Thermocouple 1 Remove the manifold burner assembly as directed previously 2 Liftthe retainer clip straight up from the back of the two piece wire connector using a flat blade screwdriver then remove the two pie
8. Ring Filter section of this manual Has the thermal switch tripped YES read 12 millivolts DC or more Check for insufficient combustion air Are there openings for make up air to enter the room YES Install correct size make up air openings per NO the Combustion Air Supply and Ventilation section in this manual Are the openings of sufficient size See Combustion Air Supply and Ventilation o Correct size of openings to section in this manual for requirements allow sufficient air YES Z Is there a furnace air handler in the same room as the water heater YES Does the return air duct for the furnace air handler draw its air from a separate location than the water heater Contact a local Heating Ventilation Air See the Location Requirements and Combustion Air Conditioning amp Refrigeration authorized Supply and Ventilation sections in this manual service provider Is there proper drafting at the Check the vent system for restrictions obstructions and check the vent draft hood See Checking the termination height Refer to the Installation Instructions section of this Draft section in this manual manual for specific requirements YES Is the flame arrestor free from Refer to the Maintenance of Your Water Heater section of this debris due to excessive lint dirt NO manual for information on cleaning the flame arrestor dust or oil YES
9. SPACE ADDITIONAL ROOMS WITHIN THE BUILDING 12 MAXIMUM 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 i PERMANENT OPENINGS 1 SQUARE INCH 1000 BTUH MINIMUM 100 SQ IN FIGURE 5 All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The 12 fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the tw
10. Shown L Union U Pilot and Main Burner D Hot Water Outlet M Inlet Water Shut off Valve V Flue E Insulation N Cold Water Inlet W Drain Pan F Gas Supply Piping O Inlet Dip Tube X Piezo Igniter G Manual Gas Shut off Valve P Temperature 8 Pressure Relief Valve Y Base Filter H Ground Joint Union Q Rating Plate Drip Leg Sediment Trap R Flue Baffle INSTALL IN ACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES S GAS CONTROL VALVE S GAS CONTROL VALVE THERMOSTAT WHITE RODGERS THERMOSTAT ROBERTSHAW ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS Ke TO VENT TERMINATION Nae ON ROOF A INSTALL THERMAL EXPANSION TANK OR DEVICE IF WATER HEATER IS INSTALLED INA CLOSED WATER SYSTEM GAS CONTROL KNOB GAS CONTROL KNOB y WATER TEMPERATURE DIAL WATER TEMPERATURE DIAL ADJUSTING DIAL ADJUSTING DIAL VACUUM RELIEF tt 13 13 VALVE OFF OFF INSTALL PER POSITION POSITION POSITION POSITION POSITION POSITION a LOCAL CODES P TOP VIEW TOP VIEW U MANIFOLD BURNER ASSEMBLY MAIN BURNER THERMOCOUPLE PILOT TUBE Q BESO Fg MANIFOLD DOOR G sl DISCHARGE PIPE DO NOT CAP OR PLUG 6 MAXIMUM AIR GAP FLOOR DRAIN NOTE Round igniter button configuration shown Igniter button configu
11. 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 could A DA N e E R result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could A WA R N N e result in death or injury CAUTION indicates a potentially hazardous situation which if not avoided may A CAU T 0 N result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAU T l 0 N 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 such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the Act IMPORTANT DEFINITIONS Qualified Technician A qualified technician must have ability equivalent to a licensed tradesm
12. all loose 9 debris in the combustion chamber Figure 29 Use compressed air to clear any dust or debris that may have accumulated in the flame arrestor COMBUSTION CHAMBER FLAME ARRESTOR 6 FIGURE 29 3 Reassemble following the procedure under Replacing the Manifold Burner Assembly 27 Replacing the Manifold Burner Assembly 4 WARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace two piece wire connector if missing or removed Replace door gasket if damaged Failure to follow these instructions can result in death explosion or fire Check the door gasket for damage or imbedded debris prior to installation Inspect the view port for damage and replace as required 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 Figures 30 amp 31 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber 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 g
13. connector from the manifold door Figure 25 IMPORTANT Be careful not to bend or alter the position of the pilot tube it will be used as a bending template for the new pilot assembly 3 Take off the burner by removing the two 2 screws located underneath the burner See Figure 24 4 Remove and keep the screw securing the pilot assembly to the pilot bracket Figure 27 5 Remove and keep the old pilot pilot tube assembly 6 Using the old pilot pilot tube assembly as a guide bend the new pilot tube and new thermocouple to match the old ones NOTE Make only the bends closest to the pilot before going to the next step Figure 27 OTHER FITTINGS NOT SHOWN FOR CLARITY IGNITER WIRE THERMOCOUPLE FIRST BEND S FIGURE 27 Route the new pilot tube thermocouple and igniter wire through the manifold burner door opening Figure 25 Re attach the pilot assembly to the pilot bracket and secure using the screw removed earlier Position the new pilot tube through the largest opening of the two piece wire connector NOTE The largest opening should be located at the top position The igniter wire should be located in the middle opening and thermocouple in the bottom opening Figure 28 PILOT TUBE THERMOCOUPLE TWO PIECE WIRE CONNECTOR FIGURE 28 10 Reposition the two piece wire connector in the manifold door opening and secure it with the retainer cl
14. drain NOTE The drain hose should be rated for at least 200 F If the drain hose does not have this rating open the cold water inlet valve and a nearby hot faucet until the water is no longer hot 5 Open the water heater drain valve and allow all the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed under the Operating Your Water Heater section 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 main burner pilot burner and flame arrestor Check the water heater for the following e Obstructions damage or deterioration in the venting system Make sure the ventilation and combustion air supplies are not obstructed e Clean any dust or debris from the base ring filter e Soot and or carbon on the main burner and pilot burner Contact a qualified technician e Leaking or damaged water and gas piping e Presence of flammable or corrosive materials in the installation area e Presence of combustible materials near the water heater e After servicing this water heater check to make sure it is working prop
15. into place NOTE Do not use the pilot ferrule nut supplied with the new gas control valve thermostat unless the existing nut is not usable Reconnect the pilot tube manifold tube igniter wire and thermal switch wires NOTE L P gas systems FVIR System Operational Checklist 1 Manifold gasket properly sealed Viewport not damaged or cracked Flame arrestor free of debris and undamaged use reverse left hand threads on the manifold tube 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 Bubbles forming indicate a leak Correct any leak found 2 Reconnect the gas piping to the gas control valve 6 Check the operation of the burner by following the thermostat NOTE Use an approved Teflon tape or lighting instructions on the front of the water heater pipe compound on the gas piping connections With the burner lit check the gas control valve 3 Attach the igniter and bracket to the new gas control thermostat supply line manifold tube and pilot 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 TEFLON is a
16. new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve e Must not be in contact with any electrical part e Must be connected to an adequate discharge line e Must not be rated higher than the working pressure shown on the rating plate of the water heater The Discharge Line e Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line e Must terminate a maximum of six inches above a floor drain or external to the building e Must be capable of withstanding 250 F 121 C without distortion e Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation Some Models 1 Locate the T amp P Relief Valve on the water heater 2 Locate the slit running the length of the insulation 3 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 tape IMPORTANT The insulation or tape should not block or cover the T amp P Relief Valve drain opening Also the insulation or tape should not block or hinder access to the T amp P Reli
17. on the pilot or pilot assembly If no spark is visible check 8 Turn gas supply on and refer to the Lighting Instruc the wire connections and make sure the electrode is not tions broken Replace the igniter if defective Dirt and rust on the 9 With the burner lit check the gas control valve pilot or electrode tip can prevent the igniter spark Wipe thermostat supply line two piece wire connector clean with a damp cloth and dry completely Rust can be manifold tube and pilot tube connections for removed from the electrode tip and metal surfaces by leaks Check for leaks by brushing on an approved lightly sanding with an emery cloth or fine grit sandpaper noncorrosive leak detection solution Bubbles forming R d Replaci he Gas C indicate a leak Correct any leak found IMPORTANT emoving an eplacing the Gas Contro All leaks must be fixed immediately Valve Thermostat 10 Replace the outer door IMPORTANT This water heater has a resettable thermal switch installed Do not attempt to disable or modify this feature in any way Use only factory authorized replacement parts Removing the Gas Valve 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 2 On the lower front of the water heater locate the gas control valve thermostat see Figure 23
18. 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 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 35 used in a non corrosive and non contaminated atmosphere used with factory approved anode s installed in its original installation location in the United States its territories or possessions and Canada sized in accordance with proper sizing techniques for residential water heaters bearing a rating plate which 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 which it was factory built fired at the factory ra
19. registered trademark of E l Du Pont De Nemours and Company 5 No leaks at pilot and manifold connection 6 Manifold door screws securely tightened 7 Depress the button on the thermal switch 2 3 4 Two piece wire connector properly installed TROUBLESHOOTING CHART REMAIN LIT BURNER WILL NOT IGNITE 1 Pilot not lit Thermostat set too low No gas Dirt in the gas lines Pilot line ceased Main burner line clogged Light pilot Turn temp dial to desired temperature Check with gas utility company Notify utility install trap in gas line Clean locate source and correct Clean locate source and correct Non functioning thermocouple Replace thermocouple Non functioning thermostat Replace thermostat Heater installed in a confined area Provide fresh air ventilation BURNER FLAME YELLOW Insufficient secondary air LAZY Low gas pressure Provide ventilation to water heater Check with gas utility company Water heater flue or vent system blocked Main burner line clogged Clean locate source and correct Clean locate source and correct Heater installed in a confined area 5 Proper fresh air ventilation Obstruction in main burner orifice Clean or replace orifice PILOT WILL NOT LIGHT OR 1 Non functioning igniter The thermal switch tripped Replace igniter pilot proa See Pilot Light Troubleshooting Flowchart section Wire lead connection at thermal Remove and reconnect the wire leads at switch
20. 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 e Ifthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water heater and its manual shut off valve must be disconnected from the gas supply piping system and the line capped e Ifthe gas lines are to be tested at a pressure less than 14 W C the water heater must be isolated from the gas supply piping system by closing its manual shut off valve NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified 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 If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL GAS instructions on the cover of this manual LP Gas Only Liquefied petroleum gas is over 50 heavier than air and in the occurrence of a leak in the system the gas 4 WARNING will settle at floor level Basement
21. 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 EF LISTED VENT CAP 2 FT MINIMUM ABOVE ANY OBJECT WITHIN 10 FT HORIZONTALLY A 3 FT MINIMUM t SUPPORT STRAP MAINTAIN CLEARANCE TYPE B DOUBLE WALL VENT PIPE t MAINTAIN SPECIFIED CLEARANCE VENT CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 11 ES 5 FT MINIMUM mrri LISTED VENT CAP MAINTAIN SPECIFIED CLEARANCE SUPPORT STRAP MAINTAIN CLEARANCE t A E Y E y T l E TA A i A VENT gt VENT CONNECTOR CONNECTOR LE PR E SLOPE UP Ht UNUSED CHIMNEY LLI _ FLUE OR MASONRY At ENCLOSURE 1 4 IN PER FT MINIMUM VENTING THROUGH A CHIMNEY WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 12 Maintain vent pipe clearance requirements to local sta
22. 22 33 34 LIMITED RESIDENTIAL GAS WARRANTY THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY in accordance with the warranty terms and conditions specified below State Water Heaters the warrantor will furnish the ORIGINAL OWNER 1 a replacement State 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 STATE WATER HEATERS 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 es ak Pas Premier towear towear oe S FEA ox ee IONES ERA 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 2 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 provided with it 3 good industry
23. ANSI Z21 22 CSA 4 4 and ASME code e Properly sized temperature pressure relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure e Can cause serious injury or death TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG DRAIN LINE 3 4 ID MINIMUM 6 MAXIMUM ci AIR GAP 1 MINIMUM gt METAL DRAIN PAN gt 1 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 valve 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
24. Connect the hot water supply 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 G The manufacturer of this water heater recommends installing a tempering 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 If installing the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion on Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater O A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T 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 ne
25. 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 e Inspect all parts for damage prior to installation and start up e Completely read all instructions before attempting to assemble and install this product e After installation dispose of recycle all packaging materials 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 The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame arrestor The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the FVIR System disables the water heater by shutting off the gas supply to the water heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off If you
26. ITH RETAINER CLIP PIEZOELECTRIC IGNITER BUTTON THERMOCOUPLE Pictured on next page 7 LEGEND A Special anode rod see Anode Rod Water Odor section m Temperature and Pressure Relief Valve is required but may not be factory installed A Unique FVIR System parts 32 8 4 la a Q Y Listed Parts Kits and Illustrations Item 12 Pilot Pilot Tube Assembly kit which contains the pilot assembly thermocouple igniter electrode and retainer clip Natural Gas Item 13 Pilot Pilot Tube Assembly kit which contains the pilot assembly thermocouple igniter electrode and retainer clip L P Gas ltem 14 Burner Natural Gas Low Nox ltem 15 Burner L P Gas Item 16 Manifold door assembly which contains the manifold tube gasket door pilot tube thermocouple two piece wire connector with retainer clip thermal switch and pilot assembly Natural Gas Low Nox Item 17 Manifold door assembly which contains the manifold tube gasket door pilot tube thermocouple two piece wire connector with retainer clip thermal switch and pilot assembly L P Gas ltem 18 Contains two piece wire connector and retainer clip ltem 19 Contains manifold door gasket Item 20 Contains view port ltem 21 Contains piezoelectric igniter button NOTE Igniter configuration and location may vary Item 22 Contains thermocouple Item 12 7 N Item 14 Item 18 Igniter Configurations Item
27. Installation Instructions and Use Care Guide RESIDENTIAL GAS WATER HEATERS WATER HEATERS FVIRGAS 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 0 edition regarding the accidental or unintended ignition of flammable vapors such as those emitted by gasoline AWA RNING For Your Safety SA A AN ODORANT IS ADDED TO THE GAS USED manual and safety messages BY THIS WATER HEATER before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Instruction manual must remain with water heater e Safety Instructions Care and Maintenance Installation Troubleshooting Do not store or use gasoline or other e Operation e Parts List eee ee flammable vapors and liquids in the INSTALLER vicinity of this or any other appliance AFFIX THESE INSTRUCTIONS TO OR ADJACENT OWNER e Do not try to light any appliance e RETAIN THESE INSTRUCTIONS AND WARRANTY l ias FOR FUTURE REFERENCE RETAIN THE e Do not touch any electrical switch ORIGINAL RECEIPT AS PROOF OF PURCHASE do not use any phone in your building WARNING Gas leaks can not
28. Long runs of exposed pipin Hot water piping in exposed wall Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure Insufficient secondary air Water heater flue or vent system blocked Low gas pressure Improper calibration Thermostat set too low Water heater too small Wrong piping connections Wasted hot water Excessive water pressure Heater stacking Closed water system 1 Thermostat not functioning prop erly 2 Improper calibration 1 Insufficient secondary air 2 Water heater flue or vent system blocked 3 Heater installed in a confined area Insufficient secondary air 1 2 Low gas pressure 3 Water heater flue or vent system blocked 4 Thermostat not functioning prop er 5 Healer installed in a confined area 6 Burner flame yellow lazy Set temperature dial to lower setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping 1 2 3 4 5 6 7 8 9 1 Turn temperature dial to desired setting 2 Drain flush provide water treatment if needed 3 Install adequate heater 4 Correct piping dip tube must be in cold inlet 5 Repair faucets 6 Advise cus
29. MPERATURE DIAL ROBERTSHAW GAS VALVE or ND 4 tont 4m eg y Nolet Ki J O Noun XG ia LA A TEMPERATURE DIAL Time to Produce 2nd 3rd Settings Degree Burns on Adult Skin 100 710 E Per FIGURE 19 Temperature NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is expected to be more than normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather 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
30. NTY THE WARRANTOR WILL PROVIDE ONLY AREPLACEMENT 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 b 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 c 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 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 State Industries Inc 500 Tennessee Waltz Parkway Ashland City Tennessee 37015 Phone 1 800 365 0024 or visit our website www statewaterheaters com Replacement Parts may be ordered through authorized servicers or distributors Refer to your local Yellow Pages for whe
31. Requirements A li ile aid T SHE LOCION S ssa es es ec ec a pats ee ete eee mse E E ae 7 clearances and ACCESSIDIY dean ios Mo seem ae tac eae dd Salute ec Satan 8 ER o A A tae re rene ne So RRP e Ee ee ETE eae E 8 Gas SUDOV na aa ES AAA RE ORAS 9 10 Gas e A a re ticeeetteaeagacs 9 Gas PIDIN a o a o ad e e ia e do en O a ere ore 9 Sas PIS SS UE a e ld e elle 9 Sas Pressure TOS a e la e ES 9 LAGAS ONY e e O o e 10 Combustion Ar AAG VentlatlO Nacion lorca tates aaa cad ett ads Lince a 11 15 UNcCONINCEA SPACE ciutat ria iris 11 GONTRSA SPACE UA iS neces ia cias 11 ANA trom Inside thie Buldi a ad 12 AMAT TO MOROS Sinsin A ad 12 ko vers anda Grilles O A ii 12 13 e A 13 Drakt FIOOGsINStall atom aia A A 13 14 NONE PIEZA e a is e o edo e eect 14 o o Ae 14 Chimney CONNECION cis IA ES AA AAA EAS AAA ee 14 vertical Exhaust Gas Vent st id 14 15 Water SV STE M PIDINO cessano a o ES 15 18 A RN 15 16 Closed System Thermal XDaAMSlOM al e ici 16 Temperature amp Pressure Relief Valve coooonccconnccccononoconononononononnnonnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnss 17 T amp R Relef Valve and Fipe ASMA a Fa WE dad A 17 Combination Space Heating Potable Water System ococooncnccccocnnccococnnnccnnccnnononnnnnnonnconnononnnnnnnnnnnnnnnnnrnnnnrnnnrncnnananinonas 17 18 Solar SF Fe 9 it it tt iS 18 Important Information About this Water Heater ooooccccoooccnccconcnocono
32. TANT e The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation e Water heaters installed in open spaces in buildings with unusually tight construction may still require out door air to function properly In this situation outside air openings should be sized the same as for a con fined space e Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 4 The size of each opening free area is determined by the total BTUH input of all gas utilization equipment i e water heaters 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 12 MAXIMUM CLOSET OR PERMANENT OTHER OPENINGS TO CONFINED THE OUTSIDE OR
33. aft hood properly installed O Vent connectors securely fastened with screws and supported properly to maintain six inch clearance O Vent connector made of approved material and sized correctly O 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 O Flue baffle properly positioned in the flue tube O Check the 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 O Recheck for sufficient combustion air supply Water System Piping O 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 Tempering valve when applicable installed per manufacturer s instructions See Water Temperature Regulation section a a Eli Gas Supply and Piping O Gas type is the same as that listed on the water heater rating plate O 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 Propane L P gases KO Adequate pipe size and approved pipe material O An approved no
34. als in the air e beauty shops e photo processing labs e buildings with indoor pools e water heaters installed in laundry hobby or craft rooms e water heaters installed near chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 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 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 TABLE 3 Minimum Square Feet with 8 Ceiling 30 000 Typical Room alee with 8 Ceiling 12000 750 25x30 IMPOR
35. 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 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 IFYOU ARE UNSUCCESSFUL CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1 800 365 0024 OR WWW STATEWATERHEATERS COM PRINTED IN THE U S A 0808 PART NO 186489 002 TABLE OF CONTENTS Water Heater Satelitales 1 2 Safe Installation Use and SSrvice sine sk tet Sores occa tee eae mates ect le tl eh ences 3 SAIC ly PRECAUTIONS ashe eee id te eed elector ae o ste e gue hee eet dest ao a as 3 4 TY IC AN MENS Cea AA E a aaa e tamed ea R lett staat atten aceite ad dete aads 5 Installing you Gas Water Heater 2 ia ios 6 8 Important Information About Your Water Heater oocccccccncccocnnococncoconnnoconnnononnnononnnononnnonannnnnnnnnnnennnnnnnnnnonnnnonnnnnnnnrnnnnnnnnnas 6 Consumer Io malo orita il ctra ido tad 6 Consumer RESHONSIDINIES ca A A AA RS 6 Unpacking teater Healer usario baaa 6 Location
36. an 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 e Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building SAFETY PRECAUTIONS 4 WARNING o FIRE AND EXPLOSION HAZARD Can result in serious injury or death yd he r i Do not store or use gasolin
37. and will settle on the floor HAT TO DO IF YOU SMELL GAS eDo not try to light any appliance e Do not touch any electric switch do not use any phone in your building e mmediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions elf you cannot reach your gas supplier call the fire department E GAS CONTROL KNOB PIEZO IGNITOR GENERATOR FIGURE A FIGURE 1 above on this label 2 Set the thermostat to lowest setting PILOT LIGHTING Turn thermostat dial fully clockwise until it stops 3 Push the gas control knob down slightly and turn clockwise to OFF SEE FIGURE A NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed down slightly Do not force 4 Remove the outer burner door located below the gas control 5 Wait ten 10 minutes to clear out any gas If you then smell gas STOP Follow B in the above on this label If go to next step safety information you don t smell gas 6 This unit is equipped with a push button pilot ignitor which is used to light the pilot Locate the ignitor 11 on the gas control 7 Turn gas control knob counterclockwise gt to PILOT SEE FIGURE B 8 The pilot is located on the left side of the burner It can be located by looking through the glass view port while pressing the piezo ignitor button several times Look for a spark at the pilot location Figure D 1 Se
38. aps 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 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 NOTE L P gas systems use reverse left hand threads on the manifold tube NOTE Ifa ferrule nut needs to be installed for the pilot tube locate the one provided with your parts kit Install it in the gas control valve thermostat at the pilot loca tion hand tight only Next insert the pilot tube into the ferrule nut until it bottoms out NOTE Hold the tube in this position Tighten the fer rule nut with a wrench until the crimp connection seals to the pilot tube Continue to tighten until the nut is tight in the gas control valve thermostat Finally start Testing the Igniter System the thermocouple nut and turn it all the way in by hand An additional quarter turn with a 3 8 open end wrench will then be sufficient to seat the lockwasher When you are finished connect the two wire leads that go to the thermal switch Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part 7 Reconnect the igniter wire
39. arest 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 yc THERMAL EXPANSION TANK COLD WATER SUPPLY TO FIXTURES PRESSURE REDUCING VALVE 2 a WITH BYPASS L__ H H a HOT WATER COLD WATER OUTLET INLET COLD WATER INLET VALVE SHUT OFF VALVE TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG DRAIN LINE 3 4 ID MINIMUM 1 MINIMUM METAL 6 MAXIMUM DRAIN PAN 1 a AIR GAP DRAIN FIGURE 13 TEMPERED WATER SRPAABERED TO FIXTURES HOT OT WATER oib Gee OUTLET TEMPERING VALVE SET TO 120 F FOLLOW THE TEMPERING VALVE MANUFACTURER S INSTRUCTIONS FIGURE 14 16 Please note the following e The system should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybutylene This water heater must not be installed using iron piping or PVC water piping Use only pumps valves or fittings that are compatible with potable water It is recommend that only full flow ball or gate valves are used in water piping installations The use of valves
40. ation 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 should 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
41. ce wire connector from the manifold door Figure 25 Remove the burner see Removing the Burner from the Manifold Burner Assembly 4 Pull the thermocouple from the pilot assembly Figure 26 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components 5 Insert the thermocouple tip into the holes provided in the pilot bracket until it clicks into place NOTE The base of the thermocouple must be flush with the base of the pilot bracket Position the new thermocouple through the bottom opening of the two piece wire connector Figure 28 Be sure igniter wire is positioned through the middle opening of the two piece wire connector 7 Re attach the burner Note the orientation of the buner Figure 24 8 See Replacing the Manifold Burner Assembly FERRULE NUT THERMOCOUPLE ig IGNITER WIRE E PILOT PILOT BRACKET 4 Me DA oS Rea FITTINGS ie QA FS NOT SHOWN FOR CLARITY 2 K I A fral D Dy DN RETAINER J CLIP IPS Q MANIFOLD TUBE C MANIFOLD BURNER TWO PIECE DOOR OPENING WIRE CONNECTOR FIGURE 25 SS tt FIGURE 26 26 r Replacing the Pilot Pilot Tube Assembly 1 Remove the manifold burner assembly See Removing the Manifold Burner Assembly 2 Lift the retainer clip straight up from the back of the two piece wire connector using a flat blade screwdriver then remove the two piece wire
42. ces have been extinguished A WARNING e Read instruction manual before installing using or servicing water heater e Improper use may result in fire or explosion e Maintain required clearances to combustibles Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location e Select a location near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface DO NOT install in bathrooms bedrooms or any occupied room normally kept closed e Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows e Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows e The water heater should be located in an area not subject to freezing temperatures Water heaters located in unconditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the rating plate e Do not locate the water heater near an air movin
43. ch vent TS A O Doing so can result in burns After successfully lighting the water heater allow the unit to operate for 15 minutes and check the draft hood relief FIGURE 17 opening for proper draft Figure 17 Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the draft hood A steady flame drawn into the opening indicates proper draft If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements 21 Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 18 A properly operating burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not 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 FIGURE 18 Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified technician Water Temperature Regulation Water temperature over 125 F 52 C can cause serve
44. e front of the Installation Instructions and Use Care Guide Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following O Installation area free of corrosive elements and flammable materials O Centrally located with the water piping system For new installations Located as close to the gas piping and vent pipe system as possible 11 Located indoors and in a vertical position Protected from freezing temperatures O Proper clearances from combustible surfaces maintained and nat installed directly on a carpeted floor O Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain O Sufficient room to service the water heater See Clearances and Accessibility section of this manual O Water heater not located near an air moving device O Is the installed environment dirty excessive amounts of lint dirt dust etc If so the base ring filter located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the base ring filter Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This exc
45. e next Step S DO NOT PRY CN Turn the gas control knob counterclockwise to PILOT 7 Depress the reset button all the way PUSHBUTTON in and IMMEDIATELY depress the igniter button until you hear a loud click Observe the pilot through the view port Do not release the reset button Repeat immediately if pilot does not light on the first try If the pilot does not light by the fourth attempt with the igniter repeat steps 4 7 Continue to hold the button for about 1 minute after the pilotis lit Release the reset button and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps 3 7 GNITER IMPORTANT If the pilot will not stay lit after several tries depress the dial stop and turn gas control knob to OFF then call your service technician or gas supplier IMPORTANT If the reset button see graphic at step 3 does not pop up when released stop and immediately shut off the gas at the line valve or tank Call your service technician or gas supplier 8 Turn the gas control knob counterclockwise to ON Set the temperature dial to the desired setting 10 Replace the outer door TO TURN OFF GAS TO APPLIANCE 1 Turn the temperature dial countercloc kwise to its lowest setting Checking the Draft 2 Turn the gas control knob clockwise y to the OFF position A WARNING Oe Hoop RELIEF gt Burn Hazard p id MATCH Y Do not tou
46. e 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 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 A WARNING Fire Hazard For continued protection against riskof fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged IND Cade Weter temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are athighestrisk forscald injury Feel water before bathing or showering Temperature limiting valves are avallable A WARNING Overheated water can cause watertank explosion Properly sized temperature and pressure relief valve must be installed in opening provided Read instruction manual for safe temperature setting Fire or Explosion Harzard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other ap
47. ef Valve manual relief lever 4 Next locate the hot water outlet amp cold water inlet pipes to the water heater 5 Select one of the sections of pipe insulation and locate the slit that runs the length of the insulation 6 Spread the slit open at the base of the insulation and slip it over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure it is fully seated around the cold water pipe Also ensure that the base of insulation is flush with the water heater Once seated secure the insulation with a section of tape 7 Repeat steps 5 through 6 for the hot water outlet pipe T amp P RELIEF VALVE INSULATION MANUAL RELIEF LEVER T amp P RELIEF VALVE T amp P RELIEF VALVE DRAIN LINE 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 e This water heater is not to be used as a replacement for an existing boiler installation e Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping e If the space heating system requires water temperature
48. erly 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 properly To prevent water damage the valve must be properly connected to a discharge line which terminates at an adequate drain Standing clear of the outlet discharged water may be hot slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position See Figure 21 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 A WARNING e Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code TEMPERATURE AND PRESSURE RELIEF VALVE MANUAL RELIEF E e Properly sized temperature pressure relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure e Can cause serious injury or death DISCHARGE LINE TO DRAIN Manually operate the temperature and pressure relief valve at least once a year to make sure it is working FIGURE 21 MAINTENANCE OF YOUR WATER HEATER 4 Remove the outer door Replacement Parts 5 Remove the two screws securing t
49. essive heat will cause a thermal switch on the door assembly to trip Is the water heater installed in a closet or other small enclosed space If so O Are there openings for make up air to enter and exit the room area O Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Location Requirements section of this water heater manual for specific requirements Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans dryers fireplaces etc Oo 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 O Fresh air supply free of corrosive elements and flammable vapors O Fresh air openings sized correctly with consideration given to the blocking effect of louvers and grilles O 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 O Dr
50. g 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 1 e Ifthe water heater is located in an area that is subjected to lint and dirt it may be necessary to periodically clean the base ring filter and flame arrestor see External Inspection amp Cleaning of the Flame arrestor 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 CAUTION All water heaters eventually leak Do notinstall 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 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 sho
51. hamber and Flame arrestor cccccoocccncccoccnnccnonnnnonnncononnnncnnnnnnnnnnnnnnrnnnnnnnrrnnnnnnnnnnnrnanrnnonnnncnnnns 27 Replacing the Manifold Burner Assembly occccccoonnncoccononoconoconnncnnnnnnononnnnnnnnnrnnnrnnnnnnnnnnnnnnnrnnrnnnnnrnnnnnnnnnnnnnnnnnnranornananens 27 28 PICZOCIOCIIGIONILEr System sit AAA AA A A A 28 Testing the la iter System jp A SS ad 28 Removing and Replacing the Gas Control Valve Thermostat ococooonnnccoocccnccccnccnnononcnnnononccnnonancnnnnnnncnnonnnnnnnnononrnnnnnnnnnnnos 28 29 FVIR System Operational Checklist srta A A AA E AA E 29 Troubleshooting Checklist tc a e o ic di oc el ieee 29 30 Pilot Light Troubleshooting Flowchart ce 31 R pair Pants MUSA OO A eC nee eee e ee 32 Eisted Parts Kits ana lOs Ta OS di 33 NOS coa e eee ave ondas 34 Wan antye E Mee ee nn Pee IS MO enn eee Are IU te Re eee nonce eee OR Clee ee eee 35 36 SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your 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
52. he manifold door IMPORTANT The following maintenance procedures are assembly to the combustion chamber Figure 23 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 GAS CONTROL VALVE THERMOSTAT PIEZO IGNITER BUTTON PILOT TUBE THERMAL SWITCH MANIFOLD DOOR See Repair Parts Section for a list of available repair parts Removing the Manifold Burner Assembly MANIFOLD SCREWS 2 TWO PIECE WIRE CONNECTOR 1 Turn off the gas supply to the water heater at the manual FIGURE 23 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 2 On the lower front of the water heater locate the gas control valve thermostat see Figure 23 Before per forming any maintenance it is important to turn the temperature dial on the gas control valve thermostat to its lowest setting 3 On top of the gas control valve thermostat turn the gas 7 Grasp the manifold tube and push down slightly to free the control knob to the OFF position NOTE
53. ip 11 Carefully bend the new pilot tube and thermocouple to match the bend of the manifold tube NOTE When bending DO NOT crimp or crease the pilot tube or thermocouple Figure 25 12 Before you proceed to the next step install the new brass ferrule nut in the gas control valve thermostat s pilot tube opening HAND TIGHT ONLY 13 See Replacing the Manifold Burner Assembly External Inspection Cleaning of the Base Ring Filter 1 At least annually check the base ring filter Figure 29 for any dust or debris that may have accumulated on the filter screen NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the base ring filter more frequently 2 Follow the Lighting Instructions to turn off the water heater and allow it to cool for 10 minutes before attempting to clean the base ring filter 3 Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the filter NOTE If unable to inspect or clean the base ring filter follow the Cleaning the Combustion 4 Chamber and Flame arrestor instructions 4 After the base ring filter has been cleaned follow 2 the Lighting Instructions to return the water heater to service 3 Cleaning the Combustion Chamber and Flame arrestor 4 1 Follow procedure outlined in Removing the Manifold Burner Assembly 2 Use a vacuum cleaner shop vac to remove
54. ises may be heard These noises are common and may result from the following 1 Normal expansion and contraction of metal parts during periods of heat up and cool down 2 Condensation causes sizzling and popping within the burner area and should be considered normal 3 Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure Drain and flush the tank as directed under the Draining and Flushing section 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 pilot flame is extinguished for any reason 2 The water temperature exceeds 195 F 91 C 3 Excessive build up of dust on the base ring filter or flame arrestor See Maintenance of your Water Heater Section 4 The ignition of flammable vapors A thermocouple is used to determine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot if the flame is absent This unit is also equipped with a thermal switch designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors e g spilled gasoline poor combustion caused by a blocked vent or insufficie
55. 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 B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces crawl spaces or any 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 e Install the vent connector avoiding unnecessary bends
56. loose Air in gas line Low gas pressure No gas Dirt in gas lines Cold drafts anna 000 0014 WN O md K function actuated ox al Base ring filter obstructed Thermocouple connection loose Thermostat ECO switch open Pilot line or orifice clogged Non functioning thermocouple Air for combustion obstructed Flammable vapors incident FVIR thermal switch confirm connections are tight and not loose Finger tighten then 1 4 turn with wrench Bleed the air from the gas line Check with gas utility company Check with gas utility company Notify utility install dirt trap in gas line Locate source and correct Replace thermostat Clean locate source and correct Replace thermocouple See maintenance section for inspection and cleaning of flame trap Replace water heater eliminate flammable vapors source Contact Residential Technical Assistance Inspect and clean base ring filter See External Cleaning amp Inspection of the Base Ring Filter AAA ROONOUA OCON O md K PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION HIGH OPERATION COSTS INSUFFICIENT HOT WATER SLOW HOT WATER RECOVERY DRIP FROM RELIEF VALVE THERMOSTAT FAILS TO SHUT OFF COMBUSTION ODORS SMOKING AND CARBON FORMATION SOOTING 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 ie
57. ncnnnonnccnnnnnnnncnnnnncnnnnnnnrnnonnnnnnnnrnnrnnnnnnrrnnnnnrrnnonanenos 19 Operating Your Wat r Heater cundo ii daa dde 20 25 White Rodgers Gas Valve Thermostat Lighting Instructions ooooncnccconnnnncconnnnnonocnnnnononcnnnnnoncnnnonnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnes 20 RobertShaw Gas Valve Thermostat Lighting Instructions oooocccccconnnncccnnnnnnnnnnnnnnonanonnnnnnncnnnnnnnnnnnnnncnnnonanrnnnnnnnrnnnnnanoss 21 Ao A A 21 A A O A E AE en 22 EMEEN y ON UIIOWN a eect eres ease A ete E EN ee eee 22 Water Temperature Regulation Bence ciicetecistente sais antiticde A dandeOicetdartie Leite ignbtdeean he eiueeebadonGakinte 22 23 Operational COMMONS ii o e A ad a o Nei ea a nd de S 23 24 Routine Preventive Maintenance A A ee ee 24 Temperature and Pressure Relief Valve o ccooonncccocconocononocononononocononononarnnonnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnss 25 Maintenance of Your Water Healer e a da o e O dd od le bs 25 29 Replacement Pals aiii is e a ete 25 Removing the Burner from the Manifold Burner Assembly ooccccccconcccccccccncccnncnnnonononnnononcnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnrnnrnnancnnns 25 26 Replacing the Nnermocouble tii A A ied Ree 26 Replacing the PilouPiIlOt TUDEASS mDIY ii io siii 26 External Inspection 4 Cleaning of the Base Ring Filter cocccoonncnccccnncnnononcnncononnncnonncnnnnnnncnnnnnnnonnnnonanrnnnonnnnnnrnnnrnnnnonaross 27 Cleaning the Combustion C
58. ncorrosive leak detection solution used to check all connections and fittings for possible gas leaks Correct any leak found OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re light the pilot Make sure the view port is not missing or damaged See Figure 23 Make sure the tank is completely filled with water before lighting the pilot Check the rating plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the rating plate If you have any questions or doubts consult your gas supplier or gas utility company 4 WARNING Explosion Hazard Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire White Rodgers Gas Control Valve Thermostat Lighting Instructions WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life FLAMMABLE BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance has a pilot which is lit by a piezo electric spark gas ignition system Do not open the inner door of the appliance and try to light the pilot by hand B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor D because some gas is heavier than air
59. ng 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 These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements GABLE VENT TO OUTDOORS INSTALL ABOVE INSULATION CONFINED ATTIC 1 SQ INCH PER 4000 BTUH ALTERNATE AIR INLET 1 SQ INCH PER 4000 BTUH OPEN a FOUNDATION VENT ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE OUTLET AIR TO VENTILATED ATTIC FIGURE 6 GABLE VENT yee TO OUTDOORS INSTALL ABOVE a INSULATION TO ATTIC 1 SQ INCH PER 4000 BTUH CONFINED INLET AIR DUCT 1 SQ INCH PER 4000 BTUH 12 MAXIMUM ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC FIGURE 7 1 SQ INCH PER 2000 BTUH CONFINED SPACE OUTDOOR AIR DUCTS 1 SQ INCH PER 2000 BTUH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS FIGURE 8A ALTERNATIVE OPENING LOCATION 1SQ INCH w PER 3000 BTUH CONFINED SPACE 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
60. nt combustion air If the thermal switch opens 1 Check the flame arrestor for signs of high temperature blue or black discoloration See Figure 29 If there are signs of high temperature inspect your installation for any problems with venting combustion air supply and for a flammable vapor event see Pilot Light Troubleshooting Flow Chart section Correct any issues prior to resetting the thermal switch If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater Reset the thermal switch by depressing the small button in the center of the thermal switch Follow the Lighting Instructions found on the front of your water heater 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 replaced by a qualified technician Contact your local dealer for service information 2 Anode Rod Water Odor Each water heater contains at least one anode rod which will slowly deplete while protecting the glass lined tank f
61. o 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 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 eg Sim Opening Source Per Opening sq in Reference Drawing Example A water heater with an input rating of 50 000 BTUH usi
62. ocal 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 4 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 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 NFPA 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 j
63. oint compound or teflon tape marked as being resistant to the action of petroleum Propane L P 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 ea MANUAL GAS SHUT OFF VEE 0 e GROUND JOINT UNION DISCHARGE PIPE DO NOT PLUG OR CAP CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT 0 3 MINIMUM 6 MAXIMUM AIR GAP CD SUITABLE DRAIN gt FIGURE 3 Gas Pressure 4 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
64. on of such tanks 18 Also see Water System Piping for additional instructions on the safe and correct installation and operation of this water heater MUST BE VERTICAL TO DOMSETIC REMOVE AIR BUBBLES HOT WATER ar EXPANSION TANK mE COLD WATER INLET S ra CONTROL PUMP VALVE VACUUM RELIEF TEMPERING VALVEN MASSACHUSETTS CODE DOES NOT ALLOW THIS TYPE OF INSTALLATION TYPICAL TEMPERING VALVE INSTALLATION COMBINATION SPACE HEATING POTABLE WATER HEATING SYSTEM FIGURE 16 Solar Installation If this water heater is used as a solar storage heater or as a backup for the solar system the water supply temperatures to the water heater tank may be in excess of 120 F A tempering 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 IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntary safety standards to reduce the likelinood 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 th
65. 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 system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere IMPORTANT The use of vent dampers is not recommended by the manufacturer of this water heater Although some vent dampers are certified by CSA International this certification applies to the vent damper device only and does not mean they are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations IMPORTANT If you lack the necessary skills required to properly install this venting system you should not proceed but get help from a qualified technician Draft Hood Installation SHEET METAL SCREWS FOUR PROVIDED INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED FIGURE 9 Align the
66. orsuling the local nara gas uliliby Cu Fl Per Hr Required Table 2 l LP Gas Capacity Table Maxamum capaci y of pipe in thousands of ATU per hour of undiluted igueted petroleum geses al 17 inches water column pressuro Based on a pressure drop of 0 5 inch water column Nominal bran Pipe AE of Pipe hee ze in e WZ 275 1589 152 114 103 yal S76 203 315 y 237 217 1 Wri 7321 590 5 448 409 1114 2205 1496 1212 o13 834 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Addibonal tables are available in te alesi edition of he National Fuel Gas Lodo ANS 223 1 10 COMBUSTION AIR amp VENTILATION 4 WARNING 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 combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemic
67. pliance Avoid all ignition sources if you smell Natural or LP gas i Do not expose water heater control to excessive gas A A p ea pressure Sranan Si q E e Use only gas shown on rating plate Supa Maintain required clearances to combustibles Keep ignition sources away from faucets after extended zi ates g period of non use Erh P Read instruction manual before installing using or servicing 44 WARNING AWARNING Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude orifice must be installed for operation above 7 700 feet 2 347 m Do not operate if soot is present 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 CAUTION Improper installation and use may result in property damage Do not operate water heater if flood damaged Inspect and replace anode Install in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service and understand instruction manual TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS A Vent Pipe J Inner Door S Gas Control Valve Thermostat B Draft hood K Outer door T Drain Valve C Anode Not
68. ration and location may vary Reference the lighting instructions on the water heater for use location of the igniter button 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 likelinood 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 non direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition This is available from the following CSA America Inc 8501 East Pleasant Valley Road Cleveland OH 44131 National Fire Protection 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 install
69. re burns instantly resulting in severe injury or death A DANGER 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 precautions 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
70. re to call or contact State Industries Inc 500 Tennessee Waltz Parkway Ashland City TN 37015 phone 1 800 821 2017 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 IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION OPERATION REPAIR OR 36 REPLACEMENT OF THE HEATER OR PARTS THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER 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 the closest comparable water heater meeting the then current governmental regulations and industry standards A supplementary fee may be assessed to cover the addi
71. rom a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do notuse this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance Water heaters subjected to flood conditions or anytime the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS Immediately call a qualified service technician to inspect the appliance Water heaters Subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater LIGHTING INSTRUCTIONS 1 STOP Itis imperative that you read all the safety warnings before lighting the pilot Remove the outer door Turn the temperature dial counterclockwise A to its lowest setting Depress the dial stop and turn y gas control knob clockwise to the OFF position To clear any gas that may have accumulated wait ten 10 minutes If you then smell gas STOP Follow B in the safety warning above If you do not smell gas go to th
72. rom corrosion and prolonging the life of the water heater Once the anode is depleted the tank will start to corrode eventually developing a leak Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is a rotten egg smell produced from the presence of hydrogen sulfide gas dissolved in the water IMPORTANT Do not remove this rod permanently as it will void any warranties The parts list includes a special anode that can be ordered if water odor or discoloration occurs NOTE This rod may reduce but not eliminate water odor problems The water supply system may require special aeration or chlorination equipment from a water conditioning company to successfully eliminate all water odor problems The use of a water softener may decrease the life of the water heater tank The anode rod should be removed from the water heater tank every 3 years for inspection The following are typical but not all signs of a depleted anode rod e The majority of the rods diameter is less than 3 8 e Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod shows signs of either or both it should be replaced NOTE Whether reinstalling or replacing the anode rod check for any leaks and immediately correct if found In replacing the anode 1 Turn off gas supply to the water heater 2 Shut off the wa
73. ry authorized piezoelectric igniter parts for and manifold tube at the gas control valve thermostat replacement Figure 22 NOTE L P gas systems use reverse left nace hand threads on the manifold tube PATR 6 Refer to Gas Piping section Figure 3 and disconnect THERMOCOUPLE the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat y A 7 To remove the gas control valve thermostat thread a A correctly sized pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use WIRE PILOT S TIP i a TO BRACKET ELECTRODE pipe wrench or equivalent to grip body Damage may ELECTRODE result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas control valve thermostat FIGURE 32 may result 28 SNAP ON CONNECTOR NOTE SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT 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 valve thermostat clipping it at the back edge of thermostat and snapping it
74. s crawl spaces closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P gas water heater smell all around the appliance at floor level If you smell gas follow the instructions as given in the warning on the front page When your L P tank runs out of fuel turn off the gas at Explosion Hazard all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their Have a qualified person make sure L P gas pressure mantenerse instructior does not exceed 13 water column Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Failure to do so can result in death explosion or fire Table 1 Natural Gas Pipe Capacity Table Cu FE Hr Cepacity of gas pipe of diferent dametera and lengths in cu per hr with pressure drop of 0 3 in and specie gravity of 0 60 natural gas Nominal fron Pipe Length of Pipe Feet size in 10 20 50 0 0 132 E 278 320 1050 VEO Aler ihe lengih of pipe has been delermined select Ihe pipe size which will provide the minimum cubis feet per hour gued for the gas impul rating of the water heater By formula Gas Input ol Water Heater B I WAR Heating Value of Gas BTUSFT Lh ag input of the water healer la marked on fhe water heaber deta pate The heating value of ihe gas BTUs FT my be delermned by c
75. s instructions for installation of the valves Before changing the factory setting on the thermostat see Figure 19 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 index bar Robsertshaw and A mark White Rodgers are indicative of approximately 120 F 49 C and are the preferred starting points see Figure 19 Some states have a requirement for a lower setting White Rodgers Valves Turn the water temperature dial clockwise Y to decrease the temperature or counterclockwise f to increase the temperature Robertshaw Valves Turn the water temperature dial clockwise Y to increase the temperature or counterclockwise f to decrease the temperature Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance lt GAS CONTROL KNOB OFF PILOT ON Na lig OS P XAM ALOH NA B HuMs3s vagon 10 D I TE
76. s in excess of 120 F a tempering valve or an anti scald device should be installed per its manufacturer s instructions in the domestic potable hot water supply to limit the risk of scald injury e Pumps valves piping and fittings must be compatible with potable water e A properly installed flow control valve is required to 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 pressure relief valve T amp P or higher than normal water temperatures are the first signs of thermosiphoning e The domestic hot water line from the water heater should be vertical past any tempering 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 e 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 installati
77. source and correct BURNER FLAME TOO HIGH 1 Orifice too large 1 Replace with correct orifice 1 Replace thermostat 2 Check with gas utility company PILOT FLAME 1 Pilot line or orifice clogged 1 Clean locate source and correct TOO SMALL 2 Low gas pressure 2 Check with gas utility company 30 PILOT LIGHT TROUBLESHOOTING FLOWCHART Does pilot light go out when NO Check Draft See Checking the button is released Draft section of this manual YES Test the thermocouple using the following procedure Disconnect the thermocouple from the Are the wires from the gas Secure connections A j j f gas control valve thermostat Using a multimeter e a te rape gt and attempt a relight with alligator clip leads attach the red lead to the body copper part of the thermocouple YES Attach the black lead to the end silver part of the thermocouple that connects to the gas control Are the wires damaged Is the thermocouple valve thermostat Follow the instruction to light NO NO the pilot and watch the voltage readings on the and or frayed connection loose p g g multimeter After 45 seconds the meter should YES YES Tighten the connection ieee pee Replace the thermocouple PE E YES 1Does the thermocouple pass the test NO Replace the thermocouple Is the base ring filter clean i e free Inspect and clean the base ring filter Refer to the External of lint dust or debris Inspection amp Cleaning of the Base
78. t the thermostat to lowest setting PILOT LIGHTING C PILOT POSITION TOP KNOB STOP Read the safety information 9 Once the pilot has been found push the gas knob Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS Immediately call a qualified service technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater a E MAIN BURNER ON POSITION THERMOCOUPLE FIGURE D all the way down Immediately press the pilot ignitor button rapidly 4 to 5 times If the pilot will not light repeat step 3 through 9 10 Continue to hold the gas control knob down for about one 1 minute after the pilot is lit Release the gas control knob and it will pop back up Pilot should remain lit If it goes out repeat step 3 through 9 It del take several minutes for air to Clear the lines before
79. te 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 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
80. ted 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 noncompany approved appliances or equipment 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 the remainder of the affected provision or the other provisions of this warranty SERVICE AND LABOR RESPONSIBILITY UNDER THIS LIMITED WARRA
81. ter supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 5 gallons of water from tank Refer to the Draining and Flushing section for proper procedures Close drain valve PITTED ANODE Remove old anode rod ROD Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 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 FIGURE 20 7 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 I Du Pont De Nemours and Company Draining and Flushing ADANGER e Hotwater discharge burn hazard e Keep clear of relief valve discharge unit Temperature limiting valves are available e 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 2 Close the cold water inlet valve 3 Open a nearby hot water faucet 4 Connect a hose to the drain valve and terminate it to an adequate
82. the burner or other hot surfaces to produce a sizzling or frying noise Excessive condensation can cause pilot outage due to water running down the flue tube onto the main burner and putting out the pilot 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 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 23 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 no
83. the pilot will light elf knob does not pop up when released stop and immediately call your service technician or gas supplier e f the pilot will not stay lit after several tries tum the gas control knob clockwise to OFF and call your service technician or gas supplier SEE FIGURE A Once the pilot flame is established replace the outer burner door 12 At arm s length away turn gas control knob counterclockwise 5 to ON SEE FIGURE C 13 Set thermostat to desired setting DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature A 2 Push gas control knob down slightly and turn clock wise to OFF Do not force SEE FIGURE A Robertshaw Gas Control Valve Thermostat Lighting Instructions FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which is lighted by a piezoelectric igniter When lighting the pilot follow these instructions exactly BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS 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 f
84. tional 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
85. tomer 7 Insulate piping 8 Insulate piping 9 Check with gas utility company 1 Provide ventilation to water heater Check flue way flue baffle and burner 2 Clean flue locate source and correct Check with gas utility company Replace thermostat Turn temperature dial to desired setting Install adequate heater Correct piping dip tube must be in cold inlet Advise customer 4 Use a pressure reducing valve and relief valve Lower the thermostat setting See Closed System Thermal Expansion Replace thermostat Replace thermostat 1 Provide ventilation to water heater Check 3 5 6 7 8 1 2 3 1 2 ue way flue baffle and burner 2 Clean locate source and correct 3 Provide fresh air ventilation 1 Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct Replace thermostat Provide fresh air ventilation 2 3 4 5 6 See Burner Flame Yellow Lazy CONDENSATION 1 Temperature setting too low 1 Increase the temperature setting BURNER FLAME FLOATS AND LIFTS OFF PORTS 1 Orifice too large 2 High gas pressure 3 Water heater flue or vent system blocked 4 Cold drafts 1 Replace with correct orifice 2 Check with gas utility company 3 wire flue and burner locate source and cor rec FLAME BURNS AT ORIFICE 1 Thermostat not functioning prop 2 Low gas pressure A Locate
86. uld be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Locate the water heater near 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 eee de De METAL DRAIN PAN ii PIPED TO AN ADEQUATE DRAIN T acs es 5 A a A AT LEAST 2 GREATER THAN THE DIAMETER OF THE WATER HEATER Ss 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 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 drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways e Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected e Sensors mo
87. unted in the drain pan that turn off the water supply to the entire home when water is detected in the 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 e 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 1 Clearances and Accessibility NOTE Minimum clearances from combustible materials are stated on the rating plate adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor e IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least three inches 76 2mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 2 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inch es of front clearance should be provided for inspection and service FRONT Y 24 MINIMUM SIDES FOR SERVICE TOP VIEW 1 FIGURE 2 State of California NOTE The water heater must be braced anchored or strapped to avoid moving during an earthquake Contact l

State Industries 186489-002 Water Heater User Manual

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