Home

Ford 2007 Escape Automobile User Manual

1. 6 Grasp the manifold tube and push down slightly to free the manifold tube pilot tube and thermocouple 7 Carefully remove the burner door assembly from the combustion chamber Be sure not to damage internal parts U Thermocouple Manifold Tube Figure 23 Burner Door Assembly Removal Gas Valve Thermostat A Piezo Igniter Button Thermocouple Manifold _ Tube Viewport _ Pilot Tube Burner Door Two Piece Wire Screw 2 Connector Natural Gas Burner Ultra Low Nox Check the burner to see if it is dirty or clogged The burner may be cleaned with soft paint brush Figure 24 Do not use a wire brush or any tool that may damage the burner screen Important Do not use the burner if the burner screen is damaged NOTE Damage may be rips or holes in the burner screen Discoloration is normal Figure 24 Natural Gas Low Nox Burner Door Assembly LY VY Y YV Y Vi Pilot Assembly Use brush on this surface Replacing the Pilot Assembly 1 Follow the instructions in Removing the Burner Door Assembly section to remove the assembly 2 Remove the retainer clip securing the two piece wire connector to the burner door assembly Note the orientation of the retainer clip Insert the tip of a large flat head screwdriver between the clip and the top of the two piece wire connector Carefully rotate the screwdrive
2. Replacement Parts IMPORTANT The following maintenance procedures are for the Flame Lock Safety System components and should be performed by a qualified person Replacement parts may be ordered through your plumber or the local distributor Parts will be shipped at prevailing prices and billed accordingly When ordering replacement parts always have the following information ready 1 model serial and product number 2 item number 3 parts description See Repair Parts section for a list of available repair parts Removing the Burner Door Assembly 1 Turn off the gas to the water heater at the manual gas shut off valve Figure 3 2 Turn the gas control knob on the combination gas control valve thermostat clockwise to the OFF position Figure 19 NOTE Depress the dial stop on Robertshaw valves before turning the gas control knob See Lighting Instructions on the water heater 3 Remove the outer door Figure 22 Gas Valve Connections Robertshaw Gas Valve S o Nat 4 Remove the two screws hey securing the burner door RS S Pilot Tube assembly to the combustion chamber Figure 23 5 Disconnect the thermocouple right hand thread pilot tube the igniter wire from the Thermocouple Manifold Tube White Rodgers Gas Valve Sl sree oonan g igniter button and manifold o PNE tube at the thermostat ma biet Figure 22 2 TT Tube
3. WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier INSTALLER AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER OWNER RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE REFERENCE RETAIN THE ORIGINAL RECEIPT AS PROOF OF PURCHASE lt gt Whirl ol Ultra Low Nox Gas Water Heater with the Flame Lock Safety System Installation Instructions and Use amp Care Guide To obtain technical warranty or service assistance during or after the installation of this water heater visit our website at http www whirlpoolwaterheatersupport com or call toll free 1 877 817 6750 When calling for assistance please have the following information ready Model number 7 digit product number Serial number Date of installation Place of purchase IRUN Table
4. 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 Figure 3 Gas Piping Manual Gas Shut off Valve ae A Ground Joint Check with local utility for minimum height 3 minimum Drip leg Gas Pressure IMPORTANT The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s data plate The minimum supply pressure is for the purpose of input adjustment Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation e Ifthe code requires the gas lines to be tested ata 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
5. Temperature setting too low Increase the 1 Increase the temperature setting setting 1 Increase the temperature setting CONDENSATION os FLAME FLOATS Orifice too large 1 Replace with correct orifice AND LIFTS OFF PORTS High gas pressure 2 Check with gas utility company Flue clogged 3 Clean flue and burner locate source and correct 4 Locate source and correct 5 Clean burner screen See Natural Gas Burner Ultra Low Nox section of this manual FLAME BURNS AT ORIFICE Non functioning thermostat 1 Replace thermostat Low gas pressure 2 Check with gas utility company Non functioning burner 3 Replace burner assembly PILOT FLAME TOO SMALL Pilot line or orifice clogged 1 Clean locate source and correct Low gas pressure 2 Check with gas utility company Dirty pilot 3 Clean pilot Cold drafts Dirty burner screen PILOT LIGHT TROUBLESHOOTING CHART Section A Pilot light will not light Section B Pilot light will not remain lit or repeatedly goes out Check the manual gas shut off valve to Is the gas turned on jaNO see if it is in the open position if it is open YES then contact the gas utility company Make sure the thermocouple is securely Is the thermocouple securely connected to the gas contro jaNO connected Finger tighten then give a additional 1 2 turn with a wrench valve thermostat While repeatedly depressing the igniter button Have you bled all the air hold down the reset button unt
6. noncorrosive leak detection solution Bubbles will show a leak Correct any leak found 10 Replace the outer door Figure 28 Burner Door Assembly Gas Control Valve ee Burner Door Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter button electrode and wire The pilot is ignited by an electric spark generated when the igniter button is pressed The electrode should be centered between the pilot and thermocouple See Figure 29 Use only factory authorized piezoelectric igniter parts for replacement Figure 29 Natural Gas Igniter Assembly Bracket Igniter 4c Button a Wire to electrode 7 Snap on Connector Testing the Igniter System Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot or pilot assembly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the electrode if defective NOTE The electrode is part of the pilot assembly and cannot be replaced separately Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit s
7. 1 Sq inch per 4000 BTUH Confined Space Inlet air duct 1 sq inch per 4000 BTUH Figure 7 12 maximum All Air from Outdoors Through Ventilated Attic 1 sq inch per 2000 BTUH Confined Outdoor Air Ducts Figure 8 1 sq Inch All Air from Outdoors Using Horizontal Ducts per 2000 BTUH 10 Vent Pipe System This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation section This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest 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
8. Gas Code ANSI Z223 1 NFPA 54 latest edition to properly install vent system Failure to do so can result in death explosion or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air beauty shops photo processing labs buildings with indoor pools water heaters installed in laundry hobby or craft rooms 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
9. ORE TOP OR SIDE a oRANVae SS Pictured on next page T amp P LEGEND A Special anode rod see Anode Rod Water Odor section E Temperature and Pressure Relief Valve is required but may not be factory installed Listed Parts Kits and Illustrations Item 12 Pilot assembly which contains the pilot assembly and igniter electrode Natural Gas Item 13 Burner Door assembly which contains the burner gasket door pilot tube two piece wire connector with retainer clip and pilot assembly Natural Gas Low Nox Item 14 Contains two piece wire connector and retainer clip Item 15 Contains burner door gasket Item 16 Contains viewport Item 17 Contains thermocouple Item 18 Contains piezoelectric igniter button Item 19 Contains flexible manifold tube Item 12 Item 13 Item 14 I v WY Item 15 Item 16 Item 18 Item 19 Alternate Igniter NCE WHIRLPOOL FLAME LOCK amp DESIGN and FLAME LOCK are trademarks of Whirlpool U S A 2007 Whirlpool Corporation All rights reserved Manufactured under license by American Water Heater Company Tennessee 30 31 32
10. Valve Follow the instructions under Temperature and Pressure Relief Valve section After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks Figure 13 Water Piping Installation In a closed system use a zx thermal expansion tank Cold Water Supply to Fixtures Hot Water PEY Cold Water an reducing Inlet Valve valve with bypass Temperature and Pressure Relief Valve Discharge line 6 maximum above drain Drain line 3 4 ID minimum Drain 4 D Massachusetts Install a vacuum relief in cold water line per Drain Pan wW section 19 MGL 142 1 3 4 depth maximum Figure 14 Typical Tempering Valve Installation Follow the tempering valve manufacturer s instructions Tempered water to fixtures Tempering valve Set to 120 F Please note the following e The system should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybutylene This water heater must not be installed using iron piping or PVC water piping e Use only pumps valves or fittings that are compatible with potable water e Use only full flow ball or gate val
11. are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations IMPORTANT If you lack the necessary skills required to properly install this venting system you should not proceed but get help from a qualified person Draft hood Installation Align the legs of the draft hood with the slots provided Insert the legs and secure the draft hood to the water heater s top with the four screws provided as shown in Figure 9 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the new draft hood supplied with the water heater Figure 9 Draft hood Installation Sheet Metal Screws four provided Install the draft hood with the four screws provided Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is required the vent transition connection must be made at the draft hood outlet Vent Connectors 1 Type B Double Wall U L Listed Vent Pipe 2 Single Wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions construct
12. by the use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is determined by the method in which the air is to be provided Refer to Table 3 to calculate the minimum free area for each opening Figures 6 7 and 8 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 automa
13. few minutes of operation Safety Shut off This water heater is designed to automatically shut off in the event of the following 1 The pilot flame is extinguished for any reason 2 The water temperature exceeds 180 F 83 C 3 Excessive build up of lint and dust inside the combustion chamber 4 The ignition of flammable vapors Check the flame trap for signs of high temperature blue or black discoloration If there are signs of high temperature inspect your installation for a flammable vapor event see Pilot Light Troubleshooting Flow Chart If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified person to inspect the appliance Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater 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 burner if the flame is absent 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 180 F 83 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 person Contact your local dealer for service information Anode Rod W
14. 1 Install the water piping and fittings as shown in Figure 13 Connect the cold water supply 3 4 NPT to the fitting marked C Connect the hot water supply 3 4 NPT to the fitting marked H IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 Some local codes may require and 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 4 Ifinstalling the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion section 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 Atemperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp P Relief
15. Figure 26 Pilot Assembly Pilot Bracket External Inspection amp Cleaning of the Flame trap Although not likely to occur if debris collects on the flame trap use a vacuum compressed air or a soft bristle brush to remove it NOTE If unable to inspect or clean the flame trap from underneath follow the Cleaning the Combustion Chamber and Flame trap section instructions Figure 27 Flame trap visual inspection Flashlight Mirror Cleaning the Combustion Chamber and Flame trap 1 2 Follow procedure outlined in Removing the Burner Door Assembly section Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 28 Use compressed air to clear any dust or debris that may have accumulated in the flame trap Reassemble following the procedure under the Replacing the Burner Door Assembly section 23 24 Replacing the Burner Door Assembly AWARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace two piece wire connector if missing or removed Replace door gasket if damaged Failure to follow these instructions can result in death explosion or fire 1 Check the door gasket for damage or imbedded debris prior to installation AWARNING Explosion Hazard Rep
16. Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows e Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition Figure 1 Air moving Devices IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure Due to the normal corrosive action of the water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the owner operator is uncomfortable with making the repair a qualified person should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must l
17. actly 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 from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department LIGHTING INSTRUCTIONS STOP It is imperative that you read all the safety warnings before lighting the pilot Remove the outer door Turn the temperature dial counterclockwise YN to its lowest setting Depress the dial stop and turn Q 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 the next step Turn the gas control knob counterclockwise to PILOT TO TURN OFF GAS TO APPLIANCE 1 Turn the temperature dial counterclockwise to its lowest setting 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 not use this appliance if any part has been under wate
18. ance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections 11 12 Water System Piping 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 Water supply pressure should not exceed 80 of the working pressure of the water heater The working pressure is stated on the water heater s data plate If this occurs a pressure limiting 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 e 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 e Always use a good grade of joint compound and be certain that all fittings are drawn up tight Piping Installation
19. andpaper Removing and Replacing the Gas Control Valve Thermostat IMPORTANT The gas control valve thermostat is a standard valve with a right hand thread thermocouple Use only factory authorized replacement parts Removing the Gas Valve 1 Turn the gas control knob on the combination gas control valve thermostat clockwise to the OFF position NOTE Depress the dial stop on Robertshaw valves before turning the gas control knob See Lighting Instructions on the water heater Turn off the gas at the manual shut off valve on the gas supply pipe Figure 3 Drain the water heater Refer to the section of Draining and Flushing section and follow the procedure Disconnect the igniter wire from the igniter NOTE There are two types of igniters 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 gas valve If you have the square igniter slide the igniter bracket backwards away from the gas valve to remove it Disconnect the thermocouple right hand threads pilot tube and manifold tube at the gas control valve thermostat Figure 22 Refer to Gas Piping section Figure 3 and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat 6 To remove the gas valve thread a correctly sized pipe into the inlet and use it to turn the gas valve
20. ap amp burner 11 Clean pilot PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION PILOT WILL NOT REMAIN LIT 1 Air in gas line 1 Bleed the air from the gas line 2 Dirt in gas lines 2 Notify utility install dirt trap in gas line 3 Pilot line or orifice clogged 3 Clean locate source and correct 4 Thermocouple connection loose 4 Finger tighten then 1 2 turn with wrench 5 Non functioning thermocouple 5 Replace thermocouple 6 Cold drafts 6 Locate source and correct 7 Flammable vapors incident Flame 7 Eliminate flammable vapor source s Lock function utilized Call 1 877 817 6750 8 8 Check with gas utility company 9 9 See maintenance section for inspection and cleaning of flame trap amp burner 10 Pilot dirty 10 Clean pilot HIGH OPERATION COSTS Thermostat set too high Set temperature dial to lower setting Sediment or lime in tank Drain flush provide water treatment if needed Water heater too small for job Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Leaking faucets Repair faucets Gas leaks Check with utility repair at once Wasted hot water Advise customer Long runs of exposed piping Insulate piping Hot water piping in exposed wall Insulate piping INSUFFICIENT HOT WATER 1 Thermostat set too low Turn temperature dial to desired setting Sediment or lime in tank Drain flush provide water treatment if needed Water heater too small Install adequat
21. ater Odor Each water heater contains at least one anode rod which will slowly deplete while protecting the glass lined tank from 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 filtration equipment from a water conditioning company to successfully eliminate all water odor problems Artificially softened water is exceedingly corrosive because the process substitutes sodium ions for magnesium and calcium ions The use of a water softener may decrease the life of the water heater tank The anode rod should be removed from the water heater tank every 3 years for inspection The following are typical but not all signs of a depleted anode rod e The majority of the rods diameter is less than 3 8 e Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod show signs of
22. aver water heaters will produce larger amounts of condensation on initial start up or when a large amount of hot water is being used NOTE Do not confuse this with a tank leak Once the water reaches a temperature of 120 F and the tank warms up usually 1 2 hours the condensation will stop IMPORTANT It is always recommended that a suitable drain pan be installed under the water heater to protect the area from water damage resulting from normal condensation production a leaking tank or piping connections Refer to the Location Requirements section Under no circumstances is the manufacturer to be held responsible for any water damage in connection with this water heater Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard These noises are common and may result from the following 1 Normal expansion and contraction of metal parts during periods of heat up and cool down 2 Condensation causes sizzling and popping within the burner area and should be considered normal 3 Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure Drain and flush the tank as directed under 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
23. counterclockwise Do not use pipe wrench or equivalent to grip body Damage may result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas valve may result Replacing the Gas Valve To replace the gas control valve thermostat reassemble in reverse order When replacing the gas valve thread a correctly sized pipe into the inlet and use it to turn the gas valve clockwise DO NOT OVER TIGHTEN damage may result e Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve that screws into tank Be sure to remove the pilot ferrule nut from the new gas control valve thermostat 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 Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions If additional information is required contact the Service Department at 1 877 817 6750 TEFLON is a registered trademark of E I Du Pont De Nemours and Company Flame Lock Safety System Operational Checklist QARWNA Burner door gasket properly sealed Viewport not damaged or cracked Flame trap free of debris and undamaged Two piece wire connector properly installed No leaks at pilot and manifold connectio
24. d to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident The new technology used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make any required installation upgrades or changes Questions Call 1 877 817 6750 Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located with the water piping system Located as close to the gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the flame arrestor located on the bottom of the water heater and the burner will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the flame trap and burn
25. e temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the data plate IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve e Must not be in contact with any electrical part e Must be connected to an adequate discharge line e Must not be rated higher than the working pressure shown on the data plate of the water heater The Discharge Line e Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the discharge 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 t
26. e gas control knob all the way in and IMMEDIATELY depress the igniter button until you hear a loud click Observe the pilot through the view port Do not release the gas control knob Repeat immediately if the 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 gas control knob down for about 1 minute after the pilot is lit Release knob and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps 3 7 IGNITER BUTTON y ALTERNATE IGNITER IGNITER 2 BUTTON IMPORTANT If the pilot will not stay lit after several tries turn gas control knob to OFF and call your service technician or gas supplier IMPORTANT If the gas control knob 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 9 Set the temperature dial to the desired setting 10 Replace the outer door TO TURN OFF GAS TO APPLIANCE Turn the temperature dial clockwise to its lowest setting Turn gas control knob clockwise to PILOT Checking the Draft AWARNING DANN aaa After successfully lighting the water heater allow the unit to operate for 15 minute
27. e heater Wrong piping connections Correct piping dip tube must be in cold inlet Leaking faucets Repair faucets Wasted hot water Advise customer Long runs of exposed piping Insulate piping Hot water piping in outside wall Insulate piping Low gas pressure Check with gas utility company SLOW HOT WATER Insufficient air Provide ventilation to water heater Check flue RECOVERY way flue baffle and burner Flue clogged Clean flue locate source and correct Low gas pressure Check with gas utility company Improper calibration Replace thermostat Thermostat set too low Turn temperature dial to desired setting Water heater too small Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Advise customer Low gas pressure Air for combustion obstructed DRIP FROM RELIEF VALVE Excessive water pressure Use a pressure reducing valve and relief valve Heater stacking Lower the thermostat setting Closed water system See Closed System Thermal Expansion THERMOSTAT FAILS TO SHUT OFF COMBUSTION ODORS Insufficient air Provide ventilation to water heater Check flue way flue baffle and burner Flue clogged Clean locate source and correct Heater installed in a confined area Provide fresh air ventilation SMOKING AND CARBON Flammable vapor incident Call 1 877 817 6750 FORMATION SOOTING CONDENSATION 1 Temperature setting too low setting too 1
28. ed 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 e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases e Install without dips or sags with an upward slope of at least 1 4 inch per foot e Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage e The length of the vent connector cannot exceed 75 of the vertical vent height The vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition 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 c
29. 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 water supply and open a nearby hot water faucet to depressurize the water tank 3 Drain approximately 5 gallons of water from tank Refer to the Draining and Flushing section for proper procedures Close drain valve 4 Remove old anode rod 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open nearby hot water faucet to purge air from water system Check for any leaks and immediately correct any if found 7 Restart the water heater as directed under the Operating Your Water Heater See the Repair Parts Illustration section for anode rod location Figure 20 Anode Rod Depletion Exposed Support Wire TEFLON is a registered trademark of E I Du Pont De Nemours and Company MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 1 Turn off the gas to the water heater at the manual gas shut off valve 2 Close the cold water inlet valve Open a
30. er Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the burner flame tips becoming longer and the pilot will begin to experience nuisance tripping Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Location Requirements section of this water heater manual for specific requirements Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air Conditioning amp Refrigeration HVAC R authorized service provider Fresh air supply free of corrosive elements and flammable vapors Fresh air openings sized correctly with consideration given to the blocking effect of louvers and grilles Ductwork is the same cross sectional area as the openings Ven
31. er check to make sure it is working properly See Operating Your Water Heater section of this manual IMPORTANT If you lack the necessary skills required to properly perform this visual inspection you should not proceed but get help from a qualified person Temperature and Pressure Relief Valve AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly To prevent water damage the valve must be properly connected to a discharge line which terminates at an adequate drain Standing clear of the outlet discharged water may be hot slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position If the valve fails to completely reset and continues to release water immediately shut off the manual gas control valve and the cold water inlet valve and call a qualified person Figure 21 Temperature and Pressure Relief Valve Manual Relief Valve Discharge line to drain 21 22
32. f a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel IMPORTANT The manufacturer and seller of this water heater will not be liable for any damages injuries or deaths caused by failure to comply with the installation and operating instructions outlined in this manual If you lack the necessary skills required to properly install this water heater or you have difficulty following the instructions you should not proceed but have a qualified person perform the installation of this water heater Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2 00 and 5 00 A data plate identifying your water heater can be found next to the gas control valve thermostat When referring to your water heater always have the information listed on the data plate readily available Retain your original receipt as proof of purchase Unpacking the Water Heater AWARNING Excessive Weight Hazard Use two or more people to move and install water heater Failure to do so can result in back or other injury Removing Packaging Materials 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 components aside Inspect all parts for damage pr
33. he slit running the length of the insulation 3 Spread this slit open and slip it over 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 Relief 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 Figure 15B T amp P Relief Valve Insulation T amp P Relief Valve Insulation T amp P Relief Valve Drain Line Special Applications Combination Space Heating Potable Water System Some water heater models are equipped with inlet outlet tappings for use with space heating applications If this water heater is to be used to supply both space heating and do
34. il the pilot is lit and from the pilot tube and NO gt maintains a stable flame then slowly release the reset button YES Test the thermocouple using the following procedure Disconnect the thermocouple from the gas control valve thermostat Using a multimeter with alligator clip leads gas supply line YES attach the red lead to the body copper part of the thermocouple Attach the black lead to the end silver part of the thermocouple that connects to the gas control valve g meaner producing a NO gt room Tog the He System thermostat Follow the instruction to light the pilot and watch the voltage readings on sparr er Pevensie Manua the multimeter After 45 seconds the meter should read 12 millivolts DC or more YES Is the thermocouple fully Does the thermocouple pass the test jaNO seated in the pilot bracket YES NO Follow the Replacing the Pilot Assembly Is the pilot tube and or orifice NO instructions found in this manual to access free from dirt and debris pilot tube and orifice Clean as needed and YES reinstall pilot tube and orifice Is the pilot free from dirt and NO Follow the Cleaning the Pilot Assembly debris gt instructions found in this manual YES Push the thermocouple Replace the thermocouple forward until it is fully seated in the pilot bracket and retest Follow the Replacing the Pilot Assembly Is the pilot tube and or orifice NO instructions found in th
35. imit the water level to a maximum depth of 1 3 4 and be two inches wider TETT than the heater and piped to an adequate drain NOTE Clearances and Accessibility The pan must not restrict combustion air flow Locate the NOTE Minimum clearances from combustible materials water heater near a suitable indoor drain Outside drains are stated on the data plate adjacent to the gas control are subject to freezing temperatures which can obstruct valve thermostat of the water heater the drain line The piping should be at least 3 4 ID and pitched for proper drainage Under no circumstance will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your e IMPORTANT If installing over carpeting the carpeting failure to follow these instructions 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 Exhaust Fan Reverse flow of gases The water heater is certified for installation on a combustible floor 1 3 4 maximum Pipe to t adequate inches of front clearance should be provided for drain inspection and service At least 2 greater tha
36. 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 2 STOP It is imperative that you read all the safety warnings before lighting the pilot Remove the outer door Turn the temperature dial clockwise to its lowest setting Depress the gas control knob slightly and turn clockwise to OFF If the knob is ON turn it clockwise VY to PILOT then depress the knob slightly and turn clockwise Q to OFF GAS CONTROL KNOB OFF PILOT ON IGNITER TEMPERATURE DIAL NOTE Knob cannot be turned from PILOT to OFF unless knob is depressed slightly Do not use tools or excessive force 5 1 2 To clear any gas that may have accumulated wait ten 10 minutes If you smell gas STOP Follow B in the safety warning above If you do not smell gas go to the next step Turn the gas control knob counterclockwise to PILOT 7 Depress th
37. 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 latest edition This is available from the following CSA America Inc 8501 East Pleasant Valley Road Cleveland OH 44131 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 Check your phone listings for the local authorities having jurisdiction over your installation Consumer Responsibilities This manual has been prepared to acquaint you with the installation operation and maintenance of your gas water heater and provide important safety information in these areas Read all of the instructions thoroughly before attempting the installation or operation of this water heater Do not discard this manual You or future users of this water heater will need it for future reference Service to the Flame Lock Safety System should only be performed by a qualified person Examples o
38. ior to installation and start up e Completely read all instructions before attempting to assemble and install this product e After installation dispose of recycle all packaging materials AWARNING Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Location Requirements AWARNING Carbon Monoxide Poisoning Hazard Do not install in a mobile home Doing so can result in death or carbon monoxide poisoning The Flame Lock Safety System is designed to reduce the risk of flammable vapor related fires The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame trap The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the Flame Lock Safety System disables the water heater by shutting off the gas supply to the water heater s burner and pilot 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 va
39. is manual to access Is the pilot protected from cold Eliminate any drafts See the free from dirt and debris pilot tube and orifice Clean as needed and drafts that could prevent it Site Location instructions found in this manual YES reinstall pilot tube and orifice Is the pilot free from dirt and debris mNO Follow ine Cleaning the Pilot Assembly instructions found in this manual YES Check for insufficient combustion air Install correct size make up air openings per the NO Combustion Air Supply and Ventilation section in this manual Remove the burner door assembly Is the flame trap free from dirt or debris Clean the flame trap See Removing the Burner Door NO with a soft bristle brush Assembly section of the manual for or vacuum cleaner removal instructions YES Are there openings for make up air to enter the room Check the water heater for a Flammable Vapor FV event YES Are the openings of sufficient size Correct size of openings to See Combustion Air Supply and Ventilation NO ilow sufficient air If the flame trap show signs of discoloration shut off the gas supply section in this manual for requirements to the water heater at the manual gas shut off valve then contact Customer Service at 1 877 817 6750 YES INOmils 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
40. lace viewport if glass is missing or damaged Failure to do so can result in death explosion or fire 2 Inspect the viewport for damage and replace as required 3 Insert the burner door assembly into the combustion chamber and slide it completely forward Note When inserting the burner door assembly tip the burner end up slightly to ensure it engages with the burner bracket 4 Inspect the door gasket and make sure there is no fiberglass insulation between the door gasket and the combustion chamber See Figure 28 5 Replace the two screws which secure the burner door assembly to the combustion chamber and tighten securely Once the burner door assembly is tightened visually inspect the door gasket between the burner door assembly and the combustion chamber for spaces or gaps that would prevent a seal IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the burner door assembly and the combustion chamber 6 Reconnect the manifold tubing pilot tubing and thermocouple to the thermostat Do not cross thread or apply any thread sealant to these fittings The thermocouple nut should be started and turned all the way in by hand An additional 1 2 3 4 turn with a 7 16 open end wrench will then be sufficient to seat the lockwasher 7 Reconnect the igniter wire 8 Turn gas supply on and refer to the Lighting Instructions 9 Check for leaks by brushing on an approved
41. ly and Piping Gas type is the same as that listed on the water heater data plate Gas line equipped with shut off valve union and drip leg Approved pipe joint compound used Adequate pipe size and approved pipe material An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks Correct any leak found OPERATING YOUR WATER HEATER Lighting Instructions AWARNING Read and understand these directions thoroughly before attempting to light or re light the pilot Make sure the Explosion Hazard viewport is not missing or damaged See Figure 23 Make sure the tank is completely filled with water before lighting the pilot Check the data plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the data plate If you have any questions or doubts consult your gas supplier or gas utility company Replace viewport if glass is missing or damaged Failure to do so can result in death explosion or fire Robertshaw Gas Valve 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 This appliance has a pilot which is lighted by a piezoelectric igniter When lighting the pilot follow these instructions ex
42. mestic potable drinking water the instructions listed below must be followed e Be sure to follow the manual s shipped with the air handler system This water heater is not to be used as a replacement for an existing boiler installation e Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping e Ifthe space heating system requires water temperatures 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 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 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
43. morandum C P S C Peter L Armstrong Sept 15 1978 Figure 19 Gas Valve Thermostat White Rodgers Gas Valve Settings lt ___ Gas Control Knob Off Pllot On Index Bar Robertshaw Gas Valve Gas Control Knob Dial Stop TI PS OY D hes Fo y S on Temperature Dial 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 19 20 Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces This will produce a sizzling or frying noise NOTE This condensation is normal and should not be confused with a leaking tank Condensation may increase or decrease at different times of the year High efficient energy s
44. n Burner door screws securely tightened TROUBLESHOOTING CHART BURNER WILL NOT IGNITE 1 Pilot not lit 2 Thermostat set too low 3 No gas 4 Dirt in the gas lines 5 Pilot line clogged 6 Main burner line clogged 7 8 9 1 Non functioning thermocouple Non functioning thermostat Heater installed in a confined area 1 Light pilot 2 Turn temp dial to desired temperature 3 Check with gas utility company 4 Notify utility install trap in gas line 5 Clean locate source and correct 6 Clean locate source and correct 7 Replace thermocouple 8 Replace thermostat 9 Provide fresh air ventilation 1 SMELLY WATER Sulfides in the water Replace the anode with a special anode PILOT WILL NOT LIGHT 1 Airin gas line 2 Nogas 3 Dirt in gas lines 4 Pilot line or orifice clogged 5 Cold drafts 6 7 8 9 Thermostat ECO switch open Non functioning igniter Flammable vapors incident Flame Lock function utilized Low gas pressure 10 Air for combustion obstructed 11 Pilot dirty 1 Bleed the air from the gas line 2 Check with gas utility company 3 Notify utility install dirt trap in gas line 4 Clean locate source and correct 5 Locate source and correct 6 Replace thermostat 7 Replace igniter pilot assembly 8 Eliminate flammable vapor source s Call 1 877 817 6750 9 Check with gas utility company 10 See maintenance section for inspection and cleaning of flame tr
45. n the diameter of the water heater Figure 2 Minimum Clearance Locations 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 data plate e Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers State of California fireplaces etc can affect the proper operation of NOTE The water heater must be braced anchored or the water heater Special attention must be given to strapped to avoid moving during an earthquake Contact conditions these devices may create Flow reversal of local utilities for code requirements in your area or call flue gases may cause an increase of carbon monoxide 1 877 817 6750 and request instructions inside of the dwelling e Ifthe water heater is located in an area that is subjected to lint dirt and oil it may be necessary to periodically clean the flame trap and pilot see External Inspection amp Cleaning of the Flame trap and Cleaning the Pilot Assembly section Gas Supply AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve D
46. n to reinstall the assembly Replacing the Thermocouple 1 Remove the Burner Door Assembly as directed previously 2 Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connector from the assembly Figure 25 3 Pull the thermocouple from the pilot assembly Figure 29 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components 4 Push the new thermocouple through the holes in the pilot bracket Insert the thermocouple tube into the holes provided in the pilot assembly until it clicks into place Leave a small straight section entering and leaving the two piece wire connector section for easier removal service 5 Position the new thermocouple through the opening of the two piece wire connector Figure 25 NOTE The pilot tube should be located at the top followed by the igniter wire then the thermocouple 6 See Replacing the Burner Door Assembly section Figure 25 Two Piece Wire Connector Assembly Igniter Wi Thermocouple ire ee Tube Two Piece Wire Connector Cleaning the Pilot Assembly 1 Follow the procedure outlined in Removing the Burner Door Assembly 2 Use a soft bristle brush to remove any debris that may have collected on the pilot Note Clean any debris found in the air slots at the base of the pilot See Figure 26 3 Follow the steps in Replacing the Burner Door Assembly section to reassemble
47. nated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 12 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys 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 ANSI Z223 1 NFPA 54 latest edition and the guidelines set forth by prevailing local codes Figure 10 Chimney Termination Vent System Maintain ft minimum clearance Slope up 1 4 in Figure 11 Vertical Gas Vent System With Type B Double Wall Vent Pipe L 3 ft minimum Maintain clearance 4 Vent connector slope up 1 4 in per ft minimum Figure 12 Venting Through a Chimney with Type B Double Wall Vent Pipe Maintain clearance THAHAHAL AAA HHH HHHHHHHI AHH THHHHHH i Listed Lined Chimney 2 ft minimum above any object within10 ft horizontally Do not extend vent beyond edge of chimney Vent Connector s Listed Vent Cap 2 ft minimum above any object within10 ft AAN horizontally lt _ Type B Double Wall Vent Pipe Maintain specified clearance Maintain lt specified clearance Connector Unused chimney lt flue or masonry enclosure Maintain vent pipe clear
48. nearby hot water faucet Connect a hose to the drain valve and terminate it to an adequate 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 trap Check the water heater for the following Obstructions damage or deterioration in the venting system Make sure the ventilation and combustion air supplies are not obstructed Build up of soot and carbon on the main burner and pilot burner Check for a soft blue flame e Leaking or damaged water and gas piping 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 heat
49. o not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Gas Requirements IMPORTANT Read the data plate to be sure the water heater is made for the type of gas you will be using in your home This information will be found on the data plate located near the gas control valve thermostat If the information does not agree with the type of gas available do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not depend upon this odorant as an indication of leaking gas Gas Piping The gas piping must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition Table 1 on the following page is provided as a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials Refer to Figure 3 NOTE When installing gas piping apply approved pipe joint compound 1 Install a readily accessible manual shut off valve in the gas supply line as recommended by the local utility Know the location of this valve and how to turn off the gas to this unit
50. of Contents ENERGY STAR 315422 000 W10123251 December 2008 WATER HEATER SAFETY Your safety and the safety of others are very important We have provided many important safety messages in this manual and on your appliance Always read and obey all safety messages This is the safety alert symbol This symbol alerts you to potential hazards that can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING These words mean Y be killed iously injured if don t A DANGER eie EEEE ease if you don WARNING e All safety messages will tell you what the potential hazard is tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed Important Instructions Do not use this appliance if any part has been under water Immediately call a qualified service technician Water heaters subjected to flood conditions or any time the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame To prevent the possibility of injury under these conditions we recommend the hot water faucet be opened for several minutes at the kitchen sink before using any elect
51. off valve U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified person after installation of the gas piping system Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Size in 10 20 30 40 50 60 Length of Pipe Feet 70 After the length of pipe has been determined select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the water heater By formula Cu Ft Per Hr Required Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Additional tables are available in the latest edition of the National Fuel Gas Code ANSI 2223 1 Combustion Air Supply and Ventilation AWARNING Carbon Monoxide Warning Follow all the local and state codes or in the absence of local and state codes the National Fuel
52. onsult 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 latest edition The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases e The connector must be firmly attached and sealed to prevent it from falling out e To aid in removing the connector a thimble or slip joint may be used The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 10 Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with U L listed type B vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 11 and 12 IMPORTANT This gas vent must be termi
53. pansion 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 IMPORTANT Do not plug or remove the temperature and pressure relief valve 13 14 Temperature and Pressure Relief Valve AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion Figure 15A Temperature and Pressure Relief Valve Installation Optional location some models only Temperature and Pressure Relief Valve Discharge line 3 4 minimum Do not cap or plug B maximum i Drain gt 4 Drain Pan For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE see Figure 15A This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic Shut off Devices for Hot Water Supply Systems ANSI Z21 22 The function of th
54. pors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified person to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame trap and require replacement of the entire water heater 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 sources have been extinguished Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location e Select a location near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface Do not install in bathrooms bedrooms or any occupied room normally kept closed e
55. r 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 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 pilot is 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 IGNITER 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
56. r to raise the clip It may be necessary to remove the connector one side at a time See Figure 25 3 Locate where the thermocouple connects to the rear of the pilot assembly and pull the thermocouple tip from the rear of the pilot assembly 4 Remove the nut securing the pilot assembly to the burner and keep it for reuse later 5 Use a 1 2 open end wrench to loosen the nut securing the pilot tube to the pilot To prevent any bending use a pair of pliers to steady the pilot bracket 6 Remove the old pilot assembly including the igniter wire from the burner door assembly 7 Insert the pilot tube into the new pilot assembly Important The new pilot assembly comes with an orifice This orifice must be installed when replacing the pilot assembly IMPORTANT Do not operate this water heater without the orifice in place 8 Use a 1 2 open end wrench to tighten the nut securing the pilot tube to the pilot To prevent any bending use a pair of pliers to steady the pilot bracket 9 Use the nut removed in a previous step to secure the new pilot assembly to the burner 10 Insert the igniter wire through the burner door and reconnect the thermocouple to the pilot assembly See Replacing the Thermocouple section 11 Reinstall the two piece wire connector NOTE The pilot tube must be at the top followed by the igniter wire then the thermocouple 12 Follow the instructions in Replacing the Burner Door Assembly sectio
57. r contain large objects may less than 100 square inches Figure 5 not be suitable for water heater installation e Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air Confined openings should be sized the same as for a confined Space space e Modern home construction usually requires supplying outside air into the water heater area H Permanent Confined Space Openings For the correct and proper operation of this water heater 1 square ample air must be supplied for the combustion ventilation A and dilution of flue gases Small enclosures and confined minimum areas must have two permanent openings so that sufficient 100 sq In fresh air can be drawn from outside of the enclosure One each 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 Figure 5 ai The size of each opening free area is determined by the Pe A liae 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 data plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or
58. r supply line to reduce the risk of scald injury Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified person Water Temperature Regulation AWARNING Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded Feel water before bathing or showering Temperature limiting valves are available The thermostat is adjusted to its lowest temperature when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 120 F Align the index bar on the thermostat with the desired water temperature as shown in Figure 19 There is a hot water scald potential if the thermostat is set too high IMPORTANT Adjusting the thermostat past 120 F on the temperature dial will increase the risk of scald injury in the times shown below Time for 1st Time tor Water Permanent Burns Degree Burn Less Severe Bums Temperature F 2nd amp 3rd Degree Most Severe Bums 110 normal shower temp 116 pain threshold 116 35 minutes 45 minutes 122 1 minute 5 minutes 131 5 seconds 25 seconds 140 2 seconds 5 seconds 149 1 second 2 seconds 154 instantaneous 1 seconds U S Government Me
59. rical appliance which is connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the faucet as water begins to flow Do not smoke or have any open flame near the faucet at the time it is open The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the Act Table Of Contents Water Heater Safety Installing Your Gas Water Heater Unpacking the Water Heater Location Requirements Gas Supply Combustion Air Supply and Ventilation Water System Piping Installation Checklist Operating Your Water Heater Lighting Instructions Operational Conditions Maintenance of Your Water Heater Troubleshooting Chart Repair Parts Illustration INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product more sensitive to
60. s and check the draft hood relief opening for proper draft Make sure all other appliances in the area are operating and all doors are closed when Burn Hazard Do not touch vent Doing so can result in burns 3 Depress the gas control knob slightly and turn clockwise to OFF Do not use tools or force performing the draft test Pass a match flame around the relief opening re Relief of the draft hood A Match Opening steady flame drawn into S the opening indicates A proper draft If the flame flutters or is blown out Nea combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Figure 17 Draft hood Burner Flames Inspect burner Figure 18 flames through Flame Characteristics viewport Flames should be very small Correct flame with a blue soft blue haze and small amounts of yellow or ee ae orange at the edges After several minutes of operation the burner screen may glow red If large flames are observed at anytime shut off unit and call a qualified person Stacking Stacking occurs when a series of short draws of hot water 3 gallons or less are taken from the water heater tank This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet An anti scald device is recommended in the hot wate
61. separate location than the water heater See the Location Requirements section and the Combustion Air Supply section Contact a local Heating Ventilation Air Conditioning amp Refrigeration authorized service provider Check the vent system for Is there proper drafting at the restrictions obstructions and check draft hood See Checking the the vent termination height Refer to Draft section in this manual the Installation Instructions section of this manual for specific requirements Remove the burner door assembly Is the flame trap and burner free from debris due to excessive lint dirt dust or oil YES Does the flame trap show signs of discoloration NO YES Replace the gas control Shut off the gas supply to the water heater at DOREA the manual gas shut off valve then contact Refer to the Use amp Care Guide section lof this manual for information on cleaning the flame trap and burner Customer Service at 1 877 817 6750 This procedure requires the removal of water heater components 27 28 REPAIR PARTS ILLUSTRATION Alternate anode location for top Anode location for side T amp P When ordering repair parts always give the following information 1 Model serial and product number 2 Type of gas 3 Item number 4 Parts description Repair Parts List Item sd Parts Description se coro warer pietose oO i z mwoero o o oal TEMPERATURE amp PRESSURE RELIEF VALVE
62. supplier 8 Turn the gas control knob counterclockwise to ON Set the temperature dial to the desired setting 10 Replace the outer door 2 Turn the gas control knob clockwise VY to the OFF position 17 18 A White Rodgers Gas Valve 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 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 from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to
63. t Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition Flue baffle engaged in slots provided in the flue tube Check the vent system for restrictions obstructions and check the vent termination height Refer to the Air Supply and Ventilation section of this water heater manual for specific requirements Recheck for sufficient combustion air supply Water System Piping Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Tempering valve when applicable installed per manufacturer s instructions see Water Temperature Regulation section Gas Supp
64. than 50 cubic feet for each 1 000 BTUH of the total input for all gas using appliances Unconfined Space Figure 4 n Opening Locations A water heater in an unconfined space uses indoor air for Confine Spaces 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 Permanent openings to confined Table 2 the outside or space additional BTUH Input 12 maximum Minimum Square Feet with 8 Ceiling j rooms within Typical Room the building with 8 Ceiling 30 000 188 9x21 45 000 14 x 20 60 000 15 x 25 12 maximum 281 375 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 IMPORTANT Each of the two openings shall have a minimum free area e The area must be open and be able to provide the of 1 square inch per 1 000 BTUH of the total input rating of proper air requirements to the water heater Areas that all gas utilization equipment in the confined area but not are being used for storage o
65. tically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions Table 3 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on the total BTUH input rating for all gas utilizing equipment within the confined space Minimum Free Area Per Opening Reference sq in Drawing 1 Square inch per 4000 Figure 6 BTUH 1 Square inch per 4000 Figure 7 BTUH Horizontal ducts 1 Square inch per 2000 Figure 8 BTUH Example A water heater with an input rate of 50 000 BTUH using horizontal ducts would require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 Sq Inches Opening Source Direct to outdoors Vertical ducts These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements Gable vent to outdoors Install above JL insulation Outlet air to attic 1 Sq inch per 4000 BTUH Confined Inlet air from the crawl space Alternate Air Inlet 1 sq inch per Open 4000 BTUL Seas Vent Figure 6 All Air from Outdoors Inlet Air from Ventilated Crawl Space Outlet Air to Ventilated Attic Gable vent xm to outdoors Install above rt insulation to attic
66. ves The use of valves that may cause excessive restriction to water flow is not recommended e Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion AWARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking have a qualified person replace it Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Do not plug valve Do not remove valve Failure to follow these instructions can result in death or explosion 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 ex
67. water heating appliances when used to supply potable water Some jurisdictions may require a backflow preventer in the incoming cold water line This may cause the temperature and pressure relief valve on the water heater to discharge or weep due to expansion of the heated water A diaphragm type expansion tank suitable for potable water will normally eliminate this weeping condition Please read and follow the manufacturer s instructions for the installation of such tanks Also see Water System Piping section for additional instructions on the safe and correct installation and operation of this water heater Figure 16 Typical Tempering Valve Installation Combination Space Heating Potable Water Heating System Domestic Must be vertical to Flow Control tot wa remove air bubbles Unions Handler Massachusetts code does not allow this type of installation Solar Installation If this water heater is used as a solar storage heater or as a backup for the solar system the water supply temperatures to the water heater tank may be in excess of 120 F A 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 15 Important Information About This Water Heater This gas water heater was manufacture

Ford 2007 Escape Automobile User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents