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Essick Air H12 400 Humidifier User Manual

1. Item 18 Item 20 Item 21 Item 22 WHIRLPOOL FLAME LOCK amp DESIGN and FLAME LOCK are trademarks of Whirlpool U S A 2006 Whirlpool Corporation All rights reserved Manufactured under license by American Water Heater Company Tennessee 28
2. result 3 Dra ne water heater Reter to he secon ot Draining 17 Be sure to use approved Teton ap or pipe joint l aah aaa compound on the gas piping connections and fitting on 4 Disconnect the igniter wire from the igniter button the back of the gas control valve that screws into tank Remove the igniter button by depressing front and rear Be sure to remove the pilot ferrule nut from the new gas holding tabs and lift Remove igniter bracket Disconnect control valve thermostat the thermocouple right hand threads pilot tube two e Turn the gas supply on and check for leaks Test all wire leads at the thermal switch and manifold tube at connections by brushing on an approved noncorrosive the gas control valve thermostat Figure 22 NOTE leak detection solution Bubbles will show a leak L P gas systems use reverse left hand threads on the Correct any leak found manifold tube Be sure tank is completely filled with water before 5 Refer to Gas Piping Figure 3 and disconnect the lighting and activating the water heater Follow the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat Lighting Instructions e f additional information is required contact the Service 6 To remove the gas valve thread a correctly sized 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 Checklis
3. 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 expansion tank must have a minimum capacity of 1 5 U S gallons for every 50 gallons of stored water Contact the local water supplier or plumbing inspector for information on other methods to control this situation IMPORTANT Do not plug or remove the temperature and pressure relief valve 13 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
4. Be sure igniter wire is positioned through the small open ing of the two piece wire connector See Replacing the Manifold Assembly Figure 25 Two Piece Wire Thermocouple Connector o a va Wire Other fittings not shown for clarity Assembly Mn itl _Two Piece Wire Connector S Manifold oor Figure 26 Thermocouple Assembly 22 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 instructions Figure 27 Flame trap visual inspection Flashlight oy Mirror e Cleaning the Combustion Chamber and Flame trap 1 Follow procedure outlined in Removing the Manifold Assembly 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 28A Use compressed air to clear any dust or debris that may have accumulated in the flame trap 3 Reassemble following the procedure under Replacing the Manifold Assembly Replacing the Manifold 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 t
5. WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier INSTALLER AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER OWNER RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE REFERENCE RETAIN THE ORIGINAL RECEIPT AS PROOF OF PURCHASE Appliances 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 1 Model number 2 7 digit product number 3 Serial number 4 Date of installation 5 Place of purchase Table of Coments sanrrsrcano ena
6. 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 LP Gas Only AWARNING Explosion Hazard Have a qualified person make sure L P gas pressure does not exceed 13 water column Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel Failure to do so can result in death explosion or fire Table 1 l Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90__ 100 125 150 175 200 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 Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT Cu Ft Per Hr Required The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Table 2 LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum
7. 3 Flue clogged 3 Clean locate source and correct 4 Thermostat not functioning properly 4 Replace thermostat 5 Heater installed in a confined area 5 Provide fresh air ventilation 6 6 1 2 3 2 2 3 3 4 4 5 Thermostat set too low 5 Turn temperature dial to desired setting 6 Water heater too small 6 7 T 8 8 1 1 2 3 Burner flame yellow lazy See Burner Flame Yellow Lazy CONDENSATION Temperature setting too low 1 Increase the temperature setting f BURNER FLAME FLOATS 1 Orifice too large Replace with correct orifice AND LIFTS OFF PORTS 2 High gas pressure Check with gas utility company 3 Flue clogged Clean flue and burner locate source and correct 4 Cold drafts 4 Locate source and correct BURNER FLAME TOO HIGH 1 Orifice too large 1 Replace with correct orifice FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly 1 Replace thermostat 5 Low gas pressure 2 Check with gas utility company PILOT FLAME 1 Pilot line or orifice clogged 1 Clean locate source and correct TOO SMALL 2 Low gas pressure 2 Check with gas utility company 25 PILOT LIGHT TROUBLESHOOTING FLOWCHART NOwjhandler in the same room 26 Does pilot light go out NO Check Draft See Checking the when button is released gt Draft section of this manual YES Test the thermocouple using the following procedure Disconnect the thermocouple 7 Are the wires from the gas dha tne the
8. Airin gas line Bleed the air from the gas line 5 Low gas pressure Check with gas utility company 6 No gas Check with gas utility company 7 Dirt in gas lines Notify utility install dirt trap in gas line 8 Cold drafts Locate source and correct 9 Thermostat ECO switch open Replace thermostat 10 Pilot line or orifice clogged Clean locate source and correct 11 Non functioning thermocouple Replace thermocouple 12 Air for combustion obstructed See maintenance section for inspection and cleaning of flame trap 13 Flammable vapors incident Flame Lock Replace water heater eliminate flammable function utilized vapors source Call 1 877 817 6750 PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION 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 1 2 3 4 5 6 7 8 9 INSUFFICIENT HOT WATER 1 Thermostat set too low 1 Turn temperature dial to desired setting Sediment or lime in tank 2 Drain flush provide water treatment if needed Water heater too small 3 Install adequate heater Wrong piping co
9. 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 Supply 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 7 attempting to light or re light the pilot Make sure the Explosion Hazard viewport is not missing or
10. 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 Water 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 T
11. damaged See Figure 23 Replace viewport if glass is Make sure the tank is completely filled with water before missing or damaged lighting the pilot Check the data plate near the gas control valve thermostat for the correct gas Do not use this water Failure to do so can result in heater with any gas other than the one listed on the data death explosion or fire plate If you have any questions or doubts consult your gas supplier or gas utility company 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 C Use only your hand to push in or turn the gas control 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 STOP It is imperative that you read all the safety warnings before lighting the pilot Remove the outer door Turn the temperature d
12. 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 The length of the vent connector cannot exceed 75 of the vertical vent height e The vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state codes the National Fuel Gas Code ANSI Z2223 1 NFPA 54 latest edition e The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases e The connector must be firmly attached and sealed to prevent it from falling out e To aid in removing the connector a thimble or slip joint may be used e The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 1
13. 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 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 N to the OFF position 17 L P G Bottled Propane Models Liquefied petroleum gas is over 50 heavier than air and in the occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces skirted areas under mobile homes even when ventilated closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P gas water heater smell all around the appliance at floor level If you smell gas fol
14. 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 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 Drafthood Installation Align the legs of the drafthood with the slots provided Insert the legs and secure the drafthood to the water heater s top with the four screws provided as shown in Figure 9 Do not alter the drafthood in any way If you are replacing an existing water hea
15. 0 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 drafthood by a listed vent connector or by directly originating at the drafthood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 11 and 12 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 12 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys Figures 10 12 are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI Z2223 1 latest edition and the guidelines set forth by prevailing local codes Figure 10 Listed Lined Chimney Termination Vent System 2 ft mini
16. 2 DESIGN 6510397 W10100910 Cj saree September 2006 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 bustina iiyoudoni ADANGER Sorne aaa WARNING rlon heimddlones T NURA yaaan 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 electrical ap
17. 3 Item number 4 Parts description Repair Parts List Fa Parts Description e conwareRop roe o Ee LOCATED TOP OR SIDE o forane ooo WITH RETAINER CLIP Pictured on next page T amp P LEGEND A Special anode rod see Anode Rod Water Odor section HM Temperature and Pressure Relief Valve is required but may not be factory installed Unique Flame Lock Safety System parts 27 Listed Parts Kits and Illustrations Item 12 Item 13 Item 14 Item 15 Item 16 Item 17 Item 18 Item 19 Item 20 Item 21 Item 22 Pilot assembly kit which contains the pilot assembly igniter electrode and retainer clip Natural Gas Pilot assembly kit which contains the pilot assembly igniter electrode and retainer clip L P Gas Burner Natural Gas Low Nox Burner L P Gas Manifold door assembly which contains the manifold tube gasket door pilot tube thermocouple two piece wire connector with retainer clip thermal switch and pilot assembly Natural Gas Low Nox Manifold door assembly which contains the manifold tube gasket door pilot tube thermocouple two piece wire connector with retainer clip thermal switch and pilot assembly L P Gas Contains two piece wire connector and retainer clip Contains manifold door gasket Contains viewport Contains piezoelectric igniter button Contains thermocouple Item 14 Item 17 Item 15
18. Care Guide section of this manual for dirt dust or oil information on cleaning the flame trap YES Check the water heater for a Flammable Vapor FV event Note it may be necessary to remove the manifold door assembly to visually inspect the water heater Reference the Maintenance of your Water Heater section of this manual for removal instructions Does the flame Is the igniter wire insulation burnt or Is the pilot tube trap show signs show signs of discoloration NOPlcamasea NO gt of discoloration YES YES and or debris Shut off the gas supply to the water heater at the manual gas shut off valve then contact Customer Service at 1 877 817 6750 Does the thermocouple pass the test the red lead to the body copper part of the thermocouple Attach the black lead to the end silver part of the thermocouple nonb rection ose NOP that connects to the gas control valve connection loose thermostat Follow the instruction to light YES the pilot and watch the voltage readings on i the multimeter After 45 seconds the meter Tighten the connection should read 12 millivolts DC or more NO Replace the thermocouple Thermal Switch 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
19. When burned vapors from these products form National Fuel Gas Code ANSI 2223 1 highly corrosive acid compounds These products should NFPA 54 latest edition to properly install vent system Combustion and ventilation air requirements are not be stored or used near the water heater or air inlet determined by the location of the water heater The water heater may be located in either an open unconfined area 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 Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1 000 BTUH of the total input for all gas appliances The table below shows a few examples of the minimum square footage area required for various BTUH inputs Table 2 BTUH Input Minimum Square Feet with 8 Ceiling 30 000 188 9x21 657 750 844 Typical Room with 8 Ceiling 105 000 20 x 33 120 000 25 x 30 135 000 28 x 30 IMPORTANT e The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation e Water heaters installed in
20. all the way in by hand An additional quarter turn with a 7 16 open end wrench will then be sufficient to seat the lockwasher Reconnect the igniter wire Turn gas supply on and refer to the Lighting Instructions CoN 9 Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately 10 Replace the outer door Figure 28A Combustion Chamber Figure 28B Manifold Assembly Close up Close up inside view of the combustion chamber Tab Manifold tube 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 spark gap of 0 125 inch is set when the electrode is installed at the factory See Figure 29 Use only factory authorized piezoelectric igniter parts for replacement Bracket Figure 29 Natural Gas amp L P Gas Igniter Assemblies Igniter Button Wire to aoe Snap on Connector Note Spark gap distance measured from electrode tip to pilot 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 asse
21. arge 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 Location Requirements 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 Draining and Flushing Smoke Odor The water heater may give off a small amount of smoke and odor during the initial start up of the unit This is due to the burning off of oil from metal parts of a new unit and will disappear after a few minutes of operation Safety Shut off This water heater is designed to automatically shut off in the event of the
22. ate the water heater near a suitable indoor drain Outside drains are subject to freezing temperatures which can obstruct the drain line The piping should be at least 3 4 ID and pitched for proper drainage Under no circumstances will the manufacturer or seller of this water heater be held liable for any water damage which is caused by your failure to follow these instructions 1 3 4 maximum S Pipe to adequate drain t least 2 greater than the diameter of the water heater 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 Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling If the water heater is located in an area that is subjected to lint dirt and oil it may be necessary to periodically clean the flame trap see External Inspection amp Cleani
23. ation 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 Manual Relief Lever T amp P Relief Valve T amp P Relief Valve Drain Line Special Applications Combination Space Heating Potable Water System Some water heater models are equipped with inlet outlet tappings for use with space heating applications If this water heater is to be used to supply both space heating and domestic potable drinking water the instructions listed below must be followed e Be sure to follow the manual s shipped with the air handler system e This water heater is not to be used as a replacement for an existing boiler installation e Do not use with piping that has been treated with chromates boiler seal or other chemicals and do not add any chemicals to the water heater piping e Ifthe space heating system requires water tempera tures 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 ris
24. d or an inadequate air supply can cause the Flame Lock Safety System to disable the water heater Please make required installation and venting air supply changes prior to resetting the system IMPORTANT This water heater has a resettable thermal switch installed as part of the Flame Lock Safety System DO NOT attempt to disable or modify this feature in any way Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished Open the doors and windows for ventilation while flammable substances are in use If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to 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 Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements wh
25. e Location Requirements section of this water heater manual for specific requirements Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air Conditioning amp Refrigeration HVAC R authorized service provider 16 Fresh air supply free of corrosive elements and flammable vapors Fresh air openings sized correctly with consideration given to the blocking effect of louvers and grilles Ductwork is the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Drafthood 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
26. e a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 Sq Inches Minimum Free Area These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements Gable vent to outdoors Install above insulation Confined Outlet air to attic 1 Sq inch per 4000 BTUH Inlet air from the crawl space Alternate Air Inlet 1 sq inch per p 4000 BTUH Sl aN 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 S insulation Outlet air to attic 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 Outdoor Air Ducts Figure 8 1 sq Inch r per All Air from Outdoors 2000 BTUH Using Horizontal Ducts Vent Pipe System This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation This water heater must be properly vented for
27. e 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 lfinstalling the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion 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 A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp P Relief Valve Follow the instructions under Temperature and Pressure Relief Valve 12 After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any ex cess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks Figure 13 Water Piping Installation In a closed system use a z amp thermal expansion tank Cold Water Supply to Fixtures Cold Water Lo ressure reducing Inlet Valve valve with bypass Ts Temperature and Pressure Relief Va
28. e 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 Drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the flame arrestor located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the flame trap Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a thermal switch on the door assembly to trip Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to th
29. en 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 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 homeowner is uncomfortable with making the repair a qualified person should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Loc
30. fold Door Assembly Burner Pilot Assembly Manifold Tube Screws L P Gas Burner 1 Separate the pilot bracket from the L P burner by removing screw 2 Loosen set screw located on top of the L P burner near the manifold door Carefully pull the burner away from the manifold door assembly 3 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 24B Manifold Door Assembly Figure 24B L P Gas Burner Assembly Manifold Door Gasket Two Piece a ee Connector Thermal Switch Pi Igniter Wire Pilot H O Burner EZ Tube Manifold Tube Thermocouple Viewport Pilot Assembly Thermocouple Retainer Clip Pilot Bracket 21 Replacing the Thermocouple 1 Remove the manifold assembly as directed previously 2 Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connec tor from the manifold door 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 pi lot bracket Insert the thermocouple tube into the holes provided in the pilot assembly until it clicks into place 5 Position the new thermocouple through the larger opening of the two piece wire connector Figure 25
31. following 1 The pilot flame is extinguished for any reason 2 The water temperature exceeds 180 F 83 C 3 Excessive combustion chamber temperatures 4 The ignition of flammable vapors A thermocouple is used to determine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot if the flame is absent This unit is also equipped with a thermal switch designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors e g spilled gasoline poor combustion caused by a blocked vent or insufficient combustion air If the thermal switch opens 1 Check the flame trap for signs of high temperature blue or black discoloration See Figure 28A 2 If there are signs of high temperature inspect your installation for any problems with venting combustion air supply and for a flammable vapor event see Pilot Light Troubleshooting Flow Chart Correct any issues prior to resetting the thermal switch Contact the Product Service and Support Department for service information at 1 877 817 6750 3 Reset the thermal switch by depressing the small button in the center of the thermal switch Follow the Lighting Instructions found on the front of your water heater A high temperature limit switch or ECO Energy Cut Off in the tank is used to shut off the unit if the water temperature exceeds 180 F 83 C The ECO is a single use switch which if activated requires
32. gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90 100 125 150 1 2 275 3 4 576 1 1071 1 1 4 2205 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI Z223 1 Combustion Air Supply and e water heaters installed in laundry hobby or craft rooms Ventilation 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 Failure to do so can result in death explosion or carbon monoxide poisoning or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTUH of the total input for all gas using appliances e water heaters installed near chemical storage areas WARN i N G Combustion air must be free of acid forming chemicals A such as sulfur fluorine and chlorine These elements are Carbon Monoxide Warning found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers Follow all the local and state codes or in refrigerants and many other commercial and household the absence of local and state codes the products
33. h and manifold tube at the gas control valve thermostat Figures 22 amp 23 NOTE L P Gas systems use reverse left hand threads on the manifold tube 6 Grasp the manifold tube and push down slightly to free the manifold pilot tube and thermocouple Right Hand Thread gt i B Thermocouple Tube Manifold Tube Thermal Switch Wires 7 Carefully remove the manifold assembly from the burner compartment NOTE Be sure not to damage internal parts Figure 23 Burner Assembly Removal Piezo Igniter Button Gas Valve Thermostat Manifold Tube Pilot Tube Thermocouple Thermal Switch Viewport Manifold Door Manifold Screw 2 Two Piece Wire Connector Removing the Burner from the Manifold Assembly Natural Gas Burner Low Nox 1 Take off the burner by removing the two 2 screws located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 24A Manifold Door Assembly Na Figure 24A Natural Gas Low Nox Burner Assembly Thermal Switch Two Piece Wire Igniter Wire Connector we Wy be Pilot amp Tube Burner er Manifold Tube Door Gasket Thermocouple Pilot Bracket Viewport Thermocouple Pilot Retainer Clip Pilot Assembly amp Tube Thermocouple _ Mani
34. he following are typical but not all signs of a depleted anode rod e The majority of the rods diameter is less than 3 8 e Significant sections of the support wire approx 1 3 or more of the anode rod s length are visible If the anode rod show signs of either or both it should be replaced NOTE Whether re installing or replacing the anode rod check for any leaks and immediately correct if found In 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 Draining and Flushing for proper procedures Close drain valve 4 Remove old anode rod 5 Use Teflon tape or approved pipe sealant on threads and install new anode rod 6 Turn on water supply and open 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 Operating Your Water Heater See the Repair Parts Illustration for anode rod location Figure 20 Anode Rod Depletion Exposed Support Wire Pitted Anode Rod Exposed Support Wire TEFLON is a registered trademark of E I Du Pont De Nemours and Company 19 MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment
35. ial counterclockwise A to its lowest setting Depress the dial stop and turn N 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 i counterclockwise to PILOT TO TURN OFF GAS TO APPLIANCE Turn the temperature dial counterclockwise to its lowest setting 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 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 7 Depress the reset button all the way PUSHBUTTON in and IMMEDIATELY depress the igniter button until you hear a loud click Observe the
36. ified person Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel IMPORTANT The manufacturer and seller of this water heater will not be liable for any damages injuries or deaths caused by failure to comply with the installation and operating instructions outlined in this manual If you lack the necessary skills required to properly install this water heater or you have difficulty following the instructions you should not proceed but have a qualified person perform the installation of this water heater Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2 00 and 5 00 A data plate identifying your water heater can be found next to the gas control valve thermostat When referring to your water heater always have the information listed on the data plate readily available Retain your original receipt as proof of purchase Unpacking the Water Heater AWARNING Excessive Weight Hazard Use two or more people to move and install water heater Failure to do can result in back or other injury IMPORTANT Do not remove any permanent instructions labels or the data label from either the outside of the water heater or on the inside of water heater panels e Remove exterior packaging and place installation com ponents aside e Inspect all parts for damage prior
37. k of scald injury e Pumps valves piping and fittings must be compatible with potable water e A properly installed flow control valve is required to pre vent thermosiphoning Thermosiphoning is the result of a continuous flow of water through the air handler circuit during the off cycle Weeping blow off of the temperature and pressure relief valve T amp P or higher than normal water temperatures are the first signs of thermosiphoning e The domestic hot water line from the water heater should be vertical past any tempering valve or supply line to the air handler to remove air bubbles from the system Otherwise these bubbles will be trapped in the air handler heat exchanger coil reducing the efficiency e Do not connect the water heater to any system or components previously used with non potable water heating appliances when used to supply potable water Some jurisdictions may require a backflow preventer in the incoming cold water line This may cause the temperature and pressure relief valve on the water heater to discharge or weep due to expansion of the heated water A diaphragm type expansion tank suitable for potable water will normally eliminate this weeping condition Please read and follow the manufacturer s instructions for the installation of such tanks Also see Water System Piping for additional instructions on the safe and correct installation and operation of this water heater Figure 16 Typical Tempe
38. low the instructions as given in the warning on the front page When your L P tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions Checking the Draft AWARNING Burn Hazard Do not touch vent Doing so can result in burns DMNA a et After successfully lighting the water heater allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the drafthood A steady flame drawn into the opening indicates proper draft If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Burner Flames Inspect the burner flames through the viewport and compare them to the drawings in Figure 18 A properly operating burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not be all yellow or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified person if the fla
39. lve Hot Water Discharge line 6 maximum above drain Drain line 3 4 ID minimum Drain 4 See Massachusetts Install a vacuum relief in cold water line per Drain Pan 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 valves The use of valves that may cause excessive restriction to water flow is not recommended e Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used e Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system 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
40. m s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTUH of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 5 Confined Space Permanent Openings 1 square inch 1000 minimum 100 sq In Figure 5 All Air from Inside Building Confined Space Installation All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is determined by the method in which the air is to be provided Refer to Table 3 to calculate the minimum free area for each opening Figures 6 7 and 8 are typical examples of each method Louvers a
41. 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 heater check to make sure it is working properly See Operating Your Water Heater section of this manual IMPORTANT If you lack the necessary skills required to properly perform this visual inspection you should not proceed but get help from a qualified person 20 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 com
42. mbly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the igniter if defective Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper 53 4125 mp Electrode Removing and Replacing the Gas Control Valve Thermostat IMPORTANT The gas control valve thermostat is a standard valve with wire leads that connect to a thermal switch Removing the Gas Valve pipe into the inlet and use it to turn the gas valve 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 1 On the gas control valve thermostat turn the temperature TO replace the gas control valve thermostat reassemble in dial counterclockwise to its lowest setting Depress the reverse order This water heater has a resettable thermal dial stop and turn the gas control knob clockwise to the Switch installed DO NOT attempt to disable or modify this OFF position Figure 19 ae in e Pea a ald n i a correctly sized pipe into the inlet and use it to turn the gas 2 ps eas manual shut off valve on the gas Valve clockwise DO NOT OVER TIGHTEN damage may i
43. me is not satisfactory 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 water 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 18 Figure 17 Drafthood Relief Match Opening Figure 18 Flame Characteristics Tips may have Ka yellow tint Yellow inner cones are satisfactory Correct flame soft blue 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 the
44. mum above any object within10 ft NE horizontally 3 ft minimum Maintain clearance Do not extend vent beyond edge of chimney HI ir LLLALI Vent Connector a ae xs Listed Vent Cap Vent System With Type B Double Wall Vent Pipe 2 ft minimum above any 3 ft minimum object within10 ft N horizontally lt lt Type B Double Wall Vent Pipe Maintain clearance t A Maintain specified Vent clearance connector slope up 1 4 in per ft minimum Figure 12 Venting Through a Chimney with Type B Double Wall Vent Pipe mm Listed Vent Cap Maintain lt specified clearance 5 in minimum Maintain clearance Connector Unused chimney a fl per ft lt flue or masonry minimum Taema enclosure Maintain vent pipe clearance 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 Water System Piping Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 13 If the indoor installation a
45. nd Grilles In calculating free area for ventilation and combustion air supply openings consideration must be given to the blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may require larger openings to achieve the required minimum free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 25 of free area while metal louvers and grilles will allow 60 75 of free area Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions Table 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 Opening Per Opening Reference Source sq in Drawing Direct to 1 Square inch per 4000 Figure 6 outdoors BTUH Vertical ducts 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 hav
46. ng of the Flame trap Figure 1 Air moving Devices Exhaust Fan Reverse flow of gases Clearances and Accessibility NOTE Minimum clearances from combustible materials are stated on the data plate adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor e IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least three inches 76 2mm in 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 inches of front clearance should be provided for inspection and service Figure 2 Minimum Clearance Locations 24 minimum Sides for service State of California NOTE The water heater must be braced anchored or strapped to avoid moving during an earthquake Contact local utilities for code requirements in your area or call 1 877 817 6750 and request instructions Gas Supply AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve Do not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these in
47. nnections 4 Correct piping dip tube must be in cold inlet Leaking faucets 5 Repair faucets Wasted hot water 6 Advise customer Long runs of exposed piping 7 Insulate piping Hot water piping in outside wall 8 Insulate piping Low gas pressure 9 Check with gas utility company 1 SLOW HOT WATER Insufficient secondary 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 Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Advise customer DRIP FROM RELIEF VALVE Excessive water pressure Use a pressure reducing valve and relief valve Heater stacking 2 Lower the thermostat setting Closed water system 3 See Closed System Thermal Expansion THERMOSTAT FAILS TO 1 Thermostat not functioning properly Replace thermostat SHUT OFF 2 Improper calibration Replace thermostat COMBUSTION ODORS Insufficient secondary air Provide ventilation to water heater Check flue way flue baffle and burner 2 Flue clogged 2 Clean locate source and correct 3 Heater installed in a confined area 3 Provide fresh air ventilation SMOKING AND CARBON 1 Insufficient secondary air 1 Provide ventilation to water heater Check flue FORMATION SOOTING way flue baffle burner 2 Low gas pressure 2 Check with gas utility company
48. open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space e Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 4 The size of each opening free area is determined by the total BTUH input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTUH input can be found on the water heater data plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors Figure 4 Opening Locations Confined Spaces 12 maximum Permanent openings to the outside or additional rooms within the building confined space 12 maximum All Air from Inside the Building When additional air is to be provided to the confined area from additional room s within the building the total volume of the roo
49. pletely 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 4 Manual Relief pne Discharge line to drain 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 type of gas 3 item number 4 parts description See Repair Parts Section for a list of available repair parts Removing the Manifold Assembly 1 Turn off the gas to the water heater at the manual shut off valve Figure 3 2 Depress the dial stop and turn the gas control knob on the combination gas control valve thermostat clockwise to the OFF position Figure 19 3 Remove the outer door a Figure 22 Igniter Button Dial Stop t Remove the two screws securing the manifold door assembly to the combustion chamber Figure 23 5 Disconnect the thermocouple right hand thread pilot tube the igniter wire from the igniter button the two connectors attached to the thermal switc
50. pliance 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 listed including formaldehyde carbon monoxide and soot 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 Charts Repair Parts Illustration INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes
51. rea 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 Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings IMPORTANT Always use a good grade of joint compound and be certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 13 Connect the cold water supply 3 4 NPT to the fitting marked C Connect the hot water supply 3 4 NPT to the fitting marked H IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a tempering valve or an anti scald device in th
52. 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 pe maximum Drain lt gt ca 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 221 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the data plate 14 IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve e Must not be in contact with any electrical part e Must be connec
53. ring Valve Installation Combination Space Heating Potable Water Heating System Domestic Hot Water Must be vertical to remove air bubbles Cold Water Flow Control Handler Shut off 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 manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident The new technology used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make any required installation upgrades or changes Questions Call 1 877 817 6750 Installation Checklist Water 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 th
54. rmal switch control valve thermostat firmly NO Secure connections from the gas control valve thermostat Using tripped y and attempt a relight F connected to the switch e a multimeter with alligator clip leads attach YES Are the wires damaged and or frayed YES Replace the gas control Check for insufficient valve thermostat YES combustion air Are there openings Install correct size make up air openings for make up air to NO gt per the Combustion Air Supply and enter the room YES Ventilation section in this manual Are the openings of sufficient size a z See Combustion Air Supply and Ventilation NOo gt Correct size of openings section in this manual for requirements to allow sufficient air YES Is there a furnace air as the water heater YES Does the return air duct for the furnace air handler draw its air from a separate location than the water Contact a local Heating Ventilation Air NO Conditioning amp Refrigeration authorized 2 i i i f A heater See the Location Requirements section service provider and the Combustion Air Supply section YES Is there proper drafting at the Check the vent system for restrictions obstructions and check drafthood See Checking the NOo gt the vent termination height Refer to the Installation Instructions Draft section in this manual section of this manual for specific requirements YES ee NO Refer to the Use amp
55. rmostat past the 120 F bar on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within 120 F 49 C more than 5 minutes 130 F 54 C at 20 seconds 140 F 60 C at 3 seconds 150 F 66 C at 1 1 2 seconds 160 F 71 C at less than 1 second a Figure 19 Robertshaw Gas Valve Thermostat Settings NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is expected to be more than normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces This will produce a sizzling or frying noise NOTE This condensation is normal and should not be confused with a leaking tank Condensation may increase or decrease at different times of the year High efficient energy saver water heaters will produce larger amounts of condensation on initial start up or when a l
56. structions 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 Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials 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 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 accumula
57. t 1 Manifold gasket properly sealed 5 No leaks at pilot and manifold connection 2 Viewport not damaged or cracked 6 Manifold door screws securely tightened 3 Flame trap free of debris and undamaged 7 Depress the button on the thermal switch 4 Two piece wire connector properly installed TROUBLESHOOTING CHART BURNER WILL NOT IGNITE 1 Pilot not lit Light pilot Thermostat set too low Turn temp dial to desired temperature No gas Check with gas utility company Dirt in the gas lines Notify utility install trap in gas line Pilot line clogged Clean locate source and correct Main burner line clogged Clean locate source and correct Non functioning thermocouple Replace thermocouple Non functioning thermostat Replace thermostat Heater installed in a confined area Provide fresh air ventilation BURNER FLAME YELLOW Insufficient secondary air Provide ventilation to water heater LAZY Low gas pressure Check with gas utility company Flue clogged Clean locate source and correct Main burner line clogged Clean locate source and correct Heater installed in a confined area Proper fresh air ventilation Obstruction in main burner orifice Clean or replace orifice PILOT WILL NOT LIGHT OR Non functioning igniter Replace igniter pilot assembly REMAIN LIT The thermal switch tripped See Pilot Light Troubleshooting Flowchart section Thermocouple connection loose Finger tighten then 1 4 turn with wrench 4
58. ted to an adequate discharge line e Must not be rated higher than the working pressure shown on the data plate of the water heater The Discharge Line e Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the dis charge line e Must terminate a maximum of six inches above a floor drain or external to the building e Must be capable of withstanding 250 F 121 C without distortion e Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation Some Models 1 Locate the T amp P Relief Valve on the water heater 2 Locate the slit running the length of the insulation 3 Spread this slit open and slip it 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 insul
59. ter be sure to use the new drafthood supplied with the water heater Figure 9 Drafthood Installation Sheet Metal Screws four provided W Drafthood Slots K o Jacket top Install the drafthood with the four screws provided R siots 10 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 drafthood outlet Vent Connectors 1 Type B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces crawl spaces or any confined or inaccessible location A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases e Install without
60. this product more sensitive to installation errors or improper installation environments Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes Consumer Information This water heater is design certified by CSA International as a Category I non direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition This is available from the following CSA America Inc 8501 East Pleasant Valley Road Cleveland OH 44131 National Fire Protection Agency 1 Batterymarch Park Quincy MA 02269 Check your phone listings for the local authorities having jurisdiction over your installation Consumer Responsibilities This manual has been prepared to acquaint you with the installation operation and maintenance of your gas water heater and provide important safety information in these areas Read all of the instructions thoroughly before attempting the installation or operation of this water heater Do not discard this manual You or future users of this water heater will need it for future reference Service to the Flame Lock Safety System should only be performed by a qual
61. tion 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 a Ground 1 Joint Check with local utility for minimum height 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 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
62. to installation and start up e Completely read all instructions before attempting to assemble and install this product After installation dispose of recycle all packaging materials AWARNING e Qt y 4 N J Y II 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 shuts 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 disable the water heater until the system is reset Note Not following these instructions an
63. 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 Close the cold water inlet valve Open a 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 Operating Your Water Heater 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 e Obstructions damage or deterioration in the venting system Make sure the ventilation and combustion air supplies are not obstructed e Build up of soot and carbon on the
64. wo 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 Replace 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 manifold assembly into the burner compartment making sure that the tab of the manifold tube engages in the slot of the bracket inside the combustion chamber Figure 28B 4 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber 5 Replace the two screws which secure the manifold assembly door to the combustion chamber and tighten securely Once the manifold assembly door is tightened visually inspect the door gasket between the manifold assembly door and the combustion chamber for spaces or gaps that would prevent a seal IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber 6 Reconnect the two wire leads to the thermal switch the manifold tubing pilot tubing and thermocouple to the gas control valve thermostat Do not cross thread or apply any thread sealant to these fittings The thermocouple nut should be started and turned

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