Instruction Manual RESIDENTIAL GAS WATER HEATERS NOT FOR USE IN MANUFACTURED (MOBILE) HOMES INSTALLATION - OPERATION - SERVICE - MAINTENANCE Low Lead Content 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.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE..................3 Outdoor Air Through Two Vertical Ducts.................... 18 APPROVALS...................................................................3 Air From Other Indoor Spaces................................... 18 Venting....................................................................... 19 GENERAL SAFETY INFORMATION...............................4 Gas Piping.................................................................
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY INFORMATION CAUTION Improper installation, use and service may result in property damage. • • • • • Do not operate water heater if any part has been exposed to flooding or water damage. Inspect anode rods regularly, replace when significantly depleted. Install in location with drainage. Fill tank with water before operation. Properly sized thermal expansion tanks are required on all closed water systems. Refer to this manual for installation and service.
INTRODUCTION PREPARING FOR THE INSTALLATION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. 1. Read the “General Safety” section, page 4 of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A. Vent Pipe I. Ground Joint Union Q. Temperature-Pressure Relief Valve B. Draft Hood J. Sediment Trap R. Rating Plate C. Anode K. Inner Door S. Flue Baffle(s) D. Hot Water Outlet L. Outer Door T. Gas Control Valve/Thermostat E. Outlet M. Union U. Drain Valve F. Insulation N. Inlet Water Shut-off Valve V. Pilot and Main Burner G. Gas Supply O. Cold Water Inlet W. Flue H. Manual Gas Shut-off Valve P. Inlet Dip Tube X.
TYPICAL INSTALLATION Figure 2. MIXING VALVE USAGE APPLICATION/USE OF WATER HEATER HOTTER WATER CAN SCALD This Water Heater has been design certified as complying with ANSI Z21.10.3-CSA 4.3 current edition for water heaters and is considered suitable for: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact.
TYPICAL INSTALLATION FACTS TO CONSIDER ABOUT THE LOCATION Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the water heater. This water heater is not for use in manufactured (mobile) homes or outdoor installation. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed: 1.
The resulting flashback and fire can cause death or serious burns to anyone in the area, as well as property damage. If installation in such areas is your only option, then installation must be accomplished in a way that the pilot flame and main burner flame are elevated from floor at least 18 inches.
CLEARANCES Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 4” (102 mm) at the front, and 6” (153 mm) from the vent pipe. Clearance from the top of the jacket is 12” (305 mm). Figure 4. NORMAL FLAMES If flames are seen to lift from the burner ports, gradually close the air shutter until a stable flame is achieved. See Figure 5. Figure 8. CLEARANCES Figure 5.
If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater or water heaters be installed so that combustion and ventilation air be taken from outside these areas. Should you choose to apply an insulation blanket to this heater, you should follow these instructions. See Leakage Test Points (page 31) for identification of components mentioned below.
INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS GAS PRESSURE REQUIREMENTS Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate.
WATER PIPING MIXING VALVES WATER (POTABLE) HEATING AND SPACE HEATING Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance. Children, the elderly and the physically or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering.
TEMPERATURE-PRESSURE RELIEF VALVE Explosion Hazard Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code. Properly sized temperaturepressure relief valve must be installed in opening provided. Can result in overheating and excessive tank pressure. Can cause serious injury or death. This water heater is provided with a properly rated/ sized and certified combination temperature-pressure relief valve (T&P valve) by the manufacturer.
No valve or other obstruction is to be placed between the temperature-pressure relief valve and the tank. Do not connect discharge piping directly to the drain unless a 6” (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in adequate quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.
AIR REQUIREMENTS UNUSUALLY TIGHT CONSTRUCTION In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of unusually tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.) additional air must be provided using the methods described in that follows.
The required size of openings for combustion, ventilation and dilution air shall be based on the “net free area” of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size of opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25% free area and metal louvers and grilles will have 75% free area.
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS Figure 14. FRESH AIR FROM TWO VERTICAL DUCTS The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See Figure 14. Figure 13.
Such temperatures may not be high enough to properly open thermally operated vent dampers. This would cause spillage of the flue gases and may cause carbon monoxide poisoning. Vent dampers must bear evidence of certification as complying with the current edition of the American National Standard ANSI Z21.66 CGA 6.14 (covering electrically and mechanically actuated vent dampers). Before installation of any vent damper, consult the local gas utility for further information.
Figure 17. VENT PIPE MINIMUM UPWARD SLOPE There must be a minimum of 6” (153 mm) clearance between single wall vent pipe and any combustible material. Fill and seal any clearance between single wall vent pipe and combustible material with mortar mix, cement, or other noncombustible substance. For other than single wall, follow vent pipe manufacturer’s clearance specifications. To insure a tight fit of the vent pipe in a brick chimney, seal around the vent pipe with mortar mix cement.
GAS PIPING • Contact your local gas service company to ensure that adequate gas service is available and to review applicable installation codes for your area. A flexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit. Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open flame. Rinse off soapy solution and wipe dry.
Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases. The water heater and its gas connection must be leak tested before placing the water heater in operation.
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. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo- 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 electric spark gas ignition system.
TEMPERATURE REGULATION Short repeated heating cycles caused by small hot water uses can cause the temperature to exceed the thermostat setting by up to 30°F (16.7°C). If you experience this type of use you should consider using lower temperature settings to reduce scald hazards. Any water heater’s intended purpose is to heat water. Hot water is needed for cleansing, cleaning, and sanitizing (bodies, dishes, clothing). Untempered hot water can present a scald hazard.
FOR YOUR INFORMATION START-UP CONDITIONS Use this formula to “clock” the meter. Be sure that other gas consuming appliances are not operating during this interval. DRAFT HOOD OPERATIONS Check draft hood operation by performing a worst case depressurization of the building.
Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. Do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided. OPERATIONAL CONDITIONS AIR IN HOT WATER FAUCETS SMELLY WATER HYDROGEN GAS: 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 explosive.
PERIODIC MAINTENANCE VENTING SYSTEM INSPECTION BURNER INSPECTION Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a flooded water heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualified installer or service agency to replace a flooded water heater.
AIR SHUTTER ADJUSTMENT ANODE ROD INSPECTION If the installation is at a high elevation and the burner flame exhibits flame lifting and/or noise, do the following: 1. Use a screw driver to loosen the air shutter screw. 2. Adjust the air shutter by rotating the shutter. Counter clockwise to close and Clockwise to open. a. Close air shutter - to prevent noisy flames that are lifting from the burner ports. Remove and inspect the anode rod. See Figure 1 (page 6) for location of the anode rod.
be extremely hot. Use care when operating valve as the valve may be hot. To check the relief valve, lift the lever at the end of the valve several times, see Figure 22. The valve should seat properly and operate freely. Explosion Hazard Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code.
DRAINING AND FLUSHING TO FLUSH THE WATER HEATER STORAGE TANK: 1. Ensure the cold water inlet valve is open. It is recommended that the water heater storage tank be drained and flushed every 6 months to reduce sediment buildup. The water heater should be drained if being shut down during freezing temperatures. See Figure 25 for the location of the water heater components described below. 2. Open a nearby hot water faucet and let the water run until the water is no longer hot.
LEAKAGE TEST POINTS A. Water at the draft hood is water vapor which has condensed out of the combustion products. This is caused by a problem in the vent. Contact the gas utility. B. *Condensation may be seen on pipes in humid weather or pipe connections may be leaking. C. *The anode rod fitting may be leaking. D. Small amounts of water from temperature-pressure relief valve may be due to thermal expansion or high water pressure in your area. E.
4. Disconnect the igniter wire from the igniter lead wire. Use needle nose pliers to disconnect the red (+) and white (-) thermopile wires. Disconnect the pilot tube (7/16” wrench) and manifold tube (3/4” wrench) at the gas control valve/thermostat. See Figure 23 (page 32). water heater. Many suspected leaks are not leaking tanks. Often the source of the water can be found and corrected. Read this manual first.
REPLACING THE GAS CONTROL VALVE/THERMOSTAT: 1. To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/thermostat, thread a 4” section of gas pipe into the inlet and use it to turn the gas control valve/thermostat (clockwise). DO NOT OVER TIGHTEN; damage may result. 2. 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 the tank. 3.
Table 5. STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED Status Problem Corrective Action 0 FLASHES (LED NOT LIT) Pilot light is not lit or Thermopile has not yet reached normal operating temperature. Turn Gas Control Valve/Thermostat knob to OFF. Wait 10 minutes, then attempt to relight Pilot by following the lighting instructions on the water heater’s label. Until the Thermopile reaches its normal operating temperature, the Status Light will not blink, even if the Pilot is lit.
Table 5. STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED Status Problem Corrective Action 5 FLASHES The temperature sensor (thermistor) is defective. Turn Gas Control Valve/Thermostat knob to OFF. Turn Main Gas Supply OFF. Replace the Gas Control Valve/ Thermostat. See Removing and Replacing the Gas Control Valve/Thermostat (page 32). 7 FLASHES Gas Control Valve failure. Turn Gas Control Valve/Thermostat knob to OFF. Turn Main Gas Supply OFF. Replace the Gas Control Valve/ Thermostat.
Table 6. GENERAL TROUBLESHOOTING GUIDELINES These guidelines should be used by a qualified service agent. Symptom WATER LEAKS LEAKING T&P VALVE SMELLY WATER PILOT WILL NOT LIGHT Problem Corrective Action Improperly sealed, hot or cold supply connection, relief valve, drain valve, or thermostat threads. Tighten threaded connections. Leakage from other appliances or water lines. Inspect other appliances near water heater. Condensation of flue products. See Condensation (page 25).
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