1

Instruction Manual

PRINTED 0712 315628-001

Keep thIs Manual In the pocKet on heater for future reference whenever MaIntenance adjustMent or servIce Is requIred.

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

all technIcal and warrantY questIons: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

resIdentIal Gas water heaters

• for Your safety •AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

Low Lead Content

2

safe InstallatIon, use and servIceYour safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

all safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury.

the california safe drinking water and toxic enforcement act requires the Governor of california to publish a list of substances known to the state of california to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

warnInG: this product contains a chemical known to the state of california to cause cancer, birth defects, or other reproductive harm.

This water heater can cause low-level exposure to some of the substances included in the Act. This product is certified to comply with a maximum weighted average of 0.25% lead content as required in some areas.

IMportant defInItIons

• Qualified Installer: Aqualifiedinstallermusthaveabilityequivalenttoalicensedtradesmaninthefieldsofplumbing, airsupply,ventingandgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGas Code as it relates to the installation of gas firedwater heaters.The qualified installermust have a thorough understandingofthisinstructionmanual.

• service agency: Aserviceagencyalsomusthaveabilityequivalenttoalicensedtradesmaninthefieldsofplumbing, airsupply,ventingandgassupply,includingathoroughunderstandingoftherequirementsoftheNationalFuelGas Codeas it relates to the installationofgasfiredwaterheaters. Theserviceagencymustalsohavea thorough understandingofthisinstructionmanual,andbeabletoperformrepairsstrictlyinaccordancewiththeserviceguidelines providedbythemanufacturer.

• Gas supplier: TheNaturalGasorPropaneUtilityorservicewhichsuppliesgasforutilizationbythegasburning applianceswithinthisapplication.Thegassuppliertypicallyhasresponsibilityfortheinspectionandcodeapprovalof gaspipinguptoandincludingtheNaturalGasmeterorPropanestoragetankofabuilding.Manygassuppliersalso offerserviceandinspectionofapplianceswithinthebuilding.

DANGER indicates an imminentlyhazardous situation which, if not avoided,will result in injury or death.

This is the safety alert symbol. It is used to alert you topotential personal injury hazards. Obey all safetymessages that follow this symbol to avoid possibleinjury or death.

WARNING indicates a potentially hazardoussituation which, if not avoided, could resultin injury or death.

CAUTION indicates a potentially hazardoussituation which, if not avoided, could result inminor or moderate injury.

CAUTION used without the safety alertsymbol indicates a potentially hazardoussituation which, if not avoided, could result inproperty damage.

WARNING

CAUTION

CAUTION

DANGER

3

General safetY

4

SAFE INSTALLATION, USE AND SERVICE............................2GENERAL SAFETY..................................................................3TABLE OF CONTENTS ............................................................4INTRODUCTION ......................................................................4 PreparingfortheNewInstallation .....................................4TYPICAL INSTALLATION ......................................................5,6LOCATING THE NEW WATER HEATER ............................. 7-9 FactstoConsiderAboutLocation ..................................7,8 InsulationBlankets ............................................................8 CombustionAirandVentilationforAppliances LocatedinUnconfinedSpaces .........................................8 CombustionAirandVentilationforAppliances LocatedinConfinedSpaces ..........................................8,9INSTALLING THE NEW WATER HEATER ...................... 10-14 WaterPiping ..............................................................10,11 ClosedWaterSystem .....................................................10 ThermalExpansion .........................................................10 Temperature-PressureReliefValve ................................11 FillingtheWaterHeater ..................................................12 Venting .......................................................................12,13 GasPiping .................................................................13,14 SedimentTraps ...............................................................14LIGHTING & OPERATING INSTRUCTIONS ....................15,16TEMPERATURE REGULATION ............................................17FOR YOUR INFORMATION ..............................................17,18

StartUpConditions ....................................................17,18 DraftHoodOperation ...................................................17 Condensation ..........................................................17,18 Smoke/Odor .................................................................18 ThermalExpansion ......................................................18 StrangeSounds ...........................................................18 OperationalConditions ...................................................18 SmellyWater ................................................................18 “Air”inHotWaterFaucets ...........................................18 HighTemperatureShutOffSystem .............................18PERIODIC MAINTENANCE ............................................. 19-21 VentingSystemInspection..............................................19 BurnerInspection ............................................................19 BurnerCleaning ..............................................................19 Housekeeping ............................................................19,20 AnodeRodInspection.....................................................20 Temperature-PressureReliefValveOperation ...............20 DrainingandFlushing .....................................................20 DrainValveWasherReplacement ..................................20 Service ............................................................................21LEAKAGE CHECKPOINTS ....................................................21REPAIR PARTS ......................................................................22TROUBLESHOOTING GUIDELINES .....................................23WARRANTY ......................................................................Insert

thank Youforpurchasingthiswaterheater.Properlyinstalledandmaintained,itshouldgiveyouyearsoftroublefreeservice.

AbbreviationsFoundInThisInstructionManual:

• UL-UnderwritersLaboratoriesInc.• ANSI-AmericanNationalStandardsInstitute• NFPA-NationalFireProtectionAssociation• ASME-AmericanSocietyofMechanicalEngineers• AHRI-Air-Conditioning,HeatingandRefrigerationInstitute• CAN-Canada• EPACT-EnergyPolicyAct• CSA-CanadianStandardsAssociationThis gas-firedwater heater is design certified byUnderwritersLaboratoriesInc.underAmericanNationalStandard/CSAStandard forGasWaterHeatersANSIZ21.10.3•CSA4.3(currentedition).

preparInG for the InstallatIon

1. Read the “General Safety” section, page 3 of thismanualfirstandthentheentiremanualcarefully. Ifyoudon’t followthesafetyrules,thewaterheaterwillnotoperateproperly.Itcould causeDEATH, SERIOUSBODILY INJURYAND/ORPROPERTY DAMAGE.

Thismanualcontainsinstructionsfortheinstallation,operation,andmaintenanceofthegas-firedwaterheater.Italsocontainswarningsthroughout themanual thatyoumust readandbeawareof. Allwarningsandallinstructionsareessentialtotheproperoperationofthewaterheaterandyoursafety.Sincewecannotputeverything

on thefirst fewpages,read the entIre Manual Before atteMptInG to Install or operate the water heater.

2.Theinstallationmustconformwiththeseinstructionsandthelocalcodeauthorityhavingjurisdiction.Intheabsenceoflocalcodes,installationsshallcomplywiththeNationalFuelGasCodeANSIZ223.1/NFPA54currentaddition.ThispublicationisavailablefromtheCSAInternational,8501EastPleasantValleyRd.,ClevelandOhio 44131, or TheNational Fire ProtectionAssociation, 1BatterymarchPark,Quincy,MA02269.

3.Ifafter reading thismanualyouhaveanyquestionsordonot understandanyportionoftheinstructions,callthelocalgasutilityorthemanufacturerwhosenameappearsontheratingplate.

4.Carefullyplan theplacewhereyouaregoing toput thewaterheater.Correctcombustion,ventaction,andventpipeinstallationare very important in preventing death frompossible carbonmonoxidepoisoningandfires.SeeFigures3and8.

Examinethelocationtoensurethewaterheatercomplieswiththe“LocatingtheNewWaterHeater”sectioninthismanual.

5.ForCalifornia installation thiswater heatermust be braced,anchored, or strapped to avoid falling ormoving during anearthquake.Seeinstructionsforcorrectinstallationprocedures.InstructionsmaybeobtainedfromCaliforniaOfficeoftheStateArchitect,400PStreet,Sacramento,CA95814.

6.MassachusettsCoderequiresthiswaterheatertobeinstalledinaccordancewithMassachusetts248-CMR2.00:StatePlumbingCodeand248-CMR5.00.

IntroductIon

taBle of contents

5

tYpIcal InstallatIonGet to Know Your water heater - Gas Models

a vent pipe B drafthood c anode d hot water outlet e outlet f Insulation G Gas supply h Manual Gas shut-off valve

fIGure 1.

I Ground joint union j sediment trap K Inner door l outer door M union n Inlet water shut-off valve o cold water Inlet p Inlet dip tube

q temperature-pressure relief valve r rating plate S Flue Baffle(s) t Gas control valve/thermostat u drain valve v pilot and Main Burner w flue X Metal drain pan

(V) PILOT & MAIN BURNER - NATURAL GAS

(T) GAS CONTROL VALVE/THERMOSTAT

MaIn Burner

therMocouplepIlot

Burner

(V) PILOT & MAIN BURNER - PROPANE GAS

**closed water sYsteMs are those wIth BacK flow preventIon devIces Installed In the water servIce lIne.

* Install In accordance wIth local codes.

* sedIMent trap as requIred BY local codes.

* all pIpInG MaterIals to Be supplIed BY custoMers.

6

tYpIcal InstallatIon

fIGure 2.

MIXInG valve usaGe

ThiswaterheaterhasbeendesigncertifiedascomplyingwithANSIZ21.10.3currenteditionforwaterheatersandisconsideredsuitablefor:

Water (Potable) Heating and Space Heating:Allmodels areconsideredsuitableforwater(potable)heatingandspaceheating.

HOTTERWATERCANSCALD:

Waterheatersareintendedtoproducehotwater.Waterheatedtoa temperaturewhichwillsatisfyspaceheating,clotheswashing,dishwashing,andothersanitizingneedscanscaldandpermanentlyinjure you upon contact. Some people aremore likely to bepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,theinfirm,orphysically/mentallyhandicapped.Ifanyoneusinghotwaterinyourhomefitsintooneofthesegroupsor if there is a local code requiring a certain temperaturewateratthehotwatertap,thenyoumusttakespecialprecautions. Inaddition to using the lowest possible temperature setting thatsatisfiesyourhotwaterneeds,ameanssuchasa*MixingValveshouldbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater.Mixingvalvesareavailableatplumbingsupplyorhardwarestores.Consultaqualifiedinstallerorserviceagency.Followmixingvalvemanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,read the “TemperatureRegulation” section in thismanual, seeFigures15and16.

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facts to consIder aBout the locatIonCarefully choose an indoor location for the newwater heater,becausetheplacementisaveryimportantconsiderationforthesafetyoftheoccupantsinthebuildingandforthemosteconomicaluse of thewater heater.this water heater is not for use in manufactured (mobile) homes or outdoor installation.Whetherreplacinganoldwaterheaterorputtingthewaterheaterinanewlocation,thefollowingcriticalpointsmustbeobserved:1.Selectalocationindoorsascloseaspracticaltothegasventor

chimneytowhichthewaterheaterventisgoingtobeconnected,andascentralizedwiththewaterpipingsystemaspossible.

2.Selected location must provide adequate clearances forservicingandproperoperationofthewaterheater.

Keepcombustiblessuchasboxes,magazines,clothes,etc.,awayfromthewaterheaterarea.

Installationofthewaterheatermustbeaccomplishedinsuchamannerthat if tankoranyconnectionsshould leak, theflowwillnotcausedamagetothestructure.Forthisreason,itisnotadvisabletoinstallwaterheaterinanatticorupperfloor.Whensuchlocationscannotbeavoided,asuitablemetaldrainpanshouldbeinstalledunderthewaterheater.Metaldrainpansareavailableatyourlocalhardwarestore.Suchametaldrainpanmusthaveaminimumlengthandwidthofatleast2”(51mm)greaterthanthewaterheaterdimensionsandmustbepipedtoanadequatedrain.Thepanmustnotrestrictcombustionairflow.Waterheaterlifedependsuponwaterquality,waterpressureandtheenvironmentinwhichthewaterheaterisinstalled.Waterheatersaresometimesinstalledinlocationswhereleakagemayresultinpropertydamage,evenwiththeuseofadrainpanpipedtoadrain.However,unanticipateddamagecanbereducedorpreventedbyaleakdetectororwatershut-offdeviceused inconjunctionwithapipeddrainpan.Thesedevicesareavailablefromsomeplumbingsupplywholesalersandretailers,anddetectandreacttoleakageinvariousways:• Sensorsmountedinthedrainpanthattriggeranalarmorturnoff

theincomingwatertothewaterheaterwhenleakageisdetected.• Sensorsmountedinthedrainpanthatturnoffthewatersupply

totheentirehomewhenwaterisdetectedinthedrainpan.• Watersupplyshut-offdevicesthatactivatebasedonthewater

pressuredifferentialbetweenthecoldwaterandhotwaterpipesconnectedtothewaterheater.

• Devicesthatwillturnoffthegassupplytoagaswaterheaterwhileatthesametimeshuttingoffitswatersupply.

locatInG the new water heater

INSTALLATIONS INAREASWHERE FLAMMABLE LIQUIDS(VAPORS)ARELIKELYTOBEPRESENTORSTORED(GARAGES,STORAGEANDUTILITYAREAS,ETC.):Flammableliquids(suchasgasoline,solvents,propane[LPorbutane,etc.]andothersubstancessuchasadhesives,etc.)emitflammablevaporswhichcanbeignitedbyagaswaterheater’spilotlightormainburner.Theresultingflashbackandfirecancausedeathorseriousburnstoanyoneinthearea,aswellaspropertydamage.Ifinstallationinsuchareasisyouronlyoption,thentheinstallationmustbeaccomplishedinawaythatthepilotflameandmainburnerflameareelevatedfromtheflooratleast18inches.Whilethismayreducethechancesofflammablevapors,fromafloorspillbeingignited,gasolineandotherflammablesubstancesshouldneverbestoredorusedinthesameroomorareacontainingagaswaterheaterorotheropenflameorsparkproducingappliance.NOTE:Flammablevaporsmaybedrawnbyaircurrentsfromotherareasofthestructuretotheappliance.Also,thewaterheatermustbelocatedand/orprotectedsoitisnotsubjecttophysicaldamagebyamovingvehicle.

This water heatermust not be installed directly on carpeting.Carpetingmustbeprotectedbymetalorwoodpanelbeneaththewaterheaterextendingbeyond the fullwidthanddepthofwaterheaterbyatleast3”(76.2mm)inanydirection,orifthewaterheaterisinstalledinanalcoveorcloset,theentirefloormustbecoveredbythepanel.Failuretoheedthiswarningmayresultinafirehazard.

8

Minimumclearancesbetween thewater heater and combustiblematerialsare0inchatthesidesandrear,4”(102mm)atthefront,and6”(153mm)fromtheventpipe.Clearancefromthetopofthejacketis12”(305mm)onmostmodels.Notethatalesserdimensionmaybeallowedonsomemodels,refertothelabelattachedadjacenttothegascontrolvalveonthewaterheater,seeFigure3.

fIGure 3.

Agaswaterheatercannotoperateproperlywithoutthecorrectamountofairforcombustion.Donotinstallinaconfinedareasuchasacloset,unlessyouprovideairasshowninthe“LocatingTheNewWaterHeater”section.Neverobstructtheflowofventilationair.Ifyouhaveanydoubtsorquestionsatall,callyourgassupplier.Failuretoprovidetheproperamountofcombustionaircanresultinafireorexplosionandcausedeath,seriousbodilyinjury,orpropertydamage.

fIGure 4.

Ifthiswaterheaterwillbeusedinbeautyshops,barbershops,cleaning establishments,orself-servicelaundrieswithdrycleaningequipment,itisimperativethatthewaterheaterorwaterheatersbeinstalledsothatcombustionandventilationairbetakenfromoutsidetheseareas.

Propellantsof aerosol spraysandvolatile compounds, (cleaners, chlorinebasedchemicals,refrigerants,etc.)inadditiontobeinghighlyflammableinmanycases,willalsochangetocorrosivehydrochloricacidwhenexposedtothecombustionproductsofthewaterheater.Theresultscanbehazardous,andalsocauseproductfailure.

InsulatIon BlanKets

Insulationblanketsareavailabletothegeneralpublicforexternaluseongaswaterheatersbutarenotnecessarywiththeseproducts.Thepurposeofaninsulationblanketistoreducethestandbyheatlossencounteredwithstoragetankheaters.YourwaterheatermeetsorexceedstheEPACTstandardswithrespecttoinsulationandstandbylossrequirements,makinganinsulationblanketunnecessary.

Shouldyouchoosetoapplyaninsulationblankettothisheater,you should followthese instructions(For identificationofcomponentsmentionedbelow,seeFigure1).Failuretofollowtheseinstructionscanrestricttheairflowrequiredforpropercombustion,potentiallyresultinginfire,asphyxiation,seriouspersonalinjuryordeath.

• Donotapplyinsulationtothetopofthewaterheater,asthiswill interferewithsafeoperationofthedrafthood.• Donotcovertheouterdoor,gascontrolvalve/thermostator temperature&pressurereliefvalve.

• Donotallowinsulationtocomewithin2”(50.8mm)ofthefloorto preventblockageofcombustionairflowtotheburner.

• Donotcovertheinstructionmanual.Keepitonthesideofthe waterheaterornearbyforfuturereference.

• Doobtainnewwarningandinstructionlabelsfromthemanufacturer forplacementontheblanketdirectlyovertheexistinglabels.

• Do inspect the insulationblanket frequently tomakecertain it doesnotsag,therebyobstructingcombustionairflow.

coMBustIon aIr and ventIlatIon for applIances located In unconfIned spaces

unconfIned space is spacewhose volume is not less than 50cubicfeetper1,000Btuperhour(4.8m3perkW)oftheaggregateinput rating of all appliances installed in that space. Roomscommunicatingdirectlywiththespaceinwhichtheappliancesareinstalled,throughopeningsnotfurnishedwithdoors,areconsideredapartoftheunconfinedspace.

Inunconfinedspacesinbuildings,infiltrationmaybeadequatetoprovideairforcombustion,ventilationanddilutionoffluegases.However,inbuildingsoftightconstruction(forexample,weatherstripping,heavilyinsulated, caulked, vaporbarrier, etc.), additionalairmayneed tobeprovidedusing themethodsdescribed in “CombustionAirandVentilationforAppliancesLocatedinConfinedSpaces.”

coMBustIon aIr and ventIlatIon for applIances located In confIned spaces

confIned spaceisaspacewhosevolumeislessthan50cubicfeetper1,000Btuperhour(4.8m3perkW)oftheaggregateinputratingofallappliancesinstalledinthatspace.

9

a. all aIr froM InsIde BuIldInGs: (SeeFigures4and5)

Theconfinedspaceshallbeprovidedwithtwopermanentopeningscommunicating directlywith an additional room(s) of sufficientvolume so that the combined volume of all spacesmeets thecriteriaforanunconfinedspace.Thetotalinputofallgasutilizationequipmentinstalledinthecombinedspaceshallbeconsideredinmaking this determination.Eachopening shall haveaminimumfreeareaofonesquareinchper1,000Btuperhour(22cm2/kW)ofthetotalinputratingofallgasutilizationequipmentintheconfinedspace,butnotlessthan100squareinches(645cm2).Oneopeningshallcommencewithin12”(30cm)ofthetopandonecommencingwithin12”(30cm)ofthebottomoftheenclosures.

fIGure 5.

B. all aIr froM outdoors:(SeeFigures6,7and8)

The confined space shall be provided with two permanentopenings,onecommencingwithin12”(30cm)ofthetopandone commencingwithin12”(30cm)fromthebottomoftheenclosure.Theopeningsshallcommunicatedirectly,orbyducts,withtheoutdoorsorspaces(crawlorattic)thatfreelycommunicatewiththeoutdoors.

1.Whendirectlycommunicatingwiththeoutdoors,eachopeningshall haveaminimumfreeareaof1squareinchper4,000Btuperhour (5.5cm2/kW)oftotalinputratingofallequipmentintheenclosure,seeFigure6.

fIGure 6.

2.Whencommunicatingwith theoutdoors throughverticalducts, eachopeningmusthaveaminimumfreeareaof1squareinchper4,000Btuperhour(5.5cm2/kW)oftotalinputratingofallequipmentintheenclosure,seeFigure7.

3. Whencommunicatingwiththeoutdoorsthroughhorizontalducts, eachopeningshallhaveaminimumfreeareaof1squareinchper2,000Btuperhour(11cm2/kW))oftotalinputratingofallequipmentintheenclosure,seeFigure8.

fIGure 7.

4. Whenductsareused,theyshallbeofthesamecross-sectionalareaasthefreeareaoftheopeningstowhichtheyconnect.Theminimumshortsidedimensionofrectangularairductsshallnotbelessthan3”(76.2mm),seeFigure8.

5.Alternatively a single permanent openingmaybeusedwhencommunicatingdirectlywith theoutdoors, orwith spaces thatfreelycommunicatewiththeoutdoors.Theopeningshallhaveaminimumfreeareaof1squareinchper3,000BTUperhour(8.3cm2/kW)oftotalinputratingofallequipmentinenclosure.SeeFigure8A.

fIGure 8.

6. LouversandGrilles:Incalculatingfreearea,considerationshallbegiventotheblockingeffectoflouvers,grillesorscreensprotectingopenings.Screensusedshallnotbesmallerthan1/4inch(6.4mm)mesh.Ifthefreeareathroughadesignoflouverorgrilleisknown,itshouldbeusedincalculatingthesizeopeningrequiredtoprovidethefreeareaspecified.Ifthedesignandfreeareaisnotknown,itmaybeassumedthatwoodlouverswillbe20-25percentfreeareaandmetallouversandgrilleswillhave60-75percentfreearea.Louversandgrillesshallbefixedintheopenpositionorinterlockedwiththeequipmentsothattheyareopenedautomaticallyduringequipmentoperation.

7.SpecialConditionsCreatedbyMechanicalExhaustingorFireplaces:operationofexhaust fans,ventilationsystems,clothesdryersorfireplacesmaycreateconditionsrequiringspecialattentiontoavoidunsatisfactoryoperationofinstalledgasutilizationequipment.

fIGure 8a.

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water pIpInG

HOTTERWATERCANSCALD:

Waterheatersareintendedtoproducehotwater.Waterheatedtoatemperaturewhichwillsatisfyspaceheating,clotheswashing,dishwashing,cleaningandothersanitizingneedscanscaldandpermanently injure you upon contact. Some people aremorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseinclude the elderly, children, the infirm, or physically/mentallyhandicapped.Ifanyoneusinghotwaterinyourhomefitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthelowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasa*mixingvalveshouldbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater,seeFigure2.Valvesforreducingpointofusetemperaturebymixingcoldandhotwaterarealsoavailable.Consult a qualified installer or service agency. Followmanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,readthe“TemperatureRegulation”sectioninthismanual.

Thiswaterheatershallnotbeconnectedtoanyheatingsystemsorcomponent(s)usedwithanon-potablewaterheatingappliance.

Allpipingcomponentsconnectedtothisunitforspaceheatingapplicationsshallbesuitableforusewithpotablewater.

Toxicchemicals,suchasthoseusedforboilertreatmentshallnotbeintroducedintothissystem.

When the system requi res water for space heat ing attemperatureshigherthanrequiredfordomesticwaterpurposes,a temperingvalvemustbe installed.Pleaserefer toFigure2forsuggestedpipingarrangement.Thewatersupplypressureshouldnotexceed80psi. If thisoccurs,apressurereducingvalvewithabypassshouldbeinstalledinthecoldwaterinletline.Thisshouldbeplacedonthesupplytotheentirehouseinordertomaintainequalhotandcoldwaterpressures.

These water heaters cannot be used in space heat ingapplicationsonly.

InstallInG the new water heaterclosed water sYsteMsWater supply systems may, because of code requirementsor such conditions as high line pressure, among others, haveinstalled devices such as pressure reducing valves, checkvalves,andbackflowpreventers.Devicessuchasthesecausethewatersystemtobeaclosedsystem.

therMal eXpansIonAswaterisheated,itexpands(thermalexpansion).Inaclosedsystemthevolumeofwaterwillgrowwhenit isheated.Asthevolumeofwatergrowstherewillbeacorrespondingincreaseinwaterpressureduetothermalexpansion.Thermalexpansioncancauseprematuretankfailure(leakage).Thistypeoffailureisnotcoveredunderthelimitedwarranty.ThermalexpansioncanalsocauseintermittentTemperature-PressureReliefValveoperation:waterdischargedfromthevalveduetoexcessivepressurebuildup. This condition is not covered under the limited warranty.TheTemperature-PressureReliefValve isnot intended for theconstantreliefofthermalexpansion.

A properly sized thermal expansion tankmust be installed onall closed systems to control the harmful effects of thermalexpansion.Contacta localplumbingserviceagency tohaveathermalexpansiontankinstalled.

Watersupplysystemsmay,becauseofsucheventsashighlinepressure,frequentcut-offs,theeffectsofwaterhammeramongothers,haveinstalleddevicessuchaspressurereducingvalves,checkvalves,backflowpreventers,etc.tocontrolthesetypesofproblems.Whenthesedevicesarenotequippedwithaninternalby-pass,andnoothermeasuresare taken, thedevicescausethewatersystemtobeclosed. Aswater isheated, itexpands(thermal expansion) and closed systems do not allow for theexpansionofheatedwater.

Thewaterwithinthewaterheatertankexpandsasitisheatedandincreasesthepressureofthewatersystem.Iftherelievingpointofthewaterheater’stemperature-pressurereliefvalveisreached,the valvewill relieve theexcesspressure. the temperature-pressure relief valve is not intended for the constant relief of thermal expansion.Thisisanunacceptableconditionandmustbecorrected.

Itisrecommendedthatanydevicesinstalledwhichcouldcreatea closed system have a by-pass and/or the system have anexpansiontanktorelievethepressurebuiltbythermalexpansioninthewatersystem.Expansiontanksareavailablefororderingthrough a local plumbing contractor. Refer to the “ThermalExpansion”sectioninthismanualand/orcontactthelocalwatersupplier and/or a service agency for assistance in controllingthesesituations.

note: to protect against untimely corrosion of hot and cold water fittings, it is strongly recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe.

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fIGure 9.

Figure9showsthetypicalattachmentofthewaterpipingtothewaterheater.Thewaterheater isequippedwith1”NPTthreadednipple (75gallonmodels)or1.25”NPTthreadednipple(100gallonmodels)waterconnections.

note: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. do not solder the cold water supply line directly to the cold water inlet. It will harm the dip tube and damage the tank.

teMperature-pressure relIef valve

This heater is provided with a properly certified combination temperature-pressurereliefvalvebythemanufacturer.

Thevalve iscertifiedbyanationally recognized testing laboratorythatmaintainsperiodicinspectionofproductionoflistedequipmentofmaterialsasmeetingtherequirementsforReliefValvesforHotWaterSupplySystems,ANSIZ21.22•CSA4.4,andthecoderequirementsofASME.

Ifreplaced,thevalvemustmeettherequirementsoflocalcodes,butnot less thanacombination temperatureandpressure reliefvalvecertifiedasindicatedintheaboveparagraph.

The valvemust bemarkedwith amaximum set pressure not toexceedthemarkedmaximumworkingpressureofthewaterheater (150psi=1,035kPa)andadischargecapacitynotlessthanthewaterheaterinputrateasshownonthemodelratingplate.

Forsafeoperationofthewaterheater,thereliefvalvemustnotberemovedfromitsdesignatedopeningnorplugged.

Thetemperature-pressurereliefvalvemustbeinstalleddirectlyintothefittingofthewaterheaterdesignedforthereliefvalve.Positionthevalvedownwardandprovidetubingsothatanydischargewillexitonlywithin6”(153mm)above,oratanydistancebelowthestructuralfloor.Becertainthatnocontactismadewithanyliveelectricalpart.Thedischargeopeningmustnotbeblockedorreducedinsizeunderanycircumstances.Excessivelength,over30’(9.14m),oruseofmorethanfourelbowscancauserestrictionandreducethedischargecapacityofthevalve,seeFigure10.

Novalveorotherobstructionistobeplacedbetweenthereliefvalveandthetank.Donotconnecttubingdirectlytodischargedrainunlessa6inchairgapisprovided.Topreventbodilyinjury,hazardtolife,orpropertydamage,thereliefvalvemustbeallowedtodischargewaterinquantitiesshouldcircumstancesdemand.Ifthedischargepipeisnotconnectedtoadrainorothersuitablemeans,thewaterflowmaycausepropertydamage.

TheDischargePipe:• Shouldnotbesmallerinsizethantheoutletpipesizeofthevalve,or haveanyreducingcouplingsorotherrestrictions.• Shouldnotbepluggedorblocked.• Shouldbeofmateriallistedforhotwaterdistribution.• Shouldbeinstalledsoastoallowcompletedrainageofboththe temperature-pressurereliefvalve,andthedischargepipe.• Mustterminateamaximumofsixinchesaboveafloordrainorexternaltothebuilding.Incoldclimates,itisrecommendedthatthedischargepipebeterminatedatanadequatedraininsidethebuilding.

• Shouldnothaveanyvalvebetweenthereliefvalveandtank.

Thetemperature-pressurereliefvalvemustbemanuallyoperatedatleastonceayear.Cautionshouldbetakentoensurethat(1)nooneisinfrontoforaroundtheoutletofthetemperature-pressurerelief valvedischargeline,and(2)thewatermanuallydischargedwillnotcauseanybodilyinjuryorpropertydamagebecausethewatermaybeextremelyhot.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetandcontinues to releasewater, immediately close the coldwater inlettothewaterheater,followthedraininginstructions,andreplacethetemperature-pressurereliefvalvewithanewone.

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fIGure 10.

fIllInG the water heater

Neveruse thiswater heater unless it is completely full ofwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gastothewaterheater.Tofillthewaterheaterwithwater:1.Closewater heater drain valveby turninghandle to the right

(clockwise).Thedrainvalveisonthelowerfrontofwaterheater.2. Open the cold water supply valve to the water heater.

note: the cold water supply valve must be left open when the water heater is in use.

3.Toinsurecompletefillingofthetank,allowairtoexitbyopeningthenearesthotwaterfaucet.Allowwatertorununtilaconstantflowisobtained.Thiswillletairoutofthewaterheaterandpiping.

4. Checkallwaterpipingandconnectionsforleaks.Repairasneeded.

ventInG

VENTDAMPERS-Anyventdamper,whetheritisoperatedthermallyorotherwisemustberemovedif itsuseinhibitsproperdraftingofthewaterheater.

ThermallyOperatedVentDampers:thisgas-firedwaterheaterhasathermalefficiencyatorabove80%whichmayproducearelativelylowfluegastemperature.Suchtemperaturesmaynotbehighenoughtoproperlyopenthermallyoperatedventdampers.Thiswouldcausespillageofthefluegasesandmaycausecarbonmonoxidepoisoning.

VentdampersmustbearevidenceofcertificationascomplyingwiththecurrenteditionoftheAmericanNationalStandardANSIZ21.66CGA6.14 (covering electrically andmechanically actuated ventdampers).Beforeinstallationofanyventdamper,consultthelocalgasutilityforfurtherinformation.

Toinsureproperventingofthisgas-firedwaterheater,thecorrectventpipediametermustbeutilized.Anyadditionsordeletionsofothergasappliancesonacommonventwiththiswaterheatermayadverselyaffecttheoperationofthewaterheater.Consultyourgassupplierifanysuchchangesareplanned.

Forproperventingincertaininstallations,alargerdiameterventpipemaybenecessary.ConsultyourgassuppliertoaidyouindeterminingtheproperventingforyourwaterheaterfromtheventtablesinthecurrenteditionoftheNationalFuelGasCodeANSIZ223.1/NFPA54.

Periodically check the venting system for signsof obstruction ordeteriorationandreplaceifneeded.

Thecombustionandventilationairflowmustnotbeobstructed.

Thewaterheaterwithdrafthoodinstalledmustbeconnectedtoachimneyorlistedventpipesystem,whichterminatestotheoutdoors.Neveroperatethewaterheaterunlessitisventedtotheoutdoorsandhasadequateairsupplytoavoidrisksof improperoperation,explosionorasphyxiation.

• Forproperdrafthoodattachment, thedrafthood legsmaybeangledslightlyinward.

• Placethedrafthoodlegsinthereceivingholesonthetopofthewaterheater.The legswillsnap intheholestogiveatightfit.Securedrafthoodwiththesuppliedbrackets.

• Placetheventpipeoverthedrafthood.Withtheventpipeinposition,drillasmallholethroughboththeventpipeanddrafthood.Securethemtogetherwithasheetmetalscrew,seeFigure11.

Obstructedordeterioratedventsystemsmaypresentserioushealthriskorasphyxiation.

fIGure 11.

Theventpipefromthewaterheatermustbenolessthanthediameterofthedrafthoodoutletonthewaterheaterandmustslopeupwardatleast1/4inchperlinearfoot(21mmpermeter),seeFigure12.

Allventgasesmustbecompletelyvented to theoutdoorsof thestructure(dwelling). Installonly thedrafthoodprovidedwith thenewwaterheaterandnootherdrafthood.

Vent pipesmust be secured at each joint with sheetmetalscrews.

13

fIGure 12.

Theremustbeaminimumof6”(153mm)clearancebetweensinglewall vent pipe and any combustiblematerial. Fill and seal anyclearancebetweensinglewallventpipeandcombustiblesurfaceswithmortarmix,cement,orothernoncombustiblesubstance.Forother thansinglewall, followventpipemanufacturer’sclearancespecifications.Toinsureatightfitoftheventpipeinabrickchimney,sealaroundtheventpipewithmortarmixcement.

Failure to have required clearances between vent piping andcombustiblematerialwillresultinafirehazard.

Be sure vent pipe is properly connected to prevent escape ofdangerousfluegaseswhichcouldcausedeadlyasphyxiation.

Chemicalvaporcorrosionoftheflueandventsystemmayoccurifairforcombustioncontainscertainchemicalvapors.Spraycanpropellants, cleaning solvents, refrigerator and air conditionerrefrigerants,swimmingpoolchemicals,calciumandsodiumchloride,waxes,bleachandprocesschemicalsaretypicalcompoundswhicharepotentiallycorrosive.

Gas pIpInG

Makesurethegassuppliedisthesametypelistedonthemodelratingplate.Theinletgaspressuremustnotexceed14inchwatercolumn(2.6kPa)fornaturalandpropane(L.P.)gas.Theminimuminletgaspressureshownontheratingplateisthatwhichwillpermitfiringatratedinput.

If thegascontrolvalve issubjected topressuresexceeding1/2poundpersquare inch(3.5kPa), thedamagetothegascontrolvalvecouldresultinafireorexplosionfromleakinggas.

If the main gas line shut-off serving all gas appliances isused, also turn “off ” the gas at each appliance. Leave allgasappliancesshut“off”untilthewaterheaterinstallationiscomplete.

Agaslineofsufficientsizemustberuntothewaterheater.Consult thecurrenteditionofNationalFuelGasCodeANSIZ223.1/NFPA54andyourgassupplierconcerningpipesize.

Theremustbe:

• Areadilyaccessiblemanualshutoffvalveinthegassupplylineservingthewaterheater,and

• A sediment trap ahead of the gas control valve to helpprevent dirt and foreignmaterials from entering the gascontrolvalve.

• A flexiblegasconnectororaground jointunionbetweentheshutoffvalveandcontrolvalvetopermitservicingoftheunit.

Besuretocheckallthegaspipingforleaksbeforelightingthewaterheater.Useasoapywatersolution,notamatchoropenflame.Rinseoffsoapysolutionandwipedry.

Theminimuminletgaspressureshownontheratingplateisthatwhichwillpermitfiringattheratedinput.

Waterheaters covered in thismanual havebeen testedandapprovedforinstallationatelevationsupto7,700feet(2,347m)abovesealevel.Forinstallationabove7,700feet(2,347m),thewaterheater’sBtu inputshouldbereducedattherateof4percent foreach1,000feet (305m)abovesea levelwhichrequiresreplacementoftheburnerorificeinaccordancewiththeNationalFuelGasCodeANSIZ223.1/NFPA54.Contactyourlocalgassupplierforfurtherinformation.

Failure to replace the standard orifice with the proper highaltitudeorificewhen installedat elevationsabove7,700 feet(2,347m)couldresultinimproperandinefficientoperationofthe water heater producing carbonmonoxide gas in excessofthesafelimits.Thiscouldresultinseriousinjuryordeath.Contactyourlocalgassupplierforanyspecificchangesthatmayberequiredinyourarea.

14

Usepipejointcompoundorteflontapemarkedasbeingresistanttotheactionofpetroleum[Propane(L.P.)]gases.

Thewaterheateranditsgasconnectionmustbeleaktestedbeforeplacingthewaterheaterinoperation.

The water heater and its individual shut-off valve shall bedisconnectedfromthegassupplypipingsystemduringanypressuretestingofthatsystemattestpressuresinexcessof1/2poundpersquareinch(3.5kPa).Itshallbeisolatedfromthegassupplypipingsystembyclosing its individualmanualshut-offvalveduringanypressuretestingofthegassupplypipingsystemattestpressuresequaltoorlessthan1/2poundpersquareinch(3.5kPa).

Connecting thegaspiping to thegas control valveof thewaterheatercanbeaccomplishedbyeitherofthetwomethodsshowninFigures13and14.

fIGure 13. Gas pIpInG wIth fleXIBle connector.

fIGure 14. Gas pIpInG wIth allBlacK Iron pIpe to Gas control.

sedIMent traps

Asedimenttrapshallbeinstalledasclosetotheinletofthewaterheater as practical at the time ofwater heater installation.Thesedimenttrapshallbeeitherateefittingwithacappednippleinthebottomoutletorotherdevicerecognizedasaneffectivesedimenttrap.Ifateefittingisused,itshallbeinstalledinconformancewithoneofthemethodsofinstallationshowninFigures13and14.

Contaminantsinthegaslinesmaycauseimproperoperationofthegascontrolvalvethatmayresultinfireorexplosion.Beforeattaching thegas linebesure thatallgaspipe iscleanon theinside.Totrapanydirtorforeignmaterialinthegassupplyline,asedimenttrapmustbeincorporatedinthepiping.Thesedimenttrapmust be readily accessible. Install in accordancewith the“GasPiping”section.RefertothecurrenteditionoftheNationalFuelGasCode,ANSIZ223.1/NFPA54.

15

16

for Your safetY read Before lIGhtInG

Before lIGhtInG: entIre sYsteM Must Be fIlled wIth water and aIr purGed at faucets.

warnInG: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

1.STOP!Readthesafetyinformationaboveon thislabel.

2. Set the thermostat to the lowest setting by turningthermostatdialfullyclockwise untilitstops.

3. Pushthegascontrolknobdownslightlyandturnclockwiseto“OFF”(FigureA).

NOTE:GascontrolknobCANNOTbeturnedfrom“PILOT” to“OFF”unlessitispusheddownslightly.Donotforce.4. Remove the innerandouterdoors locatedbelowand

behindthegascontrolunit.5. Waitfive(5)minutestoclearoutanygas.Ifyouthen

smellgasSTOP!Follow“B”inthesafetyinformationaboveonthislabel.Ifyoudonotsmellgas,gotothenextstep.

6. FindPilot.Followmetaltubefromthebottom,rightofthegascontroltothepilotburner.(FigureD).

7. Turngascontrolknobcounterclockwise to“PILOT”(FigureB).

8.Pushgascontrolknobdownallthewayandholditdown.Immediatelylightthepilotwithamatch.Continuetohold

thegascontrolknobdownforaboutone(1)minute afterthepilotislit.Releasethegascontrolknobandit willpopbackup.Pilotshouldremainlit.Ifitgoesout, repeatSteps3through8.Itmaytakeseveralminutesfor airtoclearthelines,beforethepilotwilllight. • Ifknobdoesnotpopupwhenreleased,stopand immediatelycallyourservicetechnicianorgas supplier. • Ifthepilotwillnotstaylitafterseveraltries,turnthe gascontrolknobto“OFF”(FigureA)and callyour servicetechnicianorgassupplier.9. Replaceinnerandouterburnerdoors.10. Atarm’slengthaway,turnthegascontrolknob counterclockwise to“ON”(FigureC).11. Setthermostattodesiredsetting(SeeFigure).

cautIon: hotter water increases the risk of scald injury. consult the instruction manual before changing temperature.

lIGhtInG InstructIons

to turn off Gas to applIance1. Setthethermostattolowestsetting. 2. Pushgascontrolknobdownslightlyandturnclockwise

to“OFF”.Donotforce,seeFigureA.

top vIew fIGure “d”Gas control

A. Thisappliancehasapilotwhichmustbelightedbyhand.Whenlightingthepilot,followtheseinstructionsexactly.

B. Before lIGhtInG: smellallaround theapplianceareaforgas.Besuretosmellnexttothefloorbecausesomegasisheavierthanairandwillsettleonthefloor.

what to do If You sMell Gas • Donottrytolightanyappliance. • Donottouchanyelectricswitch;donotuse

anyphoneinyourbuilding. • Immediatelycallyourgassupplierfroma

neighbor’sphone.Followthegassupplier’s instructions.

• Ifyoucannotreachyourgassupplier,callthe firedepartment.

C.Useonlyyourhandtopushdownorturnthegascontrolknob.Neverusetools.Iftheknobwillnotpushdownorturnbyhand,don’ttrytorepairit,callaqualifiedservicetechnician.Forceorattemptedrepairmayresultinafireorexplosion.

D.Donotuse thisappliance if anypart hasbeenunderwater.Immediatelycontactaqualifiedinstallerorserviceagencytoreplaceafloodedwaterheater.Donotattempttorepairtheunit!Itmustbereplaced!

17

for Your InforMatIonstart up condItIons

draft hood operatIon

Check draf t hood operation by per forming a worst casedepressurizationofthebuilding.Withalldoorsandwindowsclosed,andwithallairhandlingequipmentandexhaustfansoperatingsuchas furnaces,clothesdryers, rangehoodsandbathroom fans,amatchflameshouldstillbedrawnintothedrafthoodofthewaterheaterwithitsburnerfiring.Iftheflameisnotdrawntowardthedrafthood,shutoffwaterheaterandmakenecessaryairsupplychangestocorrect.

condensatIonWhenever the water heater is filled with cold water, somecondensatewillformwhiletheburnerison.Awaterheatermay

Neverallowsmallchildrentouseahotwatertap,ortodrawtheirownbathwater.Neverleaveachildorhandicappedpersonunattendedinabathtuborshower.NOTE:Awatertemperaturerangeof120°F-140°F(49°C-60°C)isrecommendedbymostdishwashermanufacturers.Thethermostatofthiswaterheaterhasbeenfactorysetatitslowestposition (PILOT LIGHTING). It isadjustableandmustbe reset tothedesired temperature setting to reduce the riskof scald injury.Themark( )indicativeofapproximately120°F(49°C)ispreferredstartingpoint.SomeStateshavearequirementforalowersetting.

Turn thewater temperaturedial clockwise ( ) todecrease thetemperature,orcounterclockwise( )toincreasethetemperature.

Shouldoverheatingoccurorthegassupplyfailtoshutoff,turnoffthemanualgascontrolvalvetothewaterheater.

fIGure 15.

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)

110 (43) (normal shower temp.) 116 (47) (pain threshold) 116 (47) 35 minutes 45 minutes122 (50) 1 minute 5 minutes131 (55) 5 seconds 25 seconds140 (60) 2 seconds 5 seconds149 (65) 1 second 2 seconds154 (68) instantaneous 1 second

WaterTemperature

°F (°C) Time for 1st Degree Burn

(Less Severe Burns)Time for Permanent Burns

2nd & 3rd Degree(Most Severe Burns)

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)

43 (110) (temp. normale d’une douche)

47 (116) (seuil de douleur)

47 (116) 35 minutes 45 minutes

50 (122) 1 minute 5 minutes

55 (131) 5 secondes 25 secondes

60 (140) 2 secondes 5 secondes

65 (149) 1 seconde 2 secondes

68 (154) instantaneous 1 seconde

Températurede I'eau°C (°F)

Délai pour des brûluresau 1er degré

(brûlures moins graves)

Délai pour des brûlurespermanentes au 2e et 3e degrés

(brûlures les plus graves)

fIGure 16.

Shortrepeatedheatingcyclescausedbysmallhotwaterusescancausetemperaturesatthepointofusetoexceedthethermostatsettingbyupto30°F(16.7°C).Ifyouexperiencethistypeofuseyoushouldconsiderusinglowertemperaturesettingstoreducescaldhazards.

Anywaterheater’sintendedpurposeistoheatwater.Hotwaterisneededforcleansing,cleaning,andsanitizing(bodies,dishes,clothing).Untemperedhotwatercanpresentascaldhazard.Dependingonthetimeelement,andthepeopleinvolved(adults,children,elderly,infirm,etc.)scaldingmayoccuratdifferenttemperatures.

HOTTERWATERCANSCALD:Water heaters are intended toproducehotwater.Waterheatedtoatemperaturewhichwillsatisfyspaceheating,clotheswashing,dishwashing,andothersanitizingneedscanscaldandpermanentlyinjureyouuponcontact.Somepeoplearemorelikelytobepermanentlyinjuredbyhotwaterthanothers.Theseincludetheelderly,children,theinfirm,orphysically/mentally handicapped. If anyoneusinghotwater in your homefitsintooneofthesegroupsorifthereisalocalcodeorstatelawrequiringacertaintemperaturewateratthehotwatertap,thenyoumusttakespecialprecautions.Inadditiontousingthelowestpossibletemperaturesettingthatsatisfiesyourhotwaterneeds,ameanssuchasamixingvalveshouldbeusedatthehotwatertapsusedbythesepeopleoratthewaterheater.Mixingvalvesareavailableatplumbingsupplyorhardwarestores,seeFigure2. Followmanufacturer’sinstructionsforinstallationofthevalves.Beforechangingthefactorysettingonthethermostat,readthe“TemperatureRegulation”sectioninthismanual,seeFigures15and16.

teMperature reGulatIon

appeartobeleakingwheninfactthewateriscondensation.Thisusuallyhappenswhen:

a.Anewwaterheaterisfilledwithcoldwaterforthefirsttime.b.Burninggasproduceswatervaporinwaterheaters,particularly

highefficiencymodelswherefluetemperaturesarelower.c.Largeamountsofhotwaterareusedinashorttimeandtherefill

waterinthetankisverycold.

Moisturefromtheproductsofcombustioncondenseonthecoolertanksurfacesandformdropsofwaterwhichmayfallontotheburnerorotherhotsurfacestoproducea“sizzling”or“frying”noise.

Excessivecondensationcancausepilotoutageduetowaterrunningdownthefluetubeontothemainburnerandputtingoutthepilot.

18

Becauseof the suddennessandamount ofwater, condensationwatermaybediagnosedasa“tank leak”. After thewater in thetankwarmsup(about1-2hours),theconditionshoulddisappear.

Donot assume thewater heater is leakinguntil therehasbeenenoughtimeforthewaterinthetanktowarmup.

Anundersizedwaterheaterwillcausemorecondensation.Thewaterheatermustbesizedproperlytomeetthefamily’sdemandsforhotwaterincludingdishwashers,washingmachinesandshowerheads.

Excessivecondensationmaybenoticedduringthewinterandearlyspringmonthswhenincomingwatertemperaturesareattheirlowest.

Goodventingisessentialforagasfiredwaterheatertooperateproperlyaswellastocarryawayproductsofcombustionandwatervapor.

sMoKe/odorItisnotuncommontoexperienceasmallamountofsmokeandodorduringtheinitialstart-up.Thisisduetoburningoffofoilfrommetalparts,andwilldisappearinashortwhile.

therMal eXpansIon

Aswater is heated, it expands (thermal expansion). In a closedsystem the volume of water will growwhen it is heated.As thevolumeofwatergrows therewillbeacorresponding increase inwaterpressureduetothermalexpansion.Thermalexpansioncancauseprematuretankfailure(leakage).Thistypeoffailureisnotcoveredunder the limitedwarranty.Thermalexpansioncanalsocause intermittent Temperature-Pressure Relief Valve operation:waterdischargedfromthevalveduetoexcessivepressurebuildup.Thiscondition isnotcoveredunder the limitedwarranty.TheTemperature-PressureReliefValveisnotintendedfortheconstantreliefofthermalexpansion.

Aproperlysized thermalexpansion tankmustbe installedonallclosedsystemstocontroltheharmfuleffectsofthermalexpansion.Contactalocalplumbingserviceagencytohaveathermalexpansiontankinstalled.

stranGe sounds

Possiblenoisesduetoexpansionandcontractionofsomemetalpartsduringperiodsofheat-upandcool-downdonotnecessarilyrepresentharmfulordangerousconditions.

Condensationcausessizzlingandpoppingwithintheburnerareaduringheatingandcoolingperiodsandshouldbeconsiderednormal.See“Condensation”inthissection.

operatIonal condItIons

sMellY water

Ineachwaterheaterthereisinstalledatleastoneanoderod(seepartssection) forcorrosionprotectionof the tank. Certainwater

conditionswill causea reactionbetween this rodand thewater.Themostcommoncomplaintassociatedwiththeanoderodisoneofa“rotteneggsmell”inthehotwater.Thisodorisderivedfromhydrogensulfidegasdissolvedinthewater.Thesmellistheresultoffourfactorswhichmustallbepresentfortheodortodevelop:

a.Aconcentrationofsulfateinthesupplywater.b.Littleornodissolvedoxygeninthewater.c.Asulfate reducingbacteriawhichhasaccumulatedwithin the

waterheater(thisharmlessbacteriaisnontoxictohumans).d.Anexcessofactivehydrogeninthetank.Thisiscausedbythe

corrosionprotectiveactionoftheanode.

Smellywatermaybeeliminatedor reduced insomewaterheatermodelsbyreplacingtheanode(s)withoneoflessactivematerial,andthenchlorinatingthewaterheatertankandallhotwaterlines.ContactthelocalwaterheatersupplierorserviceagencyforfurtherinformationconcerninganAnodeReplacementKitandthischlorinationtreatment.

Ifthesmellywaterpersistsaftertheanodereplacementandchlorinationtreatment,wecanonlysuggestthatchlorinationoraerationofthewatersupplybeconsideredtoeliminatethewaterproblem.

do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided.

“aIr” In hot water faucets

HYDROGENGAS:Hydrogengascanbeproducedinahotwatersystemthathasnotbeenusedforalongperiodoftime(generallytwoweeksormore). Hydrogengas isextremely flammableandexplosive.Topreventthepossibilityofinjuryundertheseconditions,we recommend the hotwater faucet, located farthest away, beopenedforseveralminutesbeforeanyelectricalapplianceswhichareconnectedtothehotwatersystemareused(suchasadishwasherorwashingmachine).Ifhydrogengasispresent,therewillprobablybeanunusualsoundsimilartoairescapingthroughthepipeasthehotwaterfaucetisopened.Theremustbenosmokingoropenflamenearthefaucetatthetimeitisopen.

hIGh water teMperature shut off sYsteM

ThiswaterheaterisequippedwithanautomaticgasShut-offsystem.Thissystemworkswhenhighwatertemperaturesarepresent.ThehightemperatureShut-off isbuilt into thegascontrolvalve. It isnon-resettable.IfthehightemperatureShut-offactivates,thegascontrolvalvemustbereplaced.Contactyourgassupplierorserviceagency.Turn“OFF”theentiregassupplytothewaterheater.

19

Youshouldcheck forsooting.Soot isnotnormalandwill impairpropercombustion.

Sootbuild-up indicatesaproblemthat requirescorrectionbeforefurtheruse.Turn“OFF”gastowaterheaterandleaveoffuntilrepairsaremade,becausefailuretocorrectthecauseofthesootingcanresultinafirecausingdeath,seriousinjury,orpropertydamage.

natural

propane

fIGure 17.

Burner cleanInG

Ifinspectionoftheburnershowsthatcleaningisrequired,turnthegas controlknobclockwise( )tothe“OFF”position,depressingslightly.

note: the knob cannot be turned from “pIlot” to “off” unless knob is depressed slightly. do not force.

Loosedepositsonoraroundtheburnercanberemovedbycarefully usingthehoseofavacuumcleanerinsertedthroughtheaccessdoorofthewaterheater.Iftheburnerneedstoberemovedforadditionalcleaning,callaserviceagencytoremoveandcleantheburnerandcorrecttheproblemthatrequiredtheburnertobecleaned.

houseKeepInG

Vacuumaroundbaseofwaterheater fordust,dirt,and lintonaregularbasis.

ventInG sYsteM InspectIon

Atleastonceayearavisualinspectionshouldbemadeoftheventingsystem.Youshouldlookfor:

1.Obstructions which could cause improper venting. Thecombustionandventilationairflowmustnotbeobstructed.

2.Damageordeteriorationwhichcouldcauseimproperventingorleakageofcombustionproducts.

3.Rustedflakesaroundtopofwaterheater.

Besuretheventpipingisproperlyconnectedtopreventescapeofdangerousfluegaseswhichcouldcausedeadlyasphyxiation.

Obstructionsanddeterioratedventsystemsmaypresentserioushealthriskorasphyxiation.

Chemicalvaporcorrosionoftheflueandventsystemmayoccurifairforcombustioncontainscertainchemicalvapors.Spraycanpropellants, cleaning solvents, refrigerator and air conditionerrefrigerants,swimmingpoolchemicals,calciumandsodiumchloride,waxes,bleachandprocesschemicalsaretypicalcompoundswhicharepotentiallycorrosive.

If after inspection of the vent system you found sooting ordeterioration, something iswrong. Call the local gas utility tocorrecttheproblemandcleanorreplacetheflueandventingbeforeresumingoperationofthewaterheater.

Burner InspectIon

Flood damage to awater heatermay not be readily visible orimmediatelydetectable.However,overaperiodoftimeafloodedwater heaterwill create dangerous conditionswhich can causeDEATH,SERIOUSBODILY INJURY,ORPROPERTYDAMAGE.Contactaqualifiedinstallerorserviceagencytoreplaceafloodedwaterheater.Donotattempttorepairtheunit!Itmustbereplaced!

Atleastonceayearavisualinspectionshouldbemadeofthemainburnerandpilotburner,seeFigure17.

perIodIc MaIntenance

20

Inreplacingtheanode:

1.Turnoffgassupplytothewaterheater.

2.Shutoffthewatersupplyandopenanearbyhotwaterfaucettodepressurizethewatertank.

3. Drain approximately 5 gallons of water from tank. (Referto “Draining and Flushing” for proper procedures). Closedrainvalve.

4.Removeoldanoderod.

5.UseTeflon® tapeorapprovedpipesealanton threadsandinstallnewanoderod.

6. Turn onwater supply and open a nearby hot water faucetto purge air from water system. Check for any leaks andimmediatelycorrectanyiffound.

7.Restart thewaterheaterasdirected in thismanual.See theRepairPartsIllustrationforanoderodlocation.

teMperature-pressure relIef valve operatIon

Thetemperature-pressurereliefvalvemustbemanuallyoperatedatleastonceayear.

When checking the temperature-pressure relief valve operation,makesurethat(1)nooneisinfrontoforaroundtheoutletofthetemperature-pressurereliefvalvedischargeline,and(2) that thewaterdischargewillnotcauseanypropertydamage,asthewatermaybeextremelyhot,seeFigure18.

fIGure 19.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyresetandcontinuestoreleasewater,immediatelyclosethecoldwaterinlettothewaterheater,followthedraininginstructions,andreplacethetemperature-pressurereliefvalvewithanewone.

Ifthetemperature-pressurereliefvalveonthewaterheaterweepsordischargesperiodically,thismaybeduetothermalexpansion.Youmayhaveacheckvalveinstalledinthewaterlineorawatermeterwith a check valve.Consult your localwater supplier orserviceagencyforfurtherinformation.Donotplugthetemperature-pressurereliefvalve.

INSTALLED INSUITABLEAREA:To insure sufficient ventilationandcombustionairsupply,properclearancesfromthewaterheatermustbemaintained.See“LocatingtheNewWaterHeater”section.Combustiblematerials such as clothing, cleaningmaterials, orflammableliquids,etc.mustnotbeplacedagainstoradjacenttothewaterheaterwhichcancauseafire.

anode rod InspectIon

Eachwaterheatercontainsatleastoneanoderod,whichwillslowly deplete (due to electrolysis) prolonging the life of thewaterheaterbyprotectingtheglass-linedtankfromcorrosion.Adversewaterquality,hotterwatertemperatures,highhotwaterusage,andwatersofteningmethodscan increasetherateofanoderoddepletion.Oncetheanoderodisdepleted,thetankwillstarttocorrode,eventuallydevelopingaleak.

Certainwaterconditionswillcauseareactionbetweentheanoderodandthewater.Themostcommoncomplaintassociatedwiththeanoderodisa“rotteneggsmell”producedfromthepresenceofhydrogensulfidegasdissolvedinthewater.IMPORTANT:Donotremovethisrodpermanentlyasitwillvoidanywarranties.Aspecialanoderodmaybeavailableifwaterodorordiscolorationoccurs.NOTE:Thisrodmayreducebutnoteliminatewaterodorproblems.Thewatersupplysystemmayrequirespecialfiltrationequipmentfromawaterconditioningcompanytosuccessfullyeliminateallwaterodorproblems.

Artificiallysoftenedwaterisexceedinglycorrosivebecausetheprocess substitutes sodium ions formagnesiumand calciumions.Theuseofawatersoftenermaydecreasethelifeofthewaterheatertank.

Theanoderodshouldbeinspectedafteramaximumofthreeyearsandannuallythereafteruntiltheconditionoftheanoderoddictatesitsreplacement.NOTE:Artificiallysoftenedwaterrequirestheanoderodtobeinspectedannually.

The following are typical (but not all) signs of a depletedanoderod:

• Themajorityoftherodsdiameterislessthan3/8”.

• Significantsectionsofthesupportwire(approx.1/3ormoreoftheanoderod’slength)arevisible.

fIGure 18.

Iftheanoderodshowsignsofeitherorbothitshouldbereplaced.NOTE:Whetherre-installingorreplacingtheanoderod,checkforanyleaksandimmediatelycorrectiffound.

21

draInInG and flushInG

It isrecommendedthatthetankbedrainedandflushedevery6monthstoremovesedimentwhichmaybuildupduringoperation.Thewaterheatershouldbedrainedifbeingshutdownduringfreezingtemperatures.Todrainthetank,performthefollowingsteps:

1.Turnoffthegastothewaterheateratthemanualgasshut-offvalve.

2.Openanearbyhotwaterfaucetuntilthewaterisnolongerhot.

3.Closethecoldwaterinletvalve.

4.Connectahosetothedrainvalveandterminateittoanadequatedrainorexternaltothebuilding.

5.Open thewater heater drain valve andallowall of thewatertodrainfromthetank.Flushthetankwithwaterasneededtoremovesediment.

6.Closethedrainvalve, refill the tank,andrestart theheaterasdirectedinthismanual.

Ifthewaterheaterisgoingtobeshutdownforanextendedperiod,thedrainvalveshouldbeleftopen.

IMPORTANT:Condensationmayoccurwhenrefillingthetankandshouldnotbeconfusedwithatankleak.

draIn valve washer replaceMent for selected Models wIth plastIc draIn valves

(SeeFigure19)

1.Turn“OFF”gassupplytowaterheater.

2.Follow“Draining”instructions.

3.Turningcounterclockwise( ),removethehexcapbelowthescrewhandle.

4.Removethewasherandputthenewoneinplace.

5.Screwthehandleandcapassemblybackintothedrainvalveandretightenusingawrench.DONOTOVERTIGHTEN.

6.Followinstructionsinthe“FillingTheWaterHeater”section.

7.Checkforleaks.

8.Follow the lighting Instructions in the “LightingandOperatingInstructions”sectiontorestartthewaterheater.

fIGure 20.

servIce

Beforecallingforrepairservice,readthe“StartUpConditions”and“OperationalConditions”foundinthe“ForYourInformation”sectionofthismanual.

Ifaconditionpersistsoryouareuncertainabouttheoperationofthewaterheatercontactaserviceagency.Ifyouarenotthoroughlyfamiliarwithgascodes,yourwaterheater,andsafetypractices,contactyourgassupplierorqualifiedinstallertocheckthewaterheater.

Use the ”Leakage Checkpoints” guide to check a “Leaking” waterheater.Manysuspected“Leakers”arenotleakingtanks.Oftenthesourceofthewatercanbefoundandcorrected.

Readthismanualfirst.Thenbeforecheckingthewaterheatermakesurethegassupplyhasbeenturned“OFF”,andneverturnthegas“ON”beforethetankiscompletelyfullofwater.

Neverusethiswaterheaterunlessitiscompletelyfilledwithwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gastothewaterheater.

22

leaKaGe checKpoInts

Readthismanualfirst.Thenbeforecheckingthewaterheatermakesurethegassupplyhasbeenturned“OFF”,andneverturnthegas“ON”beforethetankiscompletelyfullofwater.

Neverusethiswaterheaterunlessitiscompletelyfilledwithwater.Topreventdamagetothetank,thetankmustbefilledwithwater.Watermustflowfromthehotwaterfaucetbeforeturning“ON”gastothewaterheater.

A.Wateratthedrafthoodiswatervaporwhichhascondensedoutofthecombustionproducts.Thisiscausedbyaprobleminthevent.Contactthegasutility.

B.*Condensationmaybeseenonpipesinhumidweatherorpipeconnectionsmaybeleaking.

C.*Theanoderodfittingmaybeleaking.

D.Smallamountsofwaterfromtemperature-pressurereliefvalvemaybeduetothermalexpansionorhighwaterpressureinyourarea.

E.*The temperature-pressure relief valvemaybe leakingat thetankfitting.

F.Waterfromadrainvalvemaybeduetothevalvebeingslightlyopened.

G.*Thedrainvalvemaybeleakingatthetankfitting.

H.Combustionproductscontainwatervaporwhichcancondenseonthecoolersurfacesofthetank.Dropletsformanddripontotheburnerorrunonthefloor. This iscommonatthetimeofstart-upafterinstallationandwhenincomingwateriscold.

I. Waterinthewaterheaterbottomoronthefloormaybefromcondensation,looseconnections,orthereliefvalve.DONOTreplacethewaterheateruntilafullinspectionofallpossiblewatersourcesismadeandnecessarycorrectivestepstaken.

Leakage fromother appliances,water lines, or ground seepageshouldalsobechecked.

* To checkwhere threaded portion enters tank, insert cottonswabbetweenjacketopeningandfitting.Ifcottoniswet,follow“Draining”instructionsinthe“PeriodicMaintenance”sectionandthenremovefitting.Putpipedopeorteflontapeonthethreadsandreplace.Thenfollow“FillingtheWaterHeater”instructionsinthe“InstallingtheNewWaterHeater”section.

23

repaIr parts

17

a

draIn pan 23

natural

propane

Key no. part description 1 PipeNipple 2 BurnerTube 3 BurnerHead 4 Thermocouple 5 Pilot 6 DraftHood *7 DraftHoodBrace 8 InletTube 9 FlueBaffleAssembly 10 AnodeRod 11 CleanoutCover(Optional) 12 CleanoutGasket(Optional) 13 CleanoutScrew(Optional) 14 InnerDoor 15 OuterDoor 16 GasControlValve/Thermostat 17 T&PReliefValve 18 DrainValve 19 FrontCover(optional) 20 PilotTube(LP) 21 Orifice *22 FittingBreakaway *23 MetalDrainPan *24 InstructionManual

* not shown.

Nowthatyouhavepurchasedthiswaterheater,shouldaneedeverexistforrepairpartsorservice,simplycontactthecompanyitwaspurchasedfromordirectfromthemanufacturerlistedontheratingplateonthewaterheater.

Besuretoprovideallpertinentfactswhenyoucallorvisit.

selling prices will be furnished on request or parts will be shipped at prevailing prices and you will be billed accordingly.

ThemodelnumberofyourGasWaterHeaterwillbefoundontheratingplacelocatedabovethegascontrolvalve.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWINGINFORMATION:

• MODELNUMBER• TYPEGAS(NATURALORPROPANE(L.P.)• SERIALNUMBER• PARTDESCRIPTION

thIs Is a repaIr parts lIst, not a pacKInG lIst.

approX. InsulatIon teMp thIcKness press. a = relIef

> or = 1.5” 150 lBs. 2.13” 210°f < 1.5” 150 lBs. 1.88” 210°f

3/4” T&P RELIEF VALVEautoMatIc, self-closInG tYpes

24

Theseguidelinesshouldbeutilizedbyaqualifiedservicetechnician.

trouBleshootInG GuIdelInes

Problem Cause Solution

WATER LEAKS

Improperlysealed,hotorcoldsupplyconnection,reliefvalve,drainvalve,orthermostatthreads. Tightenthreadedconnections.

Leakagefromotherappliancesorwaterlines. Inspectotherappliancesnearwaterheater.

Condensationofflueproducts. RefertoCONDENSATION.

LEAKING T&P VALVE

Thermalexpansioninclosedwatersystem. Installthermalexpansiontank(DONOTplugT&Pvalve).

Improperlyseatedvalve.Checkreliefvalveforproperoperation(DONOTplugT&Pvalve).

SMELLY WATERHighsulfateormineralcontentinwatersupply. Drainandflushheaterthoroughly,thenrefill.

Bacteriainwatersupply. Chlorinateoraeratewatersupply.

PILOT WILL NOT LIGHT

Gascontrolknobnotpositionedcorrectly. RefertoLIGHTINGINSTRUCTIONS.

Maingassupplyoff. Turnonmaingasshutoffvalve.

Thermocouplemalfunction. Replacepilotassemblyand/orthermocouple.

Matchnotclosetopilot Locatepilot,movematchcloser.

BURNER WILL NOT

STAY LIT

Thermocouplemalfunction. Replacepilotassemblyand/orthermocouple.

DefectiveGasControl. ReplaceGasControl.

PILOT OUTAGE

Dirtypilotburner. Cleanpilotassembly.

Thermocouplemalfunction. Replacepilotassemblyand/orthermocouple.

DefectiveGasControl. ReplaceGasControl.

Thermocoupletipisnotincontactwithpilotflame. Insertthermocouplecorrectly.

NOT ENOUGH HOT WATER

Heaternotlitorthermostatnoton. RefertoLIGHTINGINSTRUCTIONS.

Thermostatsettoolow. RefertoTEMPERATUREREGULATION.

Heaterundersized. Reducehotwateruse.

Lowgaspressure. Contactyourgassupplier.

Incomingwaterisunusuallycold. Allowmoretimeforheatertore-heat.

Leakinghotwaterpipesorfixtures. Haveplumbercheckandrepairleaks.

Hightemperaturelimitswitchactivated. Contactaserviceagencytodeterminecause.

WATER TOO HOT Thermostatsettoohigh. RefertoTEMPERATUREREGULATION.

WATER HEATER SOUNDS Condensationdrippingonburner. RefertoCONDENSATION.

SIZZLINGORRUMBLING

Sedimentorcalciuminbottomofheatertank. Cleansedimentfromtank.RefertoDRAININGinstructionsinMaintenancesectionofmanual.

SOOTING Impropercombustion. Noadjustmentavailable.Contactaserviceagencytodeterminecause.

VENT GAS ODORS

Lackofsupplyair.

Contactaserviceagencytodeterminecause.Improperlyinstalledventpiping.

Downdraft.

Poorcombustion.

25

notes

26

notes

27

notes