A.O. Smith 185874-001 User Manual

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Instruction Manual

RESIDENTIAL GAS WATER HEATERS

FOR USE ONLY IN MANUFACTURED HOMES

GAMA certification applies to all residential gas water heaters with capacities of 20 to 100 gallons with input rating of 75,000 BTU/Hr. or less.

C3 Technology® Gas Water Heaters meet the new ANSI Z21.10.1 standard that deals with the accidental or unintended ignition of flammable vapors, such as those emitted by gasoline.

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

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.

Keep this manual in the pocket on heater for future reference whenever maintenance adjustment or service is required.

PRINTED 0807

185874-001

SAFE INSTALLATION, USE AND SERVICE

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

Many safety-relatedmessages 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.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

 

 

 

 

DANGER indicates an imminently hazardous

 

 

DANGER

 

 

 

 

 

 

 

situation which, if not avoided, could result

 

 

 

 

in death or injury.

 

 

 

 

 

 

 

 

 

 

 

 

 

WarnING indicates a potentially hazardous

 

 

warnING

 

 

 

 

 

 

 

situation which, if not avoided, could result

 

 

 

 

in death or injury.

 

 

 

 

 

 

 

 

 

 

 

 

 

CautION indicates a potentially hazardous

 

 

CAUTION

 

 

 

 

 

 

 

situation which, if not avoided, may result

 

 

 

in minor or moderate injury.

 

 

 

 

 

 

 

 

 

 

 

 

 

CautION used without the safety alert

 

 

 

 

 

CAUTION

 

symbol indicates a potentially hazardous

 

 

situation which, if not avoided, could result

 

 

 

 

in property damage.

 

 

 

 

 

 

 

 

 

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

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

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.

IMPORTANT DEFINITIONS

Qualified Installer: Aqualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the design features and have a thorough understanding of this instruction manual.

Service Agency: Aservice agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer.

Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.

GENERAL SAFETY

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE............................

2

RobertShaw Fuel Conversion Instructions

 

GENERAL SAFETY..................................................................

3

from Propane (L.P.) to Natural Gas...........................

16-18

TABLE OF CONTENTS............................................................

4

RobertShaw Fuel Conversion Instructions

 

INTRODUCTION

4

from Natural Gas to Propane (L.P.) Gas..........................

18

WHITE-RODGERSGAS VALVE

19

Preparing for the New Installation

4

ROBERTSHAW GAS VALVE

20

TYPICAL INSTALLATIONS

5-6

INSTATLLATION CHECKLIST

21

LOCATING THE NEW WATER HEATER

7

TEMPERATURE REGULATION

22

Facts to Consider About Location

7-8

FOR YOUR INFORMATION

23-24

Insulation Blankets

8

Start Up Conditions

23

INSTALLING THE NEW WATER HEATER

9-18

Operational Conditions..............................................

23-24

Securing Water Heater to Floor and Wall..........................

9

PERIODIC MAINTENANCE..............................................

25-27

T & P Valve and Pipe Insulation........................................

9

Venting System Inspection..............................................

25

Water Piping................................................................

9-10

Burner Inspection............................................................

25

Water Piping Pressure Test.............................................

10

Burner Cleaning...............................................................

25

Temperature Pressure Relief Valve............................

10-11

Housekeeping..................................................................

25

Filling the Water Heater

11-12

Anode Rod Inspection.....................................................

26

Temperature-PressureRelief Valve Operation

26

Venting

12-13

Draining

26-27

Gas Piping

13-14

Drain Valve Washer Replacement

27

Sediment Traps

14

Service

27

White-RodgersFuel Conversion Instructions

 

 

LEAKAGE CHECKPOINTS

28

from Natural Gas to Propane (L.P.) Gas

14-16

REPAIR PARTS................................................................

29-30

White Rodgers Fuel Conversion Instructions

 

TROUBLESHOOTING GUIDELINES.....................................

31

from Propane (L.P.) to Natural Gas.................................

16

WARRANTY.......................................................................

Insert

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service.

Abbreviations Found In This Instruction Manual:

CSA - Canadian Standards Association

ANSI - American National Standards Institute

NFPA - National Fire Protection Association

ASME - American Society of Mechanical Engineers

GAMA - Gas Appliance Manufacturer’s Association

Thisgas-firedwaterheaterisdesigncertifiedbyCSAINTERNATIONALunder American National Standard/CSA Standard for Gas Water Heaters for Manufactured Home Installation, ANSI Z21.10.1 • CSA 4.1 (current edition).

Preparing for the Installation

1.Read the “General Safety” section, page 3 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.

This manual contains instructions for the installation, operation, and maintenance of the gas-firedwater heater. It also contains warnings throughoutthemanualthatyoumustreadandbeawareof.Allwarnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the first few pages,Read THE ENTIRE MANUAL BEFORE ATTEMPTING

TO INSTALL OR OPERATE THE WATER HEATER.

2.Instructions to Manufactured Home Manufacturers:

The installation must conform with the Manufactured Home Construction and Safety Standards Title 24 CFR, Part 3280.

Instruction for replacement installation:

The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the National Fuel Gas Code ANSI

Z223.1/NFPA54, current edition. This publication is available from the Canadian StandardsAssociation, 8501 East Pleasant Valley Rd.,

Cleveland Ohio 44131, orThe National Fire ProtectionAssociation,

1 Batterymarch Park, Quincy, MA 02269.

3.If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.

4.Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires, see Figures 1 and 2.

Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.

5.For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures.

Instructions may be obtained from California Office of the State

Architect, 400 P Street, Sacramento, CA 95814.

6.Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR2.00: State Plumbing

Code and 248-CMR5.00.

7.Complies with SCAQMD rule #1121 and districts having equivalent

NOx requirements.

TYPICAL INSTALLATIONS

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A

Vent Pipe

J

Drip Leg (Sediment Trap)

S

Flue Baffle

B

Drafthood

K

Inner Door

T

Thermostat

C

Anode

L

Outer door

U

Drain Valve

D

Hot Water Outlet

M

Union

V

Pilot and Main Burner

E

Outlet

N

Inlet Water Shut-offValve

W

Flue

F

Roof Jack

O

Cold Water Inlet

X

Drain Pan

G

Gas Supply

P

Inlet Dip Tube/Nipple

Y

Thermostat Shield (optional)

H

Manual Gas Shut-offValve

Q

Temperature-PressureRelief Valve

Z

Air Intake Screen

I

Ground Joint Union

R

Rating Plate

 

 

 

 

 

WHITE-RODGERS

 

ROBERTSHAW

*INSTALLINACCORDANCE wITH LOCAL CODES.

*DRIP LEG AS REQUIRED BY LOCAL CODES.

VENT TERMINATION

OF ROOF JACK

VACUUM

Y

THERMOSTAT

RELIEF

 

SHIELD

 

VALVE

 

(OPTIONAL)

INSTALL PER

LOCAL CODES

INSTALL THERMAL EXPANSION TANK OR DEVICE IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM.

(V) PILOT & MAIN BURNER

*ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.

*50 gallon unit has top connections and

no side connection as shown here.

FIGURE 1.

TYPICAL INSTALLATIONS

INSTALLATION IN ENCLOSURE OF MANUFACTURED

INSTALLATION IN ENCLOSURE OF MANUFACTURED

HOME WITH LOUVERED EXTERIOR DOOR

HOME WITH SOLID EXTERIOR DOOR

 

 

* MIXING VALVE USAGE

 

FIGURE 2.

This appliance has been design certified as complying withAmerican

National Standard/CSA Standard for water heaters and is considered suitable for:

Water (Potable) Heating: All models are considered suitable for water (potable) heating.

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions.

In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a *Mixing Valve, should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. Consult a Qualified Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual, see Figures 29 and 30.

LOCATING THE NEW WATER HEATER

Facts to Consider About the Location

This manufactured home gas-firedwater heater is for use in a manufactured home. You should 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 appliance.This water heater is for use only in manufactured homes and is not intended for outdoor installation.

The installation of this water heater must be within an enclosure so as to separate the appliance combustion system and venting system from the interior atmosphere of the manufactured home. There shall not be any door, removable access panel, or other opening into the enclosure from the inside of the manufactured home.

Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed.

1.An enclosure with an exterior access door incorporating a single opening positioned a maximum of 6 inches above the lower edge of the access door and which may incorporate either 1/4 inch wire mesh or louvers. When 1/4 inch wire mesh is used, the size of the opening must be a minimum of 20 square inches. When the louvers are used, the free area must be a minimum of 20 square inches, see Figure 2 page 6.

2.An optional enclosure incorporating a solid exterior access door, when a 5 inch or 8 inch diameter, or 20 square inch minimum equivalent free air opening is located in the floor of the enclosure. The opening must be covered by a 1/4 inch wire mesh, see Figure

2 page 6.

Install water heater into closet so as to have 0 inches minimum clearance at sides and back. Clearance of 4 inches is needed to front to accommodate the gas control valve, see Figure 3. Be sure to allow adequate clearance for servicing the water heater and for access to the piping and temperature-pressurerelief valve.

The water heater should be secured to the floor and to the wall of the enclosure with the mounting brackets provided. For bracket location refer to “Securing Water Heater to Floor and Wall” in the “Installing the New Water Heater” section.

When a manufactured home is skirted, an air intake opening with a minimum free area of 32 square inches must be provided in the skirt. Other gas fired appliances in the home will require additional free air openings; consult these manufacturers for correct sizing.

If the opening is covered by louvers or screen, the total free area must be 32 square inches.

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the flow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper floor. When

such locations cannot be avoided, a suitable drain pan should be installed under the water heater. Drain pans are available at your local hardware store. Such a drain pan must have a minimum length and width of at least 2 inches (51 mm) greater that the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air flow.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-offdevice used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.

Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan.

Water supply shut-offdevices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.

Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VAPORS) ARE LIKELY TO BE PRESENT OR STORED

(GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as gasoline, solvents, propane [LP or butane, etc.] and other substances such as adhesives, etc.) emit flammable vapors which can be ignited by a gas water heater’s pilot light or main burner. The resulting flashback and fire can cause death or serious burns to anyone in the area. Even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited, gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance.

Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 inches (76.2 mm) in any direction, or if the appliance is installed in an alcove or closet, the entire floor must be covered by the panel. Failure to heed this warning may result in a fire hazard.

FIGURE 3.

Minimum clearances between the water heater and combustible and noncombustible construction are 0” at the sides and rear, 4” at the front, and 6” from the vent pipe. Clearance from the top of the draft hood is 12”. Refer to the label on the water heater located adjacent to the gas control valve for all clearances.

A gas water heater cannot operate properly without the correct amount of air for combustion. Do not install in a confined area such as a closet, unless you provide air as shown in the Typical Installations, see Figure 2 page 6. Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death, serious bodily injury, or property damage.

If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-servicelaundries 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.

Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly flammable in many cases, will also change to corrosive hydrochloric acid when exposed to the combustion products of the water heater. The results can be hazardous, and also cause product failure.

INSULATION BLANKETS

Insulation blankets are available to the general public for external use on gas water heaters but are not necessary with these products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions (For identification of components mentioned below, see Figure 1). Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death.

Do not apply insulation to the top of the water heater, as this will interfere with safe operation of the draft hood.

Do not cover the outer door, thermostat or temperature & pressure relief valve.

Do not allow insulation to come within 2” (50.8 mm) of the floor to prevent blockage of combustion air flow to the burner.

Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

Do obtainnewwarningandinstructionlabelsfromthemanufacturer for placement on the blanket directly over the existing labels.

Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow.

INSTALLING THE NEW WATER HEATER

SECURING WATER HEATER TO FLOOR AND WALL

The water heater must be secured to the floor and to the wall of the enclosure with the three mounting brackets and screws packaged in the carton with the water heater. The two small brackets stamped #0110064 are used to attach the water heater to the floor and the one large bracket #0110063 is used to secure the top of the water heater to the wall.

Because of installation variances these brackets can be located at any points around the circumference of the jacket. When the bracket locations are determined using the 1/8 inch drill bit for a pattern, drill only through the outer jacket of the water heater. Then using the screws provided, secure the bracket to the water heater, floor and wall, see Figure 4. If the heater is installed in a drain pan, seal the drilled holes and screws with a heavy bead of silicone sealant to prevent any potential water damage.

FIGURE 4.

T&P Valve and Pipe Insulation

Remove insulation for T&P Valve and pipe connections from carton.

Fit pipe insulation over the hot water line. Make sure that the insulation is against the top cover of the heater.

Fit T&P Valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T&P valve.

Secure all insulation using tape.

Water Piping

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a *mixing valve, should be used at the hot water taps used by these people or at the water heater, see Figure 2. Valves for reducing point of use temperature by mixing cold and hot water are also available:

ConsultaQualifiedInstallerorServiceAgency. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

This water heater shall not be connected to any heating systems or component(s) used with a non-potablewater heating appliance.

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

Water supply systems may, because of such events as high line pressure, frequent cut-offs,the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back flow preventers, etc. to control these types of problems. When these devices are not equipped with an internalby-pass,and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water.

The water within the water heater tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater’s temperature-pressurerelief valve is reached, the valve will relieve the excess pressure.The temperature-pressure relief valve is not intended for the constant relief of thermal expansion.

This is an unacceptable condition and must be corrected.

It is recommended that any devices installed which could create a closed system have a by-passand/or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system. Expansion tanks are available for ordering through a local plumbing contractor. Contact the local water supplier and/or a service agency for assistance in controlling these situations.

NOTE: To protect against untimely corrosion of hot and coldwaterfittings,itisstronglyrecommendedthatdi-electricunionsor couplings be installed on this water heater when connected to copper pipe.

FIGURE 5.

Figure 5 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4 inch NPT water connections.

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.

WATER PIPING PRESSURE TEST

This section is only for the manufacturer installing the water heater when the installation is to comply with H.U.D. Standards.

When testing the water ways, H.U.D. Standards state:

“Water distribution system. All water piping in the water distribution system shall be subjected to a pressure test. The test shall be made by subjecting the system to air or water at 100 psi for 15 minutes without loss of pressure. When air pressure is used, the water heater shall not be connected during the test”.

NOTE: If water piping system is to be air pressure tested, the water heater must be disconnected from the water piping system. Failure to disconnect the water heater during air pressure testing of water piping system could resultIN DEATH, SERIOUS BODILY INJURY,

OR PROPERTY DAMAGE.

FIGURE 6.

Temperature-PressureRelief Valve

10