A.O. Smith 185363-001 User Manual

Instruction Manual

RESIDENTIAL GAS WATER HEATERS

POWER VENTED GAS MODELS W/HOT SURFACE IGNITION

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

A DIVISION OF A. O. SMITH CORPORA TION

Ashland City, TN 37015

www.hotwater.com

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 WA TER HEATER.

ALL TECHNICAL AND W ARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WA TER HEA TER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLA TE ON THE WA TER HEA TER.

KEEP THIS MANUAL IN THE POCKET ON HEA TER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

PRINTED IN THE U.S.A 0905 PAR T NO. 185363-001

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-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.

IMPORTANT DEFINITIONS

• Qualified Installer: A qualified 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 use of flammable vapor ignition resistant water heaters, and have a thorough understanding of this instruction manual.

• Service Agency: A service 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 INSTALLA TION, USE AND SERVICE...............................2

GENERAL SAFETY ..................................................................3

TABLE OF CONTENTS.............................................................. 4

INTRODUCTION ........................................................................4

Preparing for the New Installation...................................4

TYPICAL INST ALLA TION ...................................................... 5-6

LOCA TING THE NEW WA TER HEA TER..................................... 7

Facts to Consider About Location ............................... 7-8

Insulation Blankets ...........................................................8

Combustion Air and V entilation for Appliances

Located in Unconfined Spaces........................................ 8

Combustion Air and V entilation for Appliances

Located in Confined Spaces........................................ 8-9

INSTALLING THE W ATER HEATER ......................................... 10

Water Piping ..............................................................10-1 1

T emperature-Pressure Relief V alve............................... 11

Gas Piping ...................................................................... 12

Sediment Traps .............................................................. 13

Blower Assembly Installation ........................................13

Vent Pipe Connection to Blower Assembly................... 14

Venting and Installation............................................ 14-15

LIGHTING & OPERA TING LABEL ............................................ 20

TEMPERA TURE REGULATION ................................................ 21

FOR YOUR INFORMATION ..................................................... 22

Start Up Conditions ........................................................ 22

Condensate .................................................................... 22

Smoke/Odor.................................................................... 22

Thermal Expansion......................................................... 22

Strange Sounds..............................................................22

Operational Conditions................................................... 22

Smelly Water .................................................................. 22

“Air” in Hot Water Faucets............................................. 22

High T emperature Shut Of f System...............................22

PERIODIC MAINTENANCE .......................................................23

Venting System Inspection ............................................ 23

Burner Inspection...........................................................23

Burner Cleaning.............................................................. 23

Housekeeping .......................................................... 23-24

Anode Rod Inspection....................................................24

T emperature-Pressure Relief Valve Operation .............. 24

Draining ..........................................................................24

Drain Valve Washer Replacement........................... 24-24

Service ........................................................................... 25

LEAKAGE CHECKPOINTS ......................................................25

REPAIR P ARTS .......................................................................26

TROUBLESHOOTING ........................................................ 27-28

NOTES .............................................................................. 29-30

WARRANTY ........................................................................... 31

INTRODUCTION

Thank Yo u 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

• UL - Underwriters Laboratories Inc.

This gas-fired water heater is design certified by Underwriters Laboratories Inc. under American National S tandard/CSA Standard for Gas Water Heaters 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 BODIL Y INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings 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 T O INST ALL OR OPERATE THE W ATER HEA TER.

2. 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/ NFPA 54 and the National Electrical Code, NFP A 70. These publications are available from The National Fire Protection Association, 1 Batterymarch Park, Quincy , MA 02269.

3. The water heater when installed must be grounded in accordance with the local codes, or in the absence of local codes: In the United States, the National Electric Code. ANSI/NFP A 70.

4. 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.

5. 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.

6. 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 St ate Architect, 400 P S treet, Sacramento, CA 95814.

7. Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

8. Complies with SCAQMD rule #1121 and districts having equivalent NOx requirements.

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe–Exhaust B Vent Terminal C Vent Adapter-Rubber Boot D Blower Assembly

E Cold Water Inlet

F Inlet Water Shut-off Valve G Union H Inlet Dip Tube

J Anode**

* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS. ** LOCATED UNDER THE BLOWER ASSEMBLY.

K Hot Water Outlet L Outlet Receptacle (115 VAC)

M Temperature-Pressure Relief Valve

N Flue

O Flue Baffle Assembly**

P Insulation

Q Control Harness

R Rating Plate S Gas Supply T Manual Gas Shut-off Valve U Ground Joint Union

NATURAL HOT SURFACE IGNITER & MAIN BURNER

SURFACE

IGNITOR

PROPANE HOT SURF ACE IGNITER & MAIN BURNER

SURFACE

IGNITOR

V Drip Leg (Sediment Trap)

W Drain Valve

X Gas Valve-Thermostat Y Drain Pan

Z Air Intake Screen - Base Pan AA Inner Door BB Outer Door CC HSI Burner Assembly DD Air Intake Screen -

Blower Assembly

EE FV Sensor Assembly

HOT

SENSOR

HOT

*CAUTION: 115 VAC IN CONTROL HARNESS AND INSIDE OUTER DOOR

GAS MODELS WITH HOT SURF ACE IGNITION & 2", 3" OR 4" PVC VENT CAPABILITY

SENSOR

TEMPERATURE INDICA TORS

TEMPERATURE ADJUSTMENT BUTTONS

FIGURE 1.

TYPICAL INSTALLATION

MIXING VAL VE USAGE

FIGURE 2.

This appliance has been design certified as complying with American National Standard/CSA S tandard for water heaters and is considered suitable for:

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

HOTTER WA TER 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, shall 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 “T emperature Regulation” section in this manual, see Figure 20.

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCA TION

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 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. Select a location indoors as close as practical to the vent terminal or location to which the water heater vent piping is going to be connected, and as centralized with the water piping system as possible.

2. Selected location must provide adequate clearances for servicing and proper operation of the water heater.

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" (5.1 cm) greater that the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air flow.

FIGURE 3.

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

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-off device 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-off devices 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 .

INSTALLA TIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as gasoline, solvent s, 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 hot surface igniter or main burner. The resulting flashback and fire can cause death or serious burns to anyone in the area. This water is equipped with a FV sensor for detecting the presence of flammable vapors, see Figure 3. When the sensor detects those vapors, the unit will shut down and not operate. Should this happen, please refer to the troubleshooting guide on pages 27-28. 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.

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" (7.6 cm) 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.

Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 5" (12.7 cm) from the front

and 12" (30.5 cm) from the top. (Standard clearance.) If clearances stated on the heater differ from standard clearances, install water heater according to clearances stated on the heater.

flammable in many cases, will also react to form corrosive hydrochloric acid when exposed to the combustion products of the water heater . The results can be hazardous, and also cause product failure.

Adequate clearance for servicing this appliance should be considered before installation, such as changing the anodes, etc.

A minimum clearance of 5" (12.7 cm) must be allowed for access to replaceable parts such as the thermostats, drain valve and relief valve.

When installing the heater, consideration must be given to proper location. Location selected should be as close to the wall as practicable and as centralized with the water piping system as possible.

FIGURE 4.

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 “Locating The New Water Heater” section. 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.

INSULA TION 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. Y our water heater meets or exceeds the National Appliance Energy Conversation 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.

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.

Propellants of aerosol sprays and volatile compounds, (cleaners, chlorine based chemicals, refrigerants, etc.) in addition to being highly

• 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" (5.1 cm) 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 obtain new warning and instruction labels from the manufacturer

• 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.

COMBUSTION AIR AND VENTILATION FOR APPLIANCES LOCATED IN UNCONFINED SP ACES

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 cubic meters per kW) of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.

In unconfined spaces in buildings, infiltration may be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in “Combustion Air and V entilation for Appliances Located in Confined S paces.”

COMBUSTION AIR AND VENTILATION FOR APPLIANCES LOCATED IN CONFINED SP ACES

CONFINED SPACE is a sp ace whose volume is less than 50 cubic feet

per 1,000 Btu per hour (4.8 cm per kW) of the aggregate input rating of all appliances installed in that space.

Chemical vapor corrosion of the flue, blower assembly and vent system may occur if air for combustion contains certain chemical vapors. Spray can propellant s, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, bleach and process chemicals are typical compounds which are potentially corrosive.

A. ALL AIR FROM INSIDE BUILDINGS: (See Figure 5 and 6) The confined space shall be provided with two permanent openings

communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of one square inch per 1,000 Btu per hour (22 cm equipment in the confined space, but not less than 100 square inches (645 cm

). One opening shall commence within 12 inches

/kW) of the total input rating of all gas utilization

(31 cm) of the top and one commencing within 12 inches (31 cm) of the bottom of the enclosures.

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 Btu per hour (5.5 cm

/kW) of total input rating of all equipment in the

enclosure, see Figure 8.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 Btu per hour (1 1 cm

/kW)) of total input rating of all equipment

in the enclosure, see Figure 9.

FIGURE 8.

FIGURE 6.

B. ALL AIR FROM OUTDOORS: (See Figures 7, 8 and 9)

The confined space shall be provided with two permanent openings,

one commencing within 12 inches (31 cm) of the top and one commencing within 12 inches (31 cm) from the bottom of the enclosure. The openings shall communicate directly , or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btu per hour

(5.5 cm

/kW) of total input rating of all equipment in the enclosure,

see Figure 7.

4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum short side dimension of rectangular air ducts shall not be less than 3 inches (7.6 cm), see Figure 9.

FIGURE 9.

5. Louvers and Grilles: In calculating free area, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch (6.4 mm) mesh. If the free area through a design of louver or grille is known, it should be used in calculating the size opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will be 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

FIGURE 7.

6. Special Conditions Created by Mechanical Exhausting or Fireplaces: operation of exhaust fans, ventilation systems, clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.

INSTALLING THE NEW WATER HEATER

WATER PIPING

HOTTER WA TER 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, shall 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:

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-pressure relief 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-pass and/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.

assistance in controlling these situations.

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.

All gas piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1/ NFP A-54) whichever applies. Copper and brass tubing and fittings (except tin lined copper tubing) shall not be used.

Contact the local water supplier and/or a service agency for

Consult a Qualified Installer or Service Agency. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “T emperature Regulation” section in this manual.

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

All piping components connected to this unit for space heating applications shall be suitable for use with potable water .

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

When the system requires water for space heating at temperatures higher than required for domestic water purposes, a tempering valve must be installed. Please refer to Figure 2 for suggested piping arrangement.

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 internal by-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.

FIGURE 10.

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A.O. Smith 185363-001 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual