Maytag HRP5975S, HRN4975S, HRN5975S, HRP4975S User Manual

Series Nine

GAS WATER HEATER

USER’S GUIDE

FOR POTABLE WATER HEATING ONLY

NOT SUITABLE FOR SPACE HEATING

NOT FOR USE IN

MANUFACTURED (MOBILE) HOMES

Model Number

HRN4975S HRP4975S HRN5975S HRP5975S

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

PRINTED IN THE U.S.A 1004 PART NO. 66001853

www.maytagwaterheaters.com

196302-001

SAFE INSTSAFE INST

SAFE INST

SAFE INSTSAFE INST

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.

DANGER

WARNING

CAUTION

ALLAALLA

ALLA

ALLAALLA

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.

TIONTION

TION

TIONTION

DANGER indicates an imminently hazardous situation which, if not avoided, could result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

, USE AND SERVICE, USE AND SERVICE

, USE AND SERVICE

, USE AND SERVICE, USE AND SERVICE

CAUTION used without the safety alert

CAUTION

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.

• Maytag Customer Service Center: The Maytag Customer Service Center has the 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 Center also has a thorough understanding of this instruction manual, and is 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 which 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.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

IMPORTANT DEFINITIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

ABLE OF CONTENTSABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE ................................................................................................. 2

SAFETY PRECAUTIONS.............................................................................................................................. 3

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

CUSTOMER RESPONSIBILITIES ................................................................................................................ 5

PRODUCT SPECIFICATIONS ...................................................................................................................... 5

ACCESSORIES AND TOOLS NEEDED ...................................................................................................... 6

Accessories ............................................................................................................................................................ 6

Tools ....................................................................................................................................................................... 6

PREPARATIONS FOR INSTALLATION ......................................................................................................... 7

Removing the Old Water Heater .............................................................................................................................. 7

TYPICAL INSTALLATION............................................................................................................................ 8,9

Get to Know Your Water Heater .............................................................................................................................. 8

Mixing Valve Usage ................................................................................................................................................. 9

LOCATING AND INSTALLING THE NEW HEATER ................................................................................ 10-18

Facts to Consider About the Location ...............................................................................................................10,11

Insulation Blankets ............................................................................................................................................ 11,12

Combustion Air and Ventilation for Appliances

Located in Unconfined Spaces .............................................................................................................................. 12

Combustion Air and Ventilation for Appliances

Located in Confined Spaces ............................................................................................................................. 12,13

Water Piping .................................................................................................................................................... 13,14

Temperature Pressure Relief Valve.................................................................................................................... 14,15

Filling the Water Heater .................................................................................................................................... 15,16

Venting ............................................................................................................................................................. 16,17

Gas Piping ....................................................................................................................................................... 17,18

Sediment Traps ..................................................................................................................................................... 18

OPERATING INSTRUCTIONS ................................................................................................................ 19-21

Lighting & Operating Label ............................................................................................................................... 19,20

Temperature Regulation ......................................................................................................................................... 21

SERVICE AND MAINTENANCE .............................................................................................................. 22-24

Tank (Sediment) Cleaning ...................................................................................................................................... 22

Vent System Inspection ........................................................................................................................................ 22

Burner Inspection .................................................................................................................................................. 22

Burner Cleaning ..................................................................................................................................................... 22

Housekeeping ....................................................................................................................................................... 23

Anode Rod Inspection ........................................................................................................................................... 23

Temperature-Pressure Relief Valve Operation ........................................................................................................ 23

Draining ............................................................................................................................................................ 23,24

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

Service .................................................................................................................................................................. 24

TROUBLESHOOTING ............................................................................................................................ 24-26

Start Up Conditions .......................................................................................................................................... 24,25

Draft Hood Operation .................................................................................................................................... 24

Condensation ........................................................................................................................................... 24,25

Smoke / Odor ............................................................................................................................................... 25

Thermal Expansion ....................................................................................................................................... 25

Strange Sounds ............................................................................................................................................ 25

Operational Conditions ..................................................................................................................................... 25,26

Smelly Water ............................................................................................................................................... 25

“AIR” In Hot Water Faucets .......................................................................................................................... 25

High Temperature Shut Off System .......................................................................................................... 25,26

Leakage Checkpoints ............................................................................................................................................ 26

TROUBLESHOOTING GUIDE .................................................................................................................... 27

REPAIR PARTS LIST .................................................................................................................................. 28

NOTES .................................................................................................................................................................. 29-31

WARRANTY ................................................................................................................................................ 32

CUSTOMER RESPONSIBILITIESCUSTOMER RESPONSIBILITIES

CUSTOMER RESPONSIBILITIES

CUSTOMER RESPONSIBILITIESCUSTOMER RESPONSIBILITIES

Thank You for purchasing a Maytag water heater. Properly installed and maintained, it should give you years of trouble free service. It is strongly suggested that this new water heater be professionally installed, contact Maytag Customer Service

(1-800-788-8899) for recommended installers.

Abbreviations Found In This Instruction Manual:

• EPACT - Energy Policy A ct

• UL - Underwriters Laboratories Inc.

• CAN - Canada

• CSA - Canadian Standards Association

• NFPA - National Fire Protection Association

• ANSI - American National Standards Institute

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturer’s Association

This gas-fired water heater is design certified by Underwriters Laboratories Inc. under American National Standard/CSA Standard for Gas Water Heaters ANSI Z21.3 • CSA 4.3 (current edition).

• Read the “Safety Precautions” 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-fired water heater. It also contains warnings through out 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

TO INSTALL OR OPERATE THE WATER HEATER.

• 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. This publication is available from CSA International, 8501 East Pleasant Valley Rd, Cleveland Ohio 44131, or the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

• If after reading this manual you have any questions or do not understand any portion of the instructions, call Maytag

Customer Service at 1-800-788-8899 for an authorized servicer.

• 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 9 through 14.

Examine the location to ensure the water heater complies with the Locating and Installing the New Heater section in this manual.

• 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 your local dealer, wholesaler, public utilities or California Office of the State Architect, 400 P Street, Sacramento, CA 95814.

• 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.

• Complies with SCAQMD rule #1146.2 and districts having equivalent NOx requirements.

PRODUCT SPECIFICAPRODUCT SPECIFICA

PRODUCT SPECIFICA

PRODUCT SPECIFICAPRODUCT SPECIFICA

TANK RECOVERY MINIMUM DIMENSIONS

CAPACITY TYPE RATE GALS. VENT PIPE DIAMETER IN INCHES (mm)

IN GALS OF BTU PER HOUR INCHES INCHES HEIGHT TOP OF

*MODEL NUMBER ( LTRS) GAS RATE @ 90°F RISE (mm) (mm) DRAFT HOOD

HRN4975S 75 (284) NATURAL 75,100 81.0 4" (102) 26 3/8" (670) 61 1/8" (1,553) HRP4975S 75 (284) PROPANE 75,100 81.0 4" (102) 26 3/8" (670) 61 1/8" (1,553)

* High altitude models HRN5975S and HRP5975S have derated B.T.U. and Recovery rates.

TIONSTIONS

TIONS

TIONSTIONS

ACCESSORIES AND TOOLS NEEDEDACCESSORIES AND TOOLS NEEDED

ACCESSORIES AND TOOLS NEEDED

ACCESSORIES AND TOOLS NEEDEDACCESSORIES AND TOOLS NEEDED

Accessories

To simplify the installation Maytag has available the installation parts shown below. You may or may not need all of these accessories depending on your type of installation. Call Maytag Customer Service at 1-800-788-8899 for an authorized installer.

EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS (7.6 LITERS), Part No. 66001013 AND 5 GALLONS (18.9 LITERS), Part No. 66001014 CAPACITY.

Tools

You may or may not need all these tools, depending on your type of installation. These tools can be purchased at your local hardware store.

• Pipe Wrenches (2) 14” (356 mm)

• Screwdriver

• Tin Snips

• 6’ (1.82 m) Tape or Folding Ruler

• Garden Hose

• Drill

• Pipe Dope or Teflon Tape

DRILL

SLOT-HEAD SCREWDRIVER

PHILLIPS SCREWDRIVER

TIN SNIPS

DRAIN PANS AVAILABLE IN 22” (559 mm) DIAMETER (PART NO.

66001011) FOR WATER HEATERS HAVING A DIAMETER 20” (508 mm) OR LESS, 24” (610mm) DIAMETER (PART NO. 66001105) FOR WATER HEATERS HAVING A DIAMETER 22” (559 mm) OR LESS AND 28” (711 mm) DIAMETER (PART NO. 66001012) FOR WATER HEATERS HAVING A DIAMETER 26” (660 mm) OR LESS.

Additional Tools Needed When Sweat Soldering

• Tubing Cutters or Hacksaw

• Propane Tank

• Soft Solder

• Solder Flux

• Emery Cloth

• Wire Brushes

PROPANE

TUBING CUTTER

TORCH

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER HEATER

CONNECTIONS)

GARDEN HOSE

6 FOOT TAPE

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

PIPE WRENCH

3/4” (19 mm) WIRE BRUSH

1/2” (13 mm) WIRE BRUSH

HACKSAW

ROLL OF

EMERY CLOTH

ROLL OF LEAD-FREE

SOFT SOLDER

SOLDER

FLUX

PREPPREP

PREP

PREPPREP

ARAARA

TIONS FOR INSTTIONS FOR INST

ARA

TIONS FOR INST

ARAARA

TIONS FOR INSTTIONS FOR INST

ALLAALLA

ALLA

ALLAALLA

TIONTION

TION

TIONTION

Removing the Old Water Heater

FIGURE 1.

4. Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors. Open the water heater drain valve. Open a nearby hot water faucet which will relieve pressure in the water heater and speed draining. The water passing out of the drain valve may be extremely hot. To avoid being scalded, make sure all connections are tight and that the water flow is directed away from any person, see Figures 1 and 4.

5. Disconnect the vent pipe from the draft hood where they connect to the water heater. In most installations the vent pipe can be lifted off after any screw or other attached devices are removed. Dispose of the draft hood. The new water heater has the draft hood which must be used for proper operation.

6. If you have copper piping to the water heater, the two copper water pipes can be cut with a hacksaw approximately four inches away from where they connect to the water heater. This will avoid cutting off pipes too short. Additional cuts can be made later if necessary. Disconnect the temperaturepressure relief valve drain line. When the water heater is drained, disconnect the hose from the drain valve. Close the drain valve. The water heater is now completely disconnected and ready to be removed, see Figure 5.

FIGURE 4.

1. Turn “OFF” the gas supply to the water heater.

If the main gas line Shut-off valve serving all gas appliances is used, also shut “OFF” the gas at each appliance. Leave all gas appliances shut “OFF” until the water heater installation is completed, see Figures 1 and 2.

2. Turn “OFF” the water supply to the water heater at the water shut-off valve or water meter. Some installations require that the water be turned off to the entire house, see Figures 1 and 3.

3. Check again to make sure the gas supply is “OFF” to the water heater. Then disconnect the gas supply connection from the gas control valve.

FIGURE 2.

FIGURE 3.

FIGURE 5.

If you have galvanized pipe to the water heater, loosen the two galvanized pipes with a pipe wrench at the union in each line. Also disconnect the piping remaining to the water heater. These pieces should be saved since they may be needed when reconnecting the new water heater. Disconnect the temperature-pressure relief valve drain line. When the water heater is drained, disconnect the hose from the drain valve. Close the drain valve. The water heater is now completely disconnected and ready to be removed. Mineral buildup or sediment may have accumulated in the old water heater. This causes the water heater to be much heavier than normal and this residue, if spilled out, could cause staining, see Figure 6.

FIGURE 6.

TYPICAL INSTTYPICAL INST

TYPICAL INST

TYPICAL INSTTYPICAL INST

ALLAALLA

ALLA

ALLAALLA

TIONTION

TION

TIONTION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe B Draft Hood C Anode D Hot Water Outlet E Outlet

F Water Connections G Gas Supply H Manual Gas Shut-off Valve

I Ground Joint Union

* INSTALL IN ACCORDANCE

WITH LOCAL CODES.

* DRIP LEG AS REQUIRED

BY LOCAL CODES.

TO VENT TERMINATION

ON ROOF

J Drip Leg (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 Thermostat U Drain Valve V Pilot and Main Burner

W Flue

X Drain Pan Y Thermostat Shield (optional)

(T) THERMOSTAT

* ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

** CLOSED WATER SYSTEMS ARE THOSE WITH

BACK FLOW PREVENTION DEVICES INSTALLED IN THE INLET WATER SERVICE LINE.

THERMOSTAT

SHIELD

(OPTIONAL)

FIGURE 7.

(V) PILOT & MAIN BURNER -NATURAL GAS

(V) PILOT & MAIN BURNER - PROPANE GAS

MAIN

BURNER

PILOT

BURNER

THERMOCOUPLE

TYPICAL INSTTYPICAL INST

TYPICAL INST

TYPICAL INSTTYPICAL INST

ALLAALLA

ALLA

ALLAALLA

MIXING VALVE USAGE

TIONTION

TION

TIONTION

FIGURE 8.

This appliance has been design certified as complying with American 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 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 province 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. See Figure 8. Valves for reducing point of use temperature by mixing cold and hot water are also available. Consult Maytag Customer Service (1-800-788-8899). 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 22 and 23 on page 21.

OCAOCA

OCA

OCAOCA

TING AND INSTTING AND INST

TING AND INST

TING AND INSTTING AND INST

ALLING THE NEW WALLING THE NEW W

ALLING THE NEW W

ALLING THE NEW WALLING THE NEW W

TER HEATER HEA

TER HEA

TER HEATER HEA

TERTER

TER

TERTER

Facts to Consider About the Location

Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the 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:

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

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

• 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.

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 than 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-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.

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, as well as property damage. If installation in such areas is your only option, then the installation must be accomplished in a way that the pilot flame and main burner flame are elevated from the floor at least 18 inches. While this may reduce the chances of flammable vapors, from a floor spill being ignited, gasoline and other flammable substances should never be stored or used in the same room or area containing a gas water heater or other open flame or spark producing appliance. NOTE: Flammable vapors may be drawn by air currents from other areas of the structure to the appliance.

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

+ 22 hidden pages