Maytag HV650YBVIT, HV640YBVIT, HV640HBVIT, HV650HBVIT user manual

Series Six

POWER VENT

GAS WATER HEATER

USER’S GUIDE

FOR POT ABLE WATER HEATING ONLY

NOT SUITABLE FOR SPACE HEATING

NOT FOR USE IN

MANUFACTURED (MOBILE) HOMES

Model Numbers

HV640YBVIT HV650YBVIT HV640HBVIT HV650HBVIT

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

For Y our Safety

AN ODORANT IS ADDED TO THE GAS USED BY THIS

WA TER HEA TER.

• Safety Instructions

• Installation

• Operation

• Care and Maintenance

• Troubleshooting

• Parts List

PRINTED IN THE U.S.A. 0906 PART NO. 185374-001

www.maytagwaterheaters.com

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

• Maytag Customer Service Center: The Maytag Customer Service Center has the 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 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 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.

SAFETY PRECAUTIONS

TABLE OF CONTENTS

SAFE INST ALLA TION, USE AND SERVICE.................................................................................................................................... 2

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

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

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

PRODUCT SPECIFICA TIONS......................................................................................................................................................... 5

MATERIALS AND BASIC TOOLS NEEDED .................................................................................................................................... 6

TYPICAL INSTALLATION.............................................................................................................................................................. 7-8

INST ALLA TION INSTRUCTIONS .............................................................................................................................................. 9-22

Removing the Old Water Heater ............................................................................................................................................. 9

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

Insulation Blankets................................................................................................................................................................. 11

Combustion Air and Ventilation for Appliances Located in Unconfined Spaces ............................................................. 11

Combustion Air and Ventilation for Appliances Located in Confined Spaces ............................................................11-12

Water Piping ...................................................................................................................................................................... 13-14

Temperature-Pressure Relief Valve .....................................................................................................................................14

Gas Piping ............................................................................................................................................................................... 15

Sediment Traps ......................................................................................................................................................................16

Fil lin g the Wat er H eat er ......................................................................................................................................................... 16

Blower Assembly Installation ................................................................................................................................................ 16

Vent Connections to Blower Assembly................................................................................................................................. 17

Venting and Installation ................................................................................................................................................... 17-18

Condensation ......................................................................................................................................................................... 18

Maximum Vent Lengths..........................................................................................................................................................18

Venting ..................................................................................................................................................................................... 19

Vent Terminal Installation ................................................................................................................................................ 19-20

Vertical Vent Through Roof.....................................................................................................................................................20

Vertical Vent Restrictions .......................................................................................................................................................20

Vent Pipe Preparation ...................................................................................................................................................... 21-22

OPERA TING INSTRUCTIONS................................................................................................................................................. 23-24

Lighting and Operating Label ...............................................................................................................................................23

Temperature Regulation ........................................................................................................................................................ 24

FOR YOUR INFORMATION............................................................................................................................................................25

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

Operational Conditions .......................................................................................................................................................... 25

SERVICE AND ADJUSTMENT ................................................................................................................................................. 26-27

Venting System Inspection ....................................................................................................................................................26

Burner Operation and Inspection ......................................................................................................................................... 26

Burner Cleaning .....................................................................................................................................................................26

Housekeeping ........................................................................................................................................................................ 26

Anode Rod Inspection ............................................................................................................................................................ 27

Temperature-Pressure Relief Valve Operation ................................................................................................................... 27

Draining ................................................................................................................................................................................... 27

Drain Valve Washer Replacement ........................................................................................................................................27

Service .....................................................................................................................................................................................27

LEAKAGE CHECKPOINTS ............................................................................................................................................................ 28

TROUBLESHOOTING GUIDELINES ...................................................................................................................................... 29-30

P ARTS ORDER LIST...................................................................................................................................................................... 31

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

.................................25

CUSTOMER RESPONSIBILITIES

Thank Yo u 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:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFP A - 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 listed by Underwriters Laboratories Inc. under American National S tandard/CSA Standard for Gas W ater Heaters ANSI Z21.10.1 • CSA 4.1 (current edition).

PREPARING FOR THE INSTALLATION

1. 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 DEA TH, SERIOUS BODILY INJUR Y 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

A TTEMPTING TO 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, the National Electrical Code NFPA 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 Maytag Customer Service at 1-800-788-8899 for an authorized servicer.

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.

Examine the location to ensure the water heater complies with the “Facts to Consider About the Location” 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. For more information see next page.

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

PRODUCT SPECIFICATIONS

TANK RECOVERY MINIMUM

CAP ACITY INPUT RATE GALS. VENT PIPE DIAMETER DIMENSIONS IN

MODEL IN GALS. TYPE OF RA TE PER HOUR INCHES INCHES INCHES (mm) HEIGHT

NUMBER (LTRS) GAS (Btu/hr) @ 90°F RISE (mm) (mm) TO JACKET TOP HV640YBVIT 40 (151) NATURAL 40,000 44 2 (51) 18 1/2 (470) 55 (1,397) HV650YBVIT 50 (189) NATURAL 40,000 44 2 (51) 20 (508) 56 3/4 (1,441) HV640HBVIT 40 (151) PROP ANE 40,000 44 2 (51) 18 1/2 (470) 55 (1,397) HV650HBVIT 50 (189) PROP ANE 40,000 44 2 (51) 20 (508) 56 3/4 (1,441)

INST ALLA TION REQUIREMENTS FOR THE COMMONWEAL TH OF MASSACHUSETTS

For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

INST ALLA TION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certified.

SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the

installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a

Product Approved side wall horizontally vented gas fueled equipment does not provide the p art s for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

MATERIALS AND BASIC TOOLS NEEDED

Accessories

T o simplify the installation Maytag has available the installation parts shown below . Y ou 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 inst aller.

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

T ools

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 A V AILABLE IN 22” (559 mm) DIAMETER (P ART NO.

66001011) FOR WA TER HEA TERS HAVING A DIAMETER 20” (508 mm) OR LESS, 24” (610mm) DIAMETER (PART NO. 66001 105) FOR WA TER HEA TERS HAVING A DIAMETER 22” (559 mm) OR LESS AND 28” (711 mm) DIAMETER (P ART NO. 66001012) FOR WA TER HEA TERS HA VING A DIAMETER 26” (660 mm) OR LESS.

Additional Tools Needed When Sweat Soldering

• Tubing Cutters or Hacksaw

• Propane Torch

• Soft Solder

• Solder Flux

• Emery Cloth

• Wire Brushes

PROPAN E

TUBING CUTTER

TORCH

ROLL OF TEFLON

TAPE (USE ONL Y ON

WA TER HEA TER

CONNECTIONS)

GARDEN HOSE

6 FOOT TA PE

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WA TER 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

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A V ent 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 SURF ACE 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 VALVE USAGE

FIGURE 2.

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 V alve, 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 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 “T emperature Regulation” section in this manual, see Figure 26.

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

4. Att ach 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. T o avoid being scalded, make sure all connections are tight and that the water flow is directed away from any person, see Figures 3 and 6.

5. Disconnect the vent pipe from the blower assembly where it connects to the water heater. In most inst allations the vent pipe can be lifted off after any screw or other attached devices are removed. Make sure existing vent complies with maximum and minimum vent lengths on page 18.

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, see Figure 7. This will avoid cutting off pipes too short. Additional cuts can be made later if necessary. 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.

FIGURE 6.

FIGURE 3.

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 3 and 4.

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 3 and 5.

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 4.

FIGURE 5.

FIGURE 7.

If you have galvanized pipes 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, see Figure 8. These pieces should be saved since they may be needed when reconnecting the new water heater. 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. 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.

FIGURE 8.

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 than the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air flow.

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, 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 hot surface igniter or main burner. The resulting flashback and fire can cause death or serious burns to anyone in the area. This water heater is equipped with a FV sensor for detecting the presence of flammable vapors, see Figure 9. 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 29-30. 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.

FIGURE 9.

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 .

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

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