Maytag HXN4975S 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

HXN4975S HXP4975S

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

PRINTED 0107 197671-001

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.

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

DANGER

WARNING

CAUTION

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.

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.

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

IMPORTANT DEFINITIONS

• 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 Natural Gas and Propane Installation 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.

SAFETY PRECAUTIONS

TABLE 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 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). The installation must conform with CAN/CSA-B149.1, installation code and/or Local Installation Codes.

• 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 Natural Gas and Propane Installation Code CAN/CSA-B149.1. This publication is available from the Canadian Standards Association, 5060 Spectrum Way, Suite 100 Mississauga, Ontario, Canada L4W 5N6.

• 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.

PRODUCT SPECIFICATIONS

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

HXN4975S 75 (284) NATURAL 75,100 81.0 4" (102) 26 3/8" (670) 61 1/8" (1,553) HXP4975S 75 (284) PROPANE 75,100 81.0 4" (102) 26 3/8" (670) 61 1/8" (1,553)

ACCESSORIES 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

EMERY CLOTH

ROLL OF LEAD-FREE

SOFT SOLDER

ROLL OF

SOLDER

FLUX

PREPARATIONS FOR INSTALLATION

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 INSTALLATION

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 INSTALLATION

MIXING VALVE USAGE

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.

LOCATING AND INSTALLING THE NEW WATER HEATER

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.

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.

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 and Installing 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.

FIGURE 10.

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.

Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 4 inches (102 mm) at the front, and 6 inches (153 mm) from the vent pipe. Clearance from the top of the jacket is 12 inches (305 mm) on most models. Note that a lesser dimension may be allowed on some models, refer to the label attached adjacent to the gas control valve on the water heater, see Figure 9.

FIGURE 9.

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 available to the general public for external use on gas water heaters are not necessary with Maytag products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your Maytag water heater meets or exceeds the EPACT 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 (See Figure 7 for identification of components mentioned below). Failure to follow

WARNING

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 obtain new warning and instruction labels from Maytag for placement on the blanket directly over the existing labels.

commence within 12 inches (30 cm) of the top and one commencing within 12 inches (30 cm) of the bottom of the enclosures.

• 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 Spaces

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 m 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 Ventilation for Appliances Located in Confined Spaces.

per kW) of the

Combustion Air and Ventilation for Appliances Located in Confined Spaces

FIGURE 11.

B. ALL AIR FROM OUTDOORS: (See Figures 12, 13 and 14)

The confined space shall be provided with two permanent

openings, one commencing within 12 inches (30 cm) of the top and one commencing within 12 inches (30 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.

CONFINED SPACE is a space whose volume is less than 50 cubic feet per 1,000 Btu per hour (4.8 m

per kW) of the

aggregate input rating of all appliances installed in that space.

A. ALL AIR FROM INSIDE BUILDINGS:

(See Figures 10 and 11)

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

/kW) of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches (645 cm

). One opening shall

FIGURE 12.

• 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 12.

• 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 13.

FIGURE 13.

• 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 (11 cm

/kW) of total input rating of all equipment in the enclosure, see Figure 14.

• When ducts are used, they shall be of the same crosssectional 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 (76.2 mm), see Figure 14.

Water Piping

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy 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 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 on page 9 and Figure 15 below. 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 manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the Temperature Regulation section in this manual.

FIGURE 14.

• 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.

• 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.

FIGURE 15.

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

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. Refer to the Thermal Expansion section under Troubleshooting

Guide or contact local plumbing authority or call Maytag Customer Service at 1-800-788-8899 for an authorized installer on how to control this situation.

can be accomplished by insulating the hot water lines from the water heater.

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.

Figure 16 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 1” NPT water connections for 75 gallon models.

NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water connections. Do not solder the water lines directly to the water connections on the tank. It will harm the dip tube and damage the tank.

• Look at the top cover of the water heater. The water outlet is marked “HOT”. Put two or three turns of teflon tape around the exposed end of the 1” NPT threaded nipple. Connect the hot water pipe to the hot water outlet on the water heater.

• Look at the top of the water heater. The cold water inlet is marked “COLD”. Put two or three turns of teflon tape around the exposed end of the 1” NPT threaded nipple. Connect the cold water pipe to the cold water inlet of the water heater.

NOTE: This water heater is super insulated to minimize heat loss from the tank. Further reduction in heat loss

FIGURE 16.

Temperature-Pressure Relief Valve

This heater is provided with a properly certified combination temperature - pressure relief valve by the manufacturer.

The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4 and the code requirements of ASME.

If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph.

The valve must be marked with a maximum set pressure not to exceed the marked maximum working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate.

For safe operation of the water heater, the relief valve must not be removed from its designated opening nor plugged.

The Discharge Pipe:

• Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

The temperature-pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only within 6 inches (153 mm) above, or at any distance below the structural floor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 feet (9.14 m), or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve, see Figure 17.

No valve or other obstruction is to be placed between the relief valve and the tank. Do not connect tubing directly to discharge drain unless a 6 inch air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water flow may cause property damage.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the temperature-pressure relief valve, and the discharge pipe.

• Shall terminate at an adequate drain.

• Shall not have any valve between the relief valve and tank.

The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot.

FIGURE 17.

If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions, and replace the temperature-pressure relief valve with a new one.

Filling the Water Heater

Never use this water heater unless it is completely full of water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” gas to the water heater.

To fill the water heater with water:

• Close the water heater drain valve by turning the handle to the right (clockwise). The drain valve is on the lower front of the water heater.

• Open the cold water supply valve to the water heater.

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

• To insure complete filling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant flow is obtained. This will let air out of the water heater and the piping.

To insure proper venting of this gas-fired water heater, the correct vent pipe diameter must be utilized. Any additions or deletions of other gas appliances on a common vent with this water heater may adversely affect the operation of the water heater. Consult your Maytag Service Center at

1-800-788-8899 or gas supplier if any such changes are planned.

For proper venting in certain installations, a larger diameter vent pipe may be necessary. Consult your Maytag Customer

Service Center at 1-800-788-8899 or gas supplier to aid you in determining the proper venting for your water heater from the vent tables in the current edition of CAN/CSA-B149.1 Installation Code.

Periodically check the venting system for signs of obstruction or deterioration and replace if needed.

• Check all water piping and connections for leaks. Repair as needed.

Venting

VENT DAMPERS - Any vent damper, whether it is operated thermally or otherwise must be removed if its use inhibits proper drafting of the water heater.

Thermally Operated Vent Dampers: This gas-fired water heater has a thermal efficiency at or above 80% which may produce a relatively low flue gas temperature. Such temperatures may not be high enough to properly open thermally operated vent dampers. This would cause spillage of the flue gases and may cause carbon monoxide poisoning.

Vent dampers must bear evidence of certification as complying with the current edition of the American National Standard ANSI Z21.66/CGA 6.14, (covering electrically and mechanically actuated vent dampers). Before installation of any vent damper,

consult your Maytag Customer Service Center at 1-800-7888899 or the local gas supplier for further information.

The combustion and ventilation air flow must not be obstructed.

The water heater with draft hood installed must be connected to a chimney or listed vent pipe system, which terminates to the outdoors. Never operate the water heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation, explosion or asphyxiation.

• For proper draft hood attachment, the draft hood legs may be angled slightly inward.

• Place the draft hood legs in the receiving holes on the top of the water heater. The legs will snap in the holes to give a tight fit. Secure draft hood with the supplied brackets.

• Place the vent pipe over the draft hood. With the vent pipe in position, drill a small hole through both the vent pipe and draft hood. Secure them together with a sheet metal screw, see Figure 18.

Obstructed or deteriorated vent systems may present serious health risk or asphyxiation.

FIGURE 18.

The vent pipe from the water heater must be no less than the diameter of the draft hood outlet on the water heater and must slope upward at least 1/4 inch per linear foot (21 mm per meter), see Figure 19.

FIGURE 19.

All vent gases must be completely vented to the outdoors of the structure (dwelling). Install only the draft hood provided with the new water heater and no other draft hood.

Vent pipes must be secured at each joint with sheet metal screws.

There must be a minimum of 6 inches (153 mm) clearance between single wall vent pipe and any combustible material. Fill and seal any clearance between single wall vent pipe and combustible material with mortar mix, cement, or other noncombustible substance. For other than single wall, follow vent pipe manufacturer’s clearance specifications. To insure a tight fit of the vent pipe in a brick chimney, seal around the vent pipe with mortar mix cement.

1/2 pound per square inch (3.5kPa), the damage to the gas control valve could result in a fire or explosion from leaking gas.

If the main gas line Shut-off serving all gas appliances is used, also turn “OFF” the gas at each appliance. Leave all gas appliances shut “OFF” until the water heater installation is complete.

A gas line of sufficient size must be run to the water heater. Consult the current edition of the CAN/CSA-B149.1, Installation Code and/or your gas supplier concerning pipe size.

Failure to have required clearances between vent piping and combustible material will result in a fire hazard.

Be sure vent pipe is properly connected to prevent escape of dangerous flue gases which could cause deadly asphyxiation.

Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors. Spray can propellants, 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.

There must be:

• A readily accessible manual shut off valve in the gas supply line serving the water heater, and

• A drip leg (sediment trap) ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve.

• A flexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open flame. Rinse off soapy solution and wipe dry.

The minimum inlet gas pressure shown on the rating plate is that which will permit firing at the rated input.

Gas Piping

Make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 14 inch water column (2.6kPa) for natural and propane (L.P.) gas. If the gas control valve is subjected to pressures exceeding

Standard Models are for installation up to 2,000 feet (610 m) above sea level.

High Altitude Models are for installation from 2,000 feet (610 m) to 4,500 feet (1,370 m) above sea level.

If a standard model is installed above 2,000 feet (610 m) or high altitude model is installed above 4,500 feet (1,370 m), the input rating should be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea level which requires replacement of the burner orifice in accordance with National CAN/CSA B-

149.1. Contact Maytag Customer Service Center at 1-800-

788-8899 or your local gas supplier or call for further information.

Failure to replace the standard orifice with a high altitude orifice when installed at elevations above 2,000 feet (610 m) or above 4,500 feet (1,370 m) for high altitude model could result in improper and inefficient operation of the appliance, producing carbon monoxide gas in excess of safe limits, which could result in serious injury or death. Contact Maytag Customer Service

at 1-800-788-8899 or your local gas supplier for any specific changes which may be required in your area.

Sediment Traps

Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a drip leg (sometimes called a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible. Install in accordance with the Gas Piping section. Refer to the current edition of CAN/CSA-B149.1 and/or Local Installation Codes.

A sediment trap shall be installed as close to the inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap. If a tee fitting is used, it shall be installed in conformance with one of the methods of installation, shown in Figures 20 and 21.

Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum (Propane [L.P.]) gases.

The appliance and its gas connection must be leak tested before placing the appliance in operation.

The appliance and its individual Shut-off valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/ 2 pound per square inch (3.5kPa). It shall be isolated from the gas supply piping system by closing its individual manual Shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 pound per square inch (3.5kPa).

Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods, shown in Figures 20 and 21.

FIGURE 20. GAS PIPING WITH FLEXIBLE CONNECTOR.

FIGURE 21. GAS PIPING WITH ALL

BLACK IRON PIPE TO GAS CONTROL.

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED AT FAUCETS.

A. This appliance has a pilot which must be lighted by hand.

When lighting the pilot, follow these instructions exactly.

B. BEFORE LIGHTING: smell all around the appliance

area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

LIGHTING INSTRUCTIONS

FIGURE 1.

1. STOP! Read the safety information above on this label.

2. Set the thermostat to the lowest setting by turning

thermostat dial fully clockwise

3. Push the gas control knob down slightly and turn

clockwise

NOTE: Gas control knob CANNOT be turned from "PILOT" to "OFF" unless it is pushed down slightly. Do not force.

4. Remove the inner and outer doors located below and

behind the gas control unit.

5. Wait five (5) minutes to clear out any gas. If you then

smell gas STOP! Follow "B" in the safety information above on this label. If you do not smell gas, go to the next step.

6. Find Pilot. Follow metal tube from the bottom , right of

the gas control to the pilot burner. (Figure D).

7. Turn gas control knob counterclockwise

(Figure B).

8. Push gas control knob down all the way and hold it down.

Immediately light the pilot with a match. Continue to hold

to "OFF" (Figure A).

until it stops.

TOP VIEW

to "PILOT"

• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push down or turn the gas control

knob. Never use tools. If the knob will not push down or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

FIGURE D.

the gas control knob down for about one (1) minute after the pilot is lit. Release the gas control knob and it will pop back up. Pilot should remain lit. If it goes out, repeat Steps 3 through 8. It may take several minutes for air to clear the lines, before the pilot will light.

• If knob does not pop up when released, stop and

immediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the

gas control knob to "OFF" (Figure A) andcall your service technician or gas supplier.

9. Replace inner and outer burner doors.

10. At arm's length away, turn the gas control knob counterclockwise

11. Set thermostat to desired setting (Figure 1).

CAUTION: Hotter water increases the risk of scald injury. Consult the instruction manual before changing temperature.

to on (Figure C).

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Push gas control knob down slightly and turn clockwise to “OFF”. Do not force, see Figure A.

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