Flammable Vapor Ignition Resistant Compliant
Power Vented
Gas Water Heater
Installation
Instructions and
Use & Care Guide
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any telephone in your
building.
• Immediately call your gas supplier
from a neighbor’s telephone. Follow
the gas supplier’s instructions.
• If you cannot reach your gas
supplier, call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
To obtain technical, warranty, or service assistance contact
place of purchase or local distributor.
1-800-456-9805
When calling for assistance, please have the
following information ready:
1. Model number
2. 7 digit product number
3. Serial number
4. Date of installation
5. Place of purchase
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6510331
September 2004
1
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or
“WARNING.” These words mean:
You can be killed or seriously injured if you don’t immediately follow instructions.
You can be killed or seriously injured if you don’t follow
instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.
Important Instructions
• Do not use this appliance if any part has been under water. Immediately call a qualified service technician. Water
heaters subjected to flood conditions or anytime the gas controls, main burner or pilot have been submerged in
water require replacement of the entire water heater.
• Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde, carbon
monoxide, and soot.
Table Of Contents
Water Heater Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installing Your Gas Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Unpacking the Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Combustion Air Supply/Vent Pipe System . . . . . . . . . . . . . . . . . 7-12
Outlet Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Operating Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-19
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operational Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance of Your Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Repair Parts Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
PAGE
2
INSTALLING YOUR GAS WATER HEATER
Consumer Information
This water heater is design-certified by CSA International
as a Category IV, non-direct vented water heater which
takes its combustion air either from the installation area or
from air ducted to the unit from the outside.
This water heater must be installed according to all local
and state codes or, in the absence of local and state
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA
54)-latest edition. Canadian installations must be
performed in accordance with CAN/CGA-B149. This is
available from the following:
CSA America, Inc.
8501 East Pleasnat Valley Road
Cleveland, OH 44131
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169-7471
Canadian Standards Association
178 Rexdale Boulevard
Toronto, ON M9W 1R3
Check your phone listings for the local authorities
having jurisdiction over your installation.
Unpacking the Water Heater
Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater or
on the inside of panels.
• Remove exterior packaging and place installation
components aside.
• Inspect all parts for damage prior to installation
andstart-up.
• Completely read all instructions before attempting
to assemble and install this product.
• After installation, dispose of packaging material in
the proper manner.
Consumer Responsibilities
This manual has been prepared to acquaint you with the
installation, operation, and maintenance of your gas water
heater and provide important safety information in these
areas.
Read all of the instructions thoroughly before attempting
the installation or operation of this water heater.
Do not discard this manual. You or future users of this
water heater will need it for future reference.
Service to the power vented system should only be
performed by a qualified service technician.
Examples of qualified service technicians include:
those trained in the plumbing and heating industry,
local gas utility personnel, or an authorized service
person.
The manufacturer and seller of this water heater will
not be liable for any damages, injuries, or deaths
caused by failure to comply with the installation and
operating instructions outlined in this manual.
If you lack the necessary skills required to properly install
this water heater, or you have difficulty following the
instructions, you should not proceed but have a qualified
service technician perform the installation of this water
heater. Massachusetts code requires this water heater to
be installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR Section 2.00 and 5.00.
A data plate identifying your water heater can be found
next to the gas control valve/thermostat. When referring to
your water heater, always have the information listed on
the data plate readily available.
Retain your original receipt as proof of purchase.
3
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance. Storage of or
use of gasoline or other flammable vapors
or liquids in the vicinity of this or any other
appliance can result in serious injury or death
Location Requirements
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas
burning appliances in the vicinity must be shut off and their
pilot lights extinguished. Open the doors and windows for
ventilation while flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in
the area of the water heater, leave the area immediately
and call the fire department from a neighbor’s home. Do
not attempt to clean the spill until all ignition sources have
been extinguished.
Site Location
• Select a location near the center of the water piping
system. The water heater must be installed indoors
and in a vertical position on a level surface.
• Consider the exhaust vent system piping and combustion air supply requirements when selecting the
water heater location. The venting system must be
able to run from the water heater to the termination
with a minimal length and number of elbows. The
venting system must comply with the requirements set
forth in the venting section of this manual.
• Locate the water heater near the existing gas
piping. If installing a new gas line, locate the water
heater to minimize the pipe length and elbows.
Note: This water heater must be installed according to all
local and state codes or, in the absence of local and state
codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA
54)-latest edition. Canadian installations must be
performed in accordance with CAN/CGA-B149.
4
Important: The water heater should be located in
an area where leakage of the tank or connections will
not result in damage to the area adjacent to the water
heater or to lower floors of the structure. Due to the
normal corrosive action of the water, the tank will
eventually leak after an extended period of time.
Also any external plumbing leak, including those
from improper installation, may cause early failure
of the water tank due to corrosion if not repaired.
A qualified service technician should be contacted
for repairs. A suitable metal drain pan should be
installed under the water heater as shown below, to
help protect the property from damage which may
occur from condensate formation or leaks in the piping connections or tank. The pan must limit the water
level to a maximum depth of 1-3/4” and be two inches
wider than the heater and piped to an adequate drain.
The pan must not restrict combustion air flow. Locate
the water heater near a suitable indoor drain. Outside
drains are subject to freezing temperatures which can
obstruct the drain line. The piping should be at least
3/4” ID and pitched for proper drainage.
Under no circumstances will the manufacturer or
seller of this water heater be held liable for any
water damage which is caused by your failure to
follow these instructions.
Pipe to an
adequate drain
1-3/4”
max.
At least 2” greater than the
the water heater and the inlet
air pipe.
• The water heater should be located in an area not
subject to freezing temperatures. Water heaters
located in unconditioned spaces (i.e., attics,
basements, etc.) may require insulation of the
water piping and drain piping to protect against
freezing. The drain and controls must be easily
accessible for operation and service. Maintain
proper clearances as specified on the data plate.
• Do not locate the water heater near an air-moving
device. The operation of air-moving devices such as
exhaust fans, ventilation systems, clothes dryers,
fire-places, etc., can affect the proper operation of
the water heater. Special attention must be given to
conditions these devices may create. Flow reversal of flue gases may cause an increase of carbon
monoxide inside of the dwelling.
FIGURE 1
Minimum Clearance
Locations
Back
Top View
Top to
ceiling
Sides
Sides
Front
24” min.
for service
Vent
Clearances and Accessibility
Notice: Minimum clearances from combustible
materials are stated on the data plate located on the
front of the water heater.
• The water heater is certified for installation on a
combustible floor.
Important: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath
the water heater. The protective panel must extend
beyond the full width and depth of the water heater by at
least 3 inches (76.2mm) in any direction or if in a alcove
or closet installation, the entire floor must be covered by
the panel.
Figure 1 may be used as a reference guide to locate the
specific clearance locations. A minimum of 24 inches
of front clearance and 4 inches on each side should be
provided for inspection and service.
State of California
Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area or call
1-800-456-9805 and request instructions.
5
GAS SUPPLY
Gas Requirements
Read the data plate to be sure the water heater is
made for the type of gas you will be using in your
home. This information will be found on the data plate
located near the gas control valve. If the information does
not agree with the type of gas available, do not install or
light. Call your dealer.
Note: An odorant is added by the gas supplier to the gas
used by this water heater. This odorant may fade over an
extended period of time. Do not depend upon this odorant
as an indication of leaking gas.
Gas Piping
This gas piping must be installed according to all local and
state codes or, in the absence of local and state codes,
the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-lat-
est edition. Canadian installations must be performed in
accordance with CAN/CGA-B149.
Tables 1 and 2 on page 7 are provided as a sizing reference for commonly used gas pipe materials. Consult the
“National Fuel Gas Code” for the recommended gas pipe
size of other materials.
Refer to Figure 2
Note: When installing gas piping, apply approved pipe
joint compound.
1. Install a readily accessible manual shut-off valve in
the gas supply line as recommended by the local
utility. Know the location of this valve and how to
turn off the gas to this unit.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be
no less than three inches long for the accumulation of
dirt, foreign material, and water droplets.
3. Install a ground joint union between the gas valve/
thermostat and the manual shut-off valve. This is to
allow easy removal of the gas valve/thermostat.
4. Turn the gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles forming
indicate a leak) or other approved method.
6
FIGURE 2
Gas Piping
Manual gas
shut-off valve
Install a readily accessible manual shut-off
valve in the gas supply
line as recommended
by the local utility.
Gas Pressure
Important: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heater’s
data plate. The minimum supply pressure is for the purpose of input adjustment.
Gas Pressure Testing
Important: This water heater and its gas connection must
be leak tested before placing the appliance in operation.
• If the code requires the gas lines to be tested at a
pressure exceeding 14” W.C., the water heater and
its manual shut-off valve must be disconnected from
the gas supply piping system and the line capped.
• If the gas lines are to be tested at a pressure less
than 14” W.C., the water heater must be isolated
from the gas supply piping system by closing its
manual shut-off valve.
U.L. recognized fuel gas and carbon monoxide (CO) detectors are recommended in all applications and should be
installed using the manufacturer’s instructions and local
codes, rules, or regulations.
Note: Air may be present in the gas lines and could
prevent the pilot from lighting on initial start-up. The gas
lines should be purged of air by a qualified service
technician after installation of the gas piping system.
L.P. Gas
COMBUSTION AIR SUPPLY/VENT PIPE SYSTEM
• buildings with indoor pools
• water heaters installed in laundry, hobby, or craft rooms
• water heaters installed near chemical storage areas
Combustion air must be free of acid-forming chemicals
such as sulfur, fluorine, and chlorine. These elements
are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint, and varnish removers,
refrigerants, and many other commercial and household
products. When burned, vapors from these products form
highly corrosive acid compounds. These products should
Combustion Air Supply
This water heater takes its combustion air either from
the installation area or from air ducted to the unit from
the outside and all combustion products are discharged
to the outdoors.
Important: Air for combustion and ventilation must not
come from a corrosive atmosphere. Any failure due to
corrosive elements in the atmosphere is excluded from
warranty coverage.
The following types of installation (not limited to the following) will require outdoor air for combustion due to
chemical exposure and may reduce but not eliminate
the presence of corrosive chemicals in the air:
• beauty shops
• photo processing labs
not be stored or used near the water heater or air inlet.
Combustion and ventilation air requirements are deter-
mined by the location of the water heater. The water heater
may be located in either an open (unconfined) area or in a
confined area or small enclosure such as a closet or small
room. Confined spaces are areas with less than 50 cubic
feet for each 1,000 BTUH of the total input for all gas-using
appliances.
7
Unconfined Space
A water heater in an unconfined space uses indoor air for
combustion and requires at least 50 cubic feet for each
1,000 BTUH of the total input for all gas appliances. The
table below shows a few examples of the minimum square
footage (area) required for various BTUH inputs.
Table 3
BTUH
Input
Min. Sq. Feet
with 8’ Ceiling
Typical Room
with 8’ Ceiling
30,000 188 9 x 21
45,000 281 14 x 20
60,000 375 15 x 25
75,000 469 15 x 31
90,000 563 20 x 28
105,000 657 20 x 33
120,000 750 25 x 30
135,000 844 28 x 30
Important: The area must be open and be able to provide
the proper air requirements to the water heater. Areas that
are being used for storage or contain large objects may not
be suitable for water heater installation.
Water heaters installed in open spaces in buildings with
unusually tight construction may still require outdoor air
to function properly. In this situation, outside air openings
should be sized the same as for a confined space.
Modern home construction usually requires supplying outside air into the water heater area.
Confined Space
For the correct and proper operation of this water heater,
ample air must be supplied for the combustion, ventilation,
and dilution of flue gases. Small enclosures and confined
areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure.
One opening shall be within 12 inches of the top and one
within 12 inches of the bottom of the enclosure as shown
in Figure 3.
The size of each opening (free area) is determined by the
total BTUH input of all gas utilization equipment (i.e., water
heaters, furnaces, clothes dryers, etc.) and the method by
which the air is provided. The BTUH input can be found on
the water heater data plate. Additional air can be provided
by two methods:
1. All air from inside the building.
2. All air from outdoors.
FIGURE 3
Opening Locations
Confined Spaces
All Air from Inside the Building
When additional air is to be provided to the confined area
from additional room(s) within the building, the total volume
of the room(s) must be of sufficient size to properly provide the necessary amount of fresh air to the water heater
and other gas utilization equipment in the area. If you are
unsure that the structure meets this requirement, contact
your local gas utility company or other qualified agency for
a safety inspection.
Each of the two openings shall have a minimum free area
of 1 square inch per 1,000 BTUH of the total input rating of
all gas utilization equipment in the confined area, but not
less than 100 square inches (Figure 4).
FIGURE 4
All Air From Inside Building
Confined Space Installation
8
All Air from Outdoors
Outdoor fresh air can be provided to a confined area either
directly or by the use of vertical and horizontal ducts. The
fresh air can be taken from the outdoors or from crawl or
attic spaces that freely communicate with the outdoors.
Attic or crawl spaces cannot be closed and must be properly ventilated to the outside.
Ductwork must be of the same cross-sectional area as
the free area of the opening to which they connect. The
minimum dimension of rectangular air ducts cannot be less
than three inches.
The size of each of the two openings is determined by the
method in which the air is to be provided. Refer to Table
4 to calculate the minimum free area for each opening.
Figures 5, 6, and 7 are typical examples of each method.
Louvers and Grilles
In calculating free area for ventilation and combustion
air supply openings, consideration must be given to the
blocking effect of protection louvers, grilles, and screens.
These devices can reduce airflow, which in turn may
require larger openings to achieve the required minimum
free area. Screens must not be smaller than 1/4” mesh. If
the free area through a particular design of louver or grille
is known, it should be used in calculating the specified
free area of the opening. If the design and free area are
not known, it can be assumed that most wood louvers will
allow 20 - 25% of free area while metal louvers and grilles
will allow 60 - 75% of free area.
Louvers and grilles must be locked open or interconnected
with the equipment so that they are opened automatically
during equipment operation.
Keep louvers and grilles clean and free of debris or other
obstructions.
Table 4
Minimum Free Area of Permanent Openings for
Ventilation and Combustion Air Supply -
All Air from Outdoors Only
Based on the total BTUH input rating for all gas utilizing equipment
within the confined space.
Minimum
Free Area Per
Opening Source
Directed to Outdoors* 1 sq. in. per 4000 BTUH Figure 5
Vertical Ducts 1 sq. in. per 4000 BTUH Figure 6
Horizontal Ducts 1 sq. in. per 2000 BTUH Figure 7
Example: A water heater with an input rating of 50,000 BTUH using
horizontal ducts would require each opening to have a minimum free
area of 25 square inches.
Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25 sq. in.
Opening (Sq. In.)
*These openings connect directly with the outdoors
through a ventilated attic, a ventilated crawl space, or
through an outside wall.
Consult the local codes of your area for specific ventilation
and combustion air requirements.
Reference
Drawing
FIGURE 5
All Air From Outdoors: Inlet Air
From Ventilated Crawl Space/
Outlet Air To Vented Attic
FIGURE 6
All AIr From Outdoors
Through Ventilated Attic
FIGURE 7
All Air From Outdoors
Using Horizontal Ducts
9
Vent Pipe System
This water heater must be properly vented for removal of
exhaust gases to the outside atmosphere. Correct instal-
lation of the vent pipe system is mandatory for the
safe and efficient operation of this water heater and is
an important factor in the life of the unit.
Vent pipe installation must be performed in accordance
with state and local codes, or in the absence of such, the
National Fuel Gas Code, NFPA 54, ANSI Z223.1-latest edition. Canadian installations must be performed
in accordance with CAN/CGA-B149.
Important: Check to make sure the vent pipe is not blocked
in any way. NOTE: Do not common vent this water heater
with any other appliance. Do not install in the same chase
or chimney with a metal or high-temperature plastic from
another gas or fuel burning appliance.
Vent Pipe Material
The following plastic materials may be used for both the
combustion air inlet and exhaust outlet piping subject to
state and local codes:
• 2 or 3 inch Schedule 40 PVC or ABS
• 2 or 3 inch Schedule 40 or 80 CPVC
• DWV Pipe is acceptable
NOTE: Use only solid (not foam core) piping.
Plastic pipe and fittings are available through most plumbing suppliers. Always check the marking on the pipe to
make sure you are using the correct material.
Vent Pipe Connection to Blower
A 3x2” reducer is supplied with the water heater to connect
either 2” or 3” venting to the blower. Important: These
connections must be properly sealed to prevent the leakage of the products of combustion into the living area.
Vent Pipe Installation
The following guidelines should be followed when installing
the exhaust outlet piping:
• Venting should be as direct as possible with a
minimum number of pipe fittings.
• Vent diameter must not be reduced unless
specifically noted in the installation instructions.
• Support all horizontal pipe runs every four feet
and all vertical pipe runs every six feet or
according to local codes.
• Vents run through unconditioned spaces where below
freezing temperatures are expected should be properly insulated to prevent freezing. For horizontal runs,
wrap the vent pipe with self-regulating 3 or 5 watt heat
tape. The heat tape must be U.L. listed and installed
per the manufacturer’s instructions.
• Do not connect this venting system with an existing
vent or chimney.
• Do not common vent with the vent pipe of
any other water heater or appliance.
The exhaust outlet piping and termination may be installed
in one of the following type terminations:
1. Standard Horizontal
2. Vertical
All pipe, fittings, pipe cement, primers and procedures
must conform to American National Standard Institute and
10
American Society for Testing and Materials (ANSI/ASTM)
standards in the United States. This water heater has been
design certified by CSA International for use with the specified (CSA) listed plastic vent pipe. Important: Do not use
vent elbows in this vent pipe installation (see figure 8).
All joints in the outlet piping
must be properly cemented.
Figure 8
Correct and Incorrect
Pipe Fittings
Size and cut all piping before
cementing.
1. Cut the pipe end square
and remove all ragged
edges and burrs. Make
sure the inside of the
pipe is clean and free of
cuttings and loose dirt.
Chamfer the end and
apply primer to the fitting
and pipe.
2. Using a suitable grade of pipe cement, apply a moderate, even coat inside the fitting. Apply a liberal amount
of cement to the outside of the pipe to socket depth.
NOTE: It is important to select the proper pipe cement
for the type plastic pipe being used.
3. Assemble the parts quickly while the cement is still
wet. Twist the pipe 1/4 turn during insertion and hold
for 30 seconds.
Vent Pipe Length
Size the exhaust outlet as specified in Tables 5 & 6 below.
These tables list the maximum allowable length in feet of
the exhaust outlet pipe as related to the number of required
elbows and the termination. The specified maximum
lengths are for exhaust pipe systems. Minimum pipe length
is 3 feet with one elbow.
1. Determine termination type and pipe size.
2. Determine number of elbows in exhaust pipe (Do not
include elbows in the termination.) Corresponding
number indicates the maximum length of exhaust pipe.
Table 5 - Maximum Allowable Length in Feet of
Exhaust Pipe - (42K BTU/Hr models only)
Pipe
Number of 90° Elbows (medium or long sweep only)
Size
Pipe
Size
Notes:
1. N/A - Not Applicable
2. The above maximum lengths are for outlet pipe systems.
3. Maximum of 6 elbows may be used. Use only medium or long
sweep elbows. See figure 8 for details.
4. Two 45° elbows are considered equivalent to one 90° elbow.
5. Minimum length is 3 foot with 1 elbow.
6. Use schedule 40 CPVC, ABS, or PVC pipe and fittings.
0123456
(in)
2 50 45 40 35 30 25 20 Std. Horizontal
2 40 35 30 25 20 15 10 Vertical
3 125 120 115 110 105 100 95 Std. Horizontal
3 115 110 105 100 95 90 85 Vertical
Table 6 - Maximum Allowable Length in Feet of
Exhaust Pipe - (50K/60K BTU/Hr models only)
Number of 90° Elbows (medium or long sweep only)
0123456
(in)
2 N/A Std. Horizontal
2 N/A Vertical
3 65 60 55 50 45 40 35 Std. Horizontal
3 55 50 45 40 35 30 25 Vertical
Termination
Options
Termination
Options
Vent Termination Locations
The exhaust outlet must be installed with the following
minimum clearances (see figure 9):
• Twelve inches above grade or maximum
anticipated snow level.
• Twelve inch minimum clearance on top or four foot
clearance below or to the side of door or window
that may be open.
• Four feet horizontally and vertically from gas
or electric meters, gas regulators, dryer vents,
vent hoods, bathroom fan exhaust, attic fans
and turbines.
• Two feet from an inside corner formed by two
exterior walls.
• Two feet from porches, decks, overhangs and
other obstructions.
Figure 9
Minimum Termination Clearance for
Outlet Vent
In addition to maintaining the minimum clearances , the
vent should terminate according to the following guidelines:
1. Do not expose any reducers or bushings to outdoor
ambient temperatures.
2. The exhaust outlet must not terminate under a patio,
deck or any covered area.
3. Do not terminate the vent near walkways or into
alleys or other publicly accessible areas.
4. Do not terminate the vent in an area where
children or animals could block pipes.
5. Do not locate the vent terminal too close to shrubs or
bushes.
6. Caulk all cracks, seams and joints within 6 feet
horizontally above and below the vent.
US Installations
A. 12 in (30 cm) min. clearance above grade,
veranda, porch, deck, balcony, or maximum
anticipated snow level.
12 in. (30 cm) min. clearance on top or 4 ft.
B.
clearance below or to the side of door or window
that may be open.
C. Clearance to permanently closed window.**
D. 12 in (30 cm) min. vertical clearance to ventilated
soffit located above the terminal within a horizontal
distance of 2 ft (61 cm) from the center line of the
terminal.
E. 12 in (30 cm) min. clearance to unventilated soffit.
F. Clearance to outside corner. **
G. 2 ft (61 cm) clearance to inside corner formed by
two exterior walls.
H. 4 ft (122 cm) clearance to each side of center line
extending above meter/regulator assembly.
I. 4 ft (122 cm) clearance to service regulator vent
outlet.
J. 12 in (30 cm) clearance on top or 4 ft (122 cm)
clearance below or to the side of nonmechanical
air supply inlet to building or the combustion air
inlet to any other appliance.
Canadian Installations
A. 12 in (30 cm) min. clearance above grade,
veranda, porch, deck, balcony, or maximum
anticipated snow level.
B. 12 in (30 cm) min. clearance on top and side of
window or door that may be opened. Do not install
below a window or door that may be opened.
C. Clearance to permanently closed window.**
D. 12 in (30 cm) min vertical clearance to ventilated
soffit located above the terminal within a horizontal
distance of 2 ft (61 cm) from the center line of the
terminal.
E. 12 in (30 cm) min. clearance to unventilated soffit.
F. Clearance to outside corner.**
G. 2 ft (61 cm) clearance to inside corner formed by
two exterior walls.
H. 3 ft (91 cm) within a height 15 ft (4.57m) above the
meter/regulator assembly.
I. 4 ft (122 cm) clearance to service regulator vent outlet.
J. 12 in (30 cm) clearance to nonmechanical air
supply inlet to building or the combustion air inlet to
any other appliance.
K. 6 ft (1.83 m) clearance to mechanical air supply
inlet.
K. 3 ft (91 cm) above if within 10 ft (3 m) horizontally
of mechanical air supply inlet.
**Clearance in accordance with local installation codes and the requirements of the gas supplier.
11
OUTLET VENT TERMINATIONS
Standard Horizontal Termination
The standard horizontal exhaust outlet termination is a 2
inch or 3 inch pipe which terminates 12 inches from the
outside wall (see figure 10). To prevent potential condensate from collecting in the venting system slope the vent
at a downward pitch of 1/8” per 5ft. away from the water
heater.
Install the correct size coupling at the outside wall on the
exhaust to prevent the termination from being pushed
inward.
FIGURE 10
Standard Horizontal Termination
Vertical Termination
The vertical exhaust outlet requires a return bend or two
medium or long sweep radius 90° elbows to keep the
exhaust outlet downward and prevent entry of rain. Do
not include these elbows when calculating the maximum
allowable vent pipe because they have already been considered in the vent tables. The vertical exhaust outlet termination is a 2 inch or 3 inch pipe which must be at least
12 inches above the roof line or anticipated snow levels.
See figure 11.
FIGURE 11
Vertical Vent Termination
12
WATER SYSTEM PIPING
Tempered Water
to fixtures
Cold
Water
Inlet
Tempering Valve
(set to 120°F
or lower)
Piping Installation
Piping, fittings, and valves should be installed according to
the installation drawing (Figure 12). If the indoor installation
area is subject to freezing temperatures, the water piping
must be protected by insulation.
Water supply pressure should not exceed 80% of the working pressure of the water heater. The working pressure
is stated on the water heater’s data plate. If this occurs
a pressure limiting valve with a bypass may need to be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures.
Important: Heat cannot be applied to the water fittings on
the heater as they may contain nonmetallic parts. If solder
connections are used, solder the pipe to the adapter before
attaching the adapter to the hot and cold water fittings.
Important: Always use a good grade of joint compound and
be certain that all fittings are drawn up tight.
1. Install the water piping and fittings as shown in Figure
12. Connect the cold water supply (3/4” NPT) to the
fitting marked “C”. Connect the hot water supply (3/4”
NPT) to the fitting marked “H”. Important: Some models may contain energy saving heat traps to prevent
the circulation of hot water within the pipes. Do not
remove the inserts within the heat traps.
2. The installation of unions in both the hot and cold
water supply lines is recommended for ease of removing the water heater for service or replacement.
3. The manufacturer of this water heater recommends
installing a tempering valve or an anti-scald device
in the domestic hot water line as shown in Figure 13.
These valves reduce the point of use temperature of
the water by mixing cold and hot water and are readily
available for use. Contact a licensed plumber or the
local plumbing authority.
4. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as
specified under “Closed System/Thermal Expansion”.
5. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be
easily accessible. Know the location of this valve and
how to shut off the water to the heater.
6. Install a temperature and pressure relief valve in the
opening marked “Temperature and Pressure (T & P)
Relief Valve” on the water heater. Add a discharge
line to the opening of the T & P relief valve. Follow the
instructions under Temperature and Pressure Relief
Valve”.
FIGURE 12
Typical Water Piping Installation
FIGURE 13
Typical Tempering
Valve Installation
Please note the following:
DO NOT install this water heater with iron piping. The
system should be installed only with piping that is suitable
for potable (drinkable) water such as copper, CPVC, or
polybutylene. DO NOT use PVC water piping.
DO NOT use any pumps, valves, or fi ttings that are not
compatible with potable water.
DO NOT use valves that may cause excessive restriction to
water fl ow. Use full fl ow ball or gate valves only.
DO NOT use 50/50 tin-lead solder (or any lead based
solder) in potable water lines. Use 95/5 tin-antimony or
other equivalent material.
DO NOT tamper with the gas valve/thermostat, igniter,
thermocouple, or temperature and pressure relief valve.
Tampering voids all warranties. Only qualifi ed service
technicians should service these components.
DO NOT use with piping that has been treated with
chromates, boiler seal, or other chemicals.
DO NOT add any chemicals to the system piping which will
contaminate the potable water supply.
13
Closed System/Thermal Expansion
Periodic discharge of the temperature and pressure
relief valve may be due to thermal expansion in a closed
water supply system. The water utility supply meter
may contain a check valve, backfl ow preventer or water
pressure reducing valve. This will create a closed water
system. During the heating cycle of the water heater, the
water expands causing pressure inside the water heater
to increase. This may cause the temperature and pressure
relief valve to discharge small quantities of hot water. To
prevent this, it is recommended that a diaphragm-type
expansion tank (suitable for potable water) be installed
on the cold water supply line. The expansion tank must
have a minimum capacity of 1.5 U.S. gallons for every 50
gallons of stored water. Contact the local water supplier
or plumbing inspector for information on other methods to
control this situation.
Important: Do not plug or remove the temperature and
pressure relief valve.
FIGURE 14
Temperature and Pressure
Relief Valve Installation
Temperature and Pressure
Relief Valve
For protection against excessive pressures and
temperatures, a temperature and pressure relief valve must
be installed in the opening marked “T & P RELIEF VALVE”
(see Figure 14.) This valve must be design certifi ed by
a nationally recognized testing laboratory that maintains
periodic inspection of the production of listed equipment or
materials as meeting the requirements for Relief Valves and
Automatic Shut-off Devices for Hot Water Supply Systems,
ANSI Z21.22. The function of the temperature and pressure
relief valve is to discharge water in large quantities in the
event of excessive temperature or pressure developing
in the water heater. The valve’s relief pressure must not
exceed the working pressure of the water heater as stated
on the data plate.
Important: Only a new temperature and pressure relief
valve should be used with your water heater. Do not use an
old or existing valve as it may be damaged or not adequate
for the working pressure of the new water heater. Do not
place any valve between the relief valve and the tank.
The Temperature and Pressure Relief Valve:
• Must not be in contact with any electrical part.
• Must be connected to an adequate discharge line.
• Must not be rated higher than the working pressure
shown on the data plate of the water heater.
The Discharge Line:
• Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in the
discharge line.
• Must not be capped, blocked, plugged or contain any
valve between the relief valve and the end of the
discharge line.
• Must terminate a maximum of six inches above a
fl oor drain or external to the building.
• Must be capable of withstanding 250°F (121°C)
without distortion.
• Must be installed to allow complete drainage of both
the valve and discharge line.
14
ELECTRICAL CONNECTIONS
Before plugging in the water heater, always make sure:
The voltage and frequency correspond to that specified
on the water heater wiring diagram.
The electrical outlet has the proper overload fuse or
breaker protection. Important: Do not use an extension
cord to connect the water heater to an electrical outlet.
The water heater and the outlet are properly grounded.
Installed in accordance with prevailing provisions of
local codes, or in the absence of such, National Electric
Code, ANSI/NFPA 70 and/or the CSA C22.1, Electrical
Code.
Note: Always reference the wiring diagram for the correct
electrical connections.
After making all electrical connections, completely fill the
tank with water and check all connections for leaks. Open
the nearest hot water faucet and let it run for 3 minutes to
purge the water lines of air and sediment and to ensure
complete filling of the tank. The electrical power may then
be turned on. Verify proper operation after servicing.
WIRING DIAGRAM
Electrical Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electrical shock.
15
INSTALLATION CHECKLIST
Water Heater Location
• Centrally located with the water piping system.
Located as close to the gas piping and vent pipe
system as possible.
• Located indoors and in a vertical position. Protected
from freezing temperatures.
• Proper clearances from combustible surfaces
maintained and not installed directly on a carpeted
fl oor.
• Provisions made to protect the area from
water damage. Drain pan installed and piped to an
adequate drain.
• Installation area free of corrosive elements and
fl ammable materials.
• Suffi cient room to service the water heater.
• Water heater not located near an air-moving device.
Gas Supply and Piping
• Gas supply is the same type as listed on the water
heater data plate.
• Gas line equipped with shut-off valve, union, and
drip leg.
• Approved pipe joint compound used.
• Adequate pipe size and of approved material.
• Chloride-free soap and water solution or other
approved means used to check all connections and
fi ttings for possible gas leaks.
Combustion Air Supply/Vent Pipe System
• Sufficient fresh air supply for proper water heater
operation.
• Fresh air not taken from areas that contain negative
pressure producing devices such as exhaust fans,
fi replaces, etc.
• Fresh air supply free of corrosive elements and
flammable vapors.
• Fresh air openings sized correctly with consideration
given to the blocking effect of louvers and grilles.
• Ductwork is the same cross-sectional area as the
openings.
• Vent pipe and fittings of approved material.
• Acceptable size, length, and number of elbows on
exhaust outlet pipe.
• Installed in accordance with prevailing provisions of
local codes, or in the absence of such, National Fuel
Gas Code, NFPA 54, ANSI Z223.1-Latest Edition.
Canadian Installations must be performed in
accordance with CAN/CGA-B149.
• Slope 2” & 3” horizontal piping at a downward pitch
of 1/8” per 5ft. away from the water heater.
• Not obstructed in any way.
Vent Termination
Horizontal
• 12” Min. above grade/snow level.
• Slope 2” & 3” horizontal piping at a downward pitch
of 1/8” per 5ft. away from the water heater.
• Away from corners, other vents, windows, etc.
Vertical
• Outlet - 12” Min. above roof/snow level.
Water System Piping
• Temperature and pressure relief valve properly
installed with a discharge line run to an
open drain and protected from freezing.
• All piping properly installed and free of leaks.
• Heater completely fi lled with water.
• Closed system pressure build-up precautions
installed.
• Tempering valve installed per manufacturer’s
instructions.
Electrical Connections
• Unit connected to a dedicated power supply.
• Unit connected to a 120V electrical supply.
• Proper polarity.
• Water heater properly grounded.
• Installed in accordance with prevailing provisions of
local codes, or in the absence of such, the latest edition
of the National Electric Code, ANSI/NFPA 70 and/or the
CSA C22.1, Electrical Code.
16
OPERATING YOUR WATER HEATER
Lighting Instructions
Read and understand these directions thoroughly before
attempting to operate the water heater. Make sure the
tank is completely fi lled with water before operating the
water heater. Check the data plate near the gas control
valve/thermostat for the correct gas. Do not use this
water heater with any gas other than the one listed on
the data plate. If you have any questions or doubts,
consult your gas supplier or gas utility company.
L.P.G. (Bottled Propane) Models
Liquefi ed petroleum gas is over 50% heavier than air
and in the occurrence of a leak in the system, the gas
will settle at fl oor level. Basements, crawl spaces, skirted
areas under mobile homes (even when ventilated),
closets and areas below ground level will serve as
pockets for the accumulation of gas. Before lighting an
L.P. gas water heater, smell all around the appliance at
fl oor level. If you smell gas, follow the instructions as
given in the warning on the front page.
When your L.P. tank runs out of fuel, turn off the gas at
all gas appliances including pilot lights. After the tank is
refi lled, all appliances must be re-lit according to their
manufacturer’s instructions.
17
Water Heater Operation
Figure 15 below shows the water heater’s sequence of
operation when a call for heat is initiated. The ignition control module will attempt to light the burner three times. If
the ignition control does not detect ignition it will enter lockout mode, indicated by a three flash error code.
FIGURE 15
Sequence of Operation
Burner Flames
Inspect the burner flames
through the viewport
and compare them to
the drawings in Figure
16. A properly operating
burner should produce a
soft blue flame. Blue tips
with yellow inner cones
are satisfactory. The
tips of the flame may have a slight yellow tint. The flame
should not be all yellow or have a sharp blue-orange color.
Contaminated air may cause an orange colored flame.
Contact a qualified service technician if the flame is not
satisfactory.
FIGURE 16
Flame Characteristics
The thermostat is adjusted to its lowest temperature when
it is shipped from the factory. Water temperature can be
regulated by moving the temperature dial to the preferred
setting. The preferred starting point is 120°F (49°C). Align
the index bar on the thermostat with the desired water
temperature as shown in Figure 17. There is a hot water
scald potential if the thermostat is set too high.
Important: Adjusting the thermostat past the 120°F (49°C)
bar on the temperature dial will increase the risk of scald
injury. Hot water can produce fi rst degree burns within:
120°F (49°C) more than 5 minutes
130°F (54°C) at 20 seconds
140°F (60°C) at 3 seconds
150°F (66°C) at 1-1/2 seconds
160°F (71°C) at less than 1 second
Note: During low demand periods when hot water is not
being used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs. If hot
water use is expected to be more than normal, a higher
thermostat setting may be required to meet the increased
demand. When leaving your home for extended periods
(vacations, etc.) turn the temperature dial to its lowest
setting. This will maintain the water at low temperatures
with minimum energy losses and prevent the tank from
freezing during cold weather.
Figure 17
Robertshaw Gas Valve/Thermostat
Settings
Stacking
Stacking occurs when a series of short draws of hot water
(3 gallons or less) are taken from the water heater tank.
This causes increased cycling of the burner and can result
in increased water temperatures at the hot water outlet. An
anti-scald device is recommended in the hot water supply
line to reduce the risk of scald injury.
Emergency Shut Down
Important: Should overheating occur or the gas supply fails
to shut off, turn off the water heater’s manual gas control
valve and call a qualified service technician.
18
Operational Conditions
Condensation
Moisture from the products of combustion condenses on
the tank surface and the outside jacket of the water heater
and forms drops of water which may fall onto the burner or
other hot surfaces. This will produce a “sizzling” or “frying”
noise. This condensation is normal and should not be
confused with a leaking tank. Condensation may increase
or decrease at different times of the year.
High effi cient energy saver water heaters will produce
larger amounts of condensation on initial start-up or
when a large amount of hot water is being used. Do not
confuse this with a “tank leak”. Once the water reaches
a temperature of 120°F (49°C) and the tank warms up
(usually 1-2 hours), the condensation will stop.
Important: It is always recommended that a suitable drain
pan be installed under the water heater to protect the area
from water damage resulting from normal condensation
production, a leaking tank or piping connections. Refer
to “Location Requirements” on page 4. Under no
circumstances is the manufacturer to be held responsible
for any water damage in connection with this water heater.
Water Heater Sounds
During the normal operation of the water heater, sounds or
noises may be heard. These noises are common and may
result from the following:
1. Normal expansion and contraction of metal parts
during periods of heat-up and cool-down.
2. Condensation causes sizzling and popping within the
burner area and should be considered normal.
3. Sediment buildup in the tank bottom will create
varying amounts of noise and may cause premature
tank failure. Drain and fl ush the tank as directed
under “Draining and Flushing”.
Smoke/Odor
The water heater may give off a small amount of smoke
and odor during the initial start-up of the unit. This is due to
the burning off of oil from metal parts of a new unit and will
disappear after a few minutes of operation.
Anode Rod/Water Odor
Each water heater contains at least one anode rod, which
will slowly deplete while protecting the glass-lined tank
from corrosion and prolonging the life of the water heater.
Certain water conditions will cause a reaction between
this rod and the water. Once the anode is depleted, the
tank will start to corrode, eventually developing a leak. The
most common complaint associated with the anode rod is a
“rotten egg smell” produced from the presence of hydrogen
sulfi de gas dissolved in the water. Do not remove this
rod permanently as it will void any warranties, stated
or implied. A special anode can be ordered if water odor
or discoloration occurs. This rod may reduce but not
eliminate water odor problems. The water supply system
may require special fi ltration equipment from a water
conditioning company to successfully eliminate all water
odor problems.
Artifi cially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease
the life of the water heater tank.
The anode rod should be removed from the water heater
tank every 3 years for inspection. If the rod is more than
50% depleted, the anode rod should be replaced.
In replacing the anode:
1. Turn off gas supply to the water heater.
2. Shut off the water supply and open a nearby hot
water faucet to depressurize the water tank.
3. Drain approximately 5 gallons of water from tank
(Refer to “Draining and Flushing” for proper
procedures.) Close drain valve.
4. Remove old anode rod.
5. Use Tefl on® tape or approved pipe sealant on
threads and install new anode rod.
6. Turn on water supply and open nearby hot water
faucet to purge air from water system.
7. Restart the water heater as directed under
“Operating Your Water Heater.” See the “Repair
Parts Illustration” for anode rod location on page 24.
Safety Shut-off
This water heater is designed to automatically shut-off in
the event of the following:
1. The water temperature exceeds 180°F (83°C.)
2. A blockage occurs in the combustion chamber air inlet,
the fl ue gas exhaust outlet, or both the inlet and outlet.
3. The blower fails to operate or operates improperly.
A high temperature limit switch or ECO (Energy Cut Off) in
the tank is used to shut off the unit if the water temperature
exceeds 180°F (83°C.) The ECO is a single use switch and
requires complete replacement of the entire thermostat.
If the ECO should function, the water heater cannot
be used until the thermostat is replaced by a qualifi ed
service technician. Contact your local dealer for service
information.
19
MAINTENANCE OF YOUR WATER HEATER
Draining and Flushing
It is recommended that the tank be drained and fl ushed
every 6 months to remove sediment which may build up
during operation. The water heater should be drained if
being shut down during freezing temperatures. To drain
the tank, perform the following steps:
1. Turn off the gas to the water heater at the manual
gas shut-off valve.
2. Turn off the electrical supply to the water heater.
3. Close the cold water inlet valve.
4. Open a nearby hot water faucet.
5. Connect a hose to the drain valve and terminate it to
an adequate drain.
Note: The drain hose should be rated for at least 200°F
(93°C). If the drain hose does not have this rating, open
the cold water inlet valve and a nearby hot faucet until
the water is no longer hot.
6. Open the water heater drain valve and allow all the
water to drain from the tank. Flush the tank with
water as needed to remove sediment.
7. Close the drain valve, refi ll the tank, and restart the
heater as directed under “Operating Your Water
Heater”.
If the water heater is going to be shut down for an
extended period, the drain valve should be left open.
Important: Condensation may occur when refi lling the
tank and should not be confused with a tank leak.
Routine Preventative
Maintenance
At least annually, a visual inspection should be made of
the venting and air supply system, piping systems, main
burner, and pilot burner. Check the water heater for the
following:
• Obstructions, damage, or deterioration in the venting
system. Make sure the ventilation and combustion
air supplies are not obstructed.
• Build up of soot and carbon on the main burner and
pilot burner. Check for a soft blue fl ame.
• Leaking or damaged water and gas piping.
• Presence of fl ammable or corrosive materials in the
installation area.
• Presence of combustible materials near the water
heater.
• Verify proper operation after servicing this water
heater.
Important: If you lack the necessary skills required to
properly perform this visual inspection, you should not
proceed, but get help from a qualifi ed service technician.
Temperature and Pressure
Relief Valve
Manually operate the temperature and pressure relief
valve at least once a year to make sure it is working
properly (see Figure
14.) To prevent
water damage,
the valve must be
properly connected
to a discharge line
which terminates at
an adequate drain.
Standing clear of the
outlet (discharged
water may be hot),
slowly lift and release
the lever handle on the
temperature and pressure relief valve to allow the valve
to operate freely and return to its closed position. If the
valve fails to completely reset and continues to release
water, immediately shut off the manual gas valve and
the cold water inlet valve and call a qualifi ed service
technician.
FIGURE 14
Temperature & Pressure Relief Valve
20
Replacement Parts
Replacement parts may be ordered through your
plumber or the local distributor. Parts will be shipped at
prevailing prices and billed accordingly. When ordering
replacement parts, always have the following information
ready:
1. model, serial, and product number
2. type of gas
3. item number
4. parts description
See pages 24 & 25 for a list of available repair parts.
Removing the Burner/Manifold Assembly
1. Turn off the gas to the
water heater at the manual shut-off valve (See
figure 2), and disconnect
power to the water heater.
2. Depress the gas control lever to turn it to the
“OFF” position (Figure
17.)
3. Remove the outer
doors.
4. Remove the 2 screws
securing the manifold
door assembly to the
skirt.
5. Disconnect the pilot
tube, the igniter wire and
manifold tube at the
thermostat. (Figure 19) Note: L.P. gas systems use
reverse (left-hand) threads on the manifold tube.
6. Grasp the manifold tube and push down slightly to
free themanifold, and pilot tube.
7. Carefully remove the manifold assembly from the
burner compartment. Be sure not to damage internal
parts.
8. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water.
FIGURE 19
Gas Valve/Manifold Assembly
FIGURE 20A
Natural Gas Burner Assembly
FIGURE 20B
50K BTU/Hr L.P. Gas
Burner Assembly
L.P. Gas Burner - 42K BTU Models
1. Separate the pilot bracket from the L.P. burner by
removing screw.
2. Loosen set screw located on top of the L.P. burner
near the manifold door. Carefully, pull the burner
away from the manifold door assembly.
3. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(Figure 21).
Removing the Burner from
the Manifold Assembly
Natural Gas Burner & 50K BTU/Hr L.P. Models
1. Take off the burner by removing the two (2) screws
located underneath the burner.
2. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(See Figure 20A-Natural Gas, See Figure 20B-L.P.
Gas).
FIGURE 21
L.P. Burner Assemblies
21
Replacing the Manifold Assembly
1. Check the door gasket for damage or imbedded debris
prior to installation.
2. Inspect the viewport for damage and replace as required.
3. Insert the manifold
assembly into the
burner compartment
making sure that the
tab of the manifold
tube engages in the
slot of the bracket
inside the combustion chamber (Figure
22). The tab is located at the bottom of the burner for L.P. Models.
4. Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion
chamber.
5. Replace the two screws which secure the manifold
assembly door to the combustion chamber. Tighten
securely. There should be no space between the gasket
part of the manifold door and combustion chamber. Do
not operate the water heater if the door gasket is not
sealed
6. Reconnect the manifold tubing and pilot tubing to the
thermostat. Do not cross-thread or apply any thread
sealant to these fittings.
Note: L.P. gas systems use reverse (left-hand) threads on
the manifold tube.
7. Reconnect the igniter wire.
8. Turn gas supply on and refer to the “Lighting Instructions”
on page 17.
9. Check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved
method. All leaks must be fixed immediately.
10. Replace the outer door.
FIGURE 22
Manifold Tab
Removing and Replacing the Gas
Control Valve/Thermostat
Important: Use only factory authorized replacement parts.
1. On the gas control valve/thermostat turn the temperature dial counterclockwise to its lowest setting.
Depress the gas control lever to turn it to the “OFF”
position (Figure 17).
2. Turn off the gas at the manual shut-off valve on the
gas supply pipe (Figure 2).
3. Drain the water heater. Refer to the section of
“Draining and Flushing” on page 20 and follow the procedure.
4. Disconnect the igniter wire from the thermostat.
Disconnect the manifold and pilot tube at the thermostat (Figure 19). Note: L.P. gas systems use reverse
(left-hand) threads on the manifold tube.
5. Refer to “Gas Piping” (Figure 2) and disconnect the
ground joint union in the gas piping. Disconnect the
remaining pipe from the gas valve/thermostat.
Important: When removing the gas control valve/
thermostat do not use pipe wrench or vise to grip body.
Do not insert any type of blunt instr ument into the inlet or
outlet connections. Using these t ype tools may result in
damage to the gas control valve/ther mostat.
6. Turn the gas control valve/thermostat counter-clockwise. Remove the gas control valve/thermostat.
To replace the gas control valve/thermostat, reassemble
in reverse order. Use only factory authorized replacement
parts.
Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the
back of the gas valve that screws into tank.
Be sure to remove the pilot ferrule nut from the new gas
control valve/thermostat.
Turn gas supply on and check for leaks. Use a chloridefree soap and water solution (bubbles forming indicate a
leak) or other approved method.
Be sure tank is completely filled with water before lighting and activating the water heater. Follow the “Lighting
Instructions” on page 17.
If additional information is required, contact the Service
Department at: 1-800-456-9805.
22
TROUBLESHOOTING FLOWCHART
23
REPAIR PARTS ILLUSTRATION
When ordering repair parts always give the following
information:
1. Model, serial and product number
2. Type of gas
3. Item number
4. Parts description
7
1
5
4
Repair Parts List
Item
No.
1 Blower
2 Outlet Pressure Switch (Not Pictured)
3 Flue Baffle
4 Heat Trap (Cold)
5 Heat Trap (Hot)
6 Cold Water Dip Tube
7 Anode Rod*
8 Temperature and Pressure Valve
9 Drain Valve
10 Gas Valve/Thermostat
11 Restrictor Plate
12 Pilot Assembly - Natural Gas/L.P. Gas**
13 Natural Gas Burner
14 L.P. Gas Burner**
15 Manifold Door Assembly - Natural Gas
16 Manifold Door Assembly - L.P. Gas**
17 Two Piece Wire Connector w/Retainer Clip**
18 Manifold Door Gasket**
19 Viewport Assembly**
20 Outer Door
* Special anode rod available, see page 19.
** Pictured on next page.
Parts Description
15
13
6
3
11
8
10
9
20
24
Listed Parts Kits and Illustrations
Item 12: Pilot Assembly. (Note: Pilot Assembly is specific to type of gas, please specifiy model for correct
assembly.)
Item 13: Burner (Natural Gas)
Item 14: Burner (L.P. Gas) 42K BTU/Hr & 50T60 Models
Item 15: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, two piece wire connector
with retainer clip, and pilot assembly. (Natural Gas)
Item 16: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, two piece wire connector
with retainer clip, and pilot assembly. (L.P. Gas)
Item 17: Contains two piece wire connector with retainer clip.
Item 18: Contains manifold door gasket.
Item 19: Contains viewport.
ITEM 12
ITEM 15 ITEM 16
ITEM 13
ITEM 14
ITEM 17
© 2004 American Water Heater Company, All Rights Reserved. Printed in the U.S.
ITEM 18
ITEM 19
25
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