Reliance 6 40 NOMT Owner's Manual & Installation Guide

Installation Instructions and Use & Care Guide

RESIDENTIAL GAS WATER HEATERS

FVIR

(FLAMMABLE VAPOR IGNITION RESISTANT)

(MOBILE) HOME AND SHALL NOT BE INSTALLED IN THE

SHIPPED SET FOR NA TURAL GAS AND CONVERTIBLE TO

This water heater complies with ANSI Z21.10.1-current edition regarding the accidental or unintended ignition of ﬂ ammable vapors, such as those emitted by gasoline.

• Safety Instructions

• Installation

• Operation

GAS WATER HEATER

FOR POT ABLE W A TER HEATING ONLY .

NOT SUIT ABLE FOR SP ACE HEATING

FOR USE ONL Y IN A MANUF ACTURED

OCCUPIED SP ACE OF THA T MOBILE HOME

L.P. PROPANE GAS

(ALL P ARTS INCLUDED)

• Care and Maintenance

• Troubleshooting

• Parts List

For Manufactured (Mobile) Homes

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

INSTALLER:

• AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER.

OWNER:

• RETAIN THESE INSTRUCTIONS AND WARR ANT Y FOR FUTURE REFERENCE. RETAIN THE ORIGINAL RECEIPT AS PROOF OF PURCHASE.

WARNING: Gas leaks can not always be detected by smell.

Gas suppliers recommend that you use a gas detector approved by UL or CSA.

For more information, contact your gas supplier. If a gas leak is detected, follow the “WHAT TO DO IF YOU

SMELL GAS” instructions.

LOW LEAD

CONTENT

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 phone in your building.

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

ALL TECHNICAL AND W ARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED.

IF YOU ARE UNSUCCESSFUL, CONTACT THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

PRINTED IN THE U.S.A 0213 PART NO. 322604-001

SAFE INSTALLATION, USE AND SERVICE

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 hazardous situation which, if not avoided, will 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, could result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury.

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 included in the act.

This product is certified to comply with a maximum weighted average of 0.25% lead content as required in some areas.

IMPORTANT DEFINITIONS

• Qualified Technician: A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing, air

supply, venting, and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters. The qualified technician must also be familiar with the design features and use of flammable vapor ignition resistant water heaters, and have a thorough understanding of this instruction manual.

• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply,

venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer.

• Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within

this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.

SAFETY PRECAUTIONS

WARNING

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

FLAMM ABLES

Flammable V apors

gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death.

Read and follow water heater warnings and instructions.

Fire or Explosion Harzard

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure.

Use only gas shown on rating plate. Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Fire or Explosion Harzard

Hydrogen gas can be produced in a hot water system after a period of non-use (generally two or more weeks).

Hydrogen gas is extremely flammable and can ignite. To return hot water system to service, open a hot water

faucet in kitchen for several minutes before using electrical appliances.

Do not smoke or have open flame near faucet while it is open. Leave hot water faucet open until the sound of escaping

air stops.

After extended period of non-use,

purge gases from hot water system.

TABLE OF CONTENTS

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

SAFETY PRECAUTIONS .................................................................................................................................................................. 2-3

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

TYPICAL INSTALLATION ..................................................................................................................................................................... 5

INSTALLING YOUR GAS WATER HEATER ........................................................................................................................................ 6

Important Information About Your Water Heater ........................................................................................................................... 6

Consumer Information ................................................................................................................................................................... 6

Consumer Responsibilities ............................................................................................................................................................ 6

Unpacking the Water Heater ......................................................................................................................................................... 6

Location Requirements ................................................................................................................................................................. 7

Site Location............................................................................................................................................................................... 7-8

Securing Water Heater to Floor and Wall ...................................................................................................................................... 8

Clearances and Accessibility ......................................................................................................................................................... 8

Filling the Water Heater ................................................................................................................................................................. 9

GAS CONVERSION ........................................................................................................................................................................ 9-10

GAS SUPPLY ................................................................................................................................................................................ 11-12

Gas Requirements .......................................................................................................................................................................11

Gas Piping ....................................................................................................................................................................................11

Gas Pressure ...............................................................................................................................................................................11

Gas Pressure Testing ...................................................................................................................................................................11

LP Gas Only ................................................................................................................................................................................ 12

COMBUSTION AIR SUPPLY AND VENTILATION ........................................................................................................................ 13-14

Vent Pipe System ........................................................................................................................................................................ 13

Draft Hood Installation ................................................................................................................................................................. 13

Roof Jack Installation .................................................................................................................................................................. 13

Enclosure Installations ................................................................................................................................................................ 14

WATER SYSTEM PIPING ............................................................................................................................................................. 15-17

Piping Installation ........................................................................................................................................................................ 15

Water Piping Pressure Test ......................................................................................................................................................... 16

Closed System/Thermal Expansion ............................................................................................................................................ 16

Temperature and Pressure Relief Valve ...................................................................................................................................... 16

T&P Relief Valve and Pipe Insulation (Some Models) ................................................................................................................ 17

IMPORTANT INFORMATION ABOUT THIS WATER HEATER .......................................................................................................... 18

OPERATING YOUR WATER HEATER .........................................................................................................................................19-23

Lighting Instructions ............................................................................................................................................................... 19-20

Checking the Draft....................................................................................................................................................................... 21

Burner Flames ............................................................................................................................................................................. 21

Emergency Shut Down................................................................................................................................................................ 21

Water Temperature Regulation...............................................................................................................................................21-22

Operational Conditions ........................................................................................................................................................... 22-23

MAINTENANCE OF YOUR WATER HEATER ..............................................................................................................................24-29

Routine Preventive Maintenance ................................................................................................................................................ 24

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

Temperature-Pressure Relief Valve Operation ....................................................................................................................... 24-25

Draining and Flushing ................................................................................................................................................................. 25

Replacement Parts ...................................................................................................................................................................... 25

External Inspection & Cleaning of the Base-Ring Filter .............................................................................................................. 25

Removing the Manifold/Burner Assembly .............................................................................................................................. 25-26

Removing the Burner from the Manifold/Burner Assembly ......................................................................................................... 26

Replacing the Pilot/Thermopile Assembly .............................................................................................................................. 26-27

Cleaning the Combustion Chamber and Flame-arrestor............................................................................

Replacing the Manifold/Burner Assembly...............................................................................................................................27-28

Piezoelectric Igniter System ........................................................................................................................................................ 28

Testing the Igniter System ........................................................................................................................................................... 28

Removing and Replacing the

Gas Control Valve/Thermostat ............................................................................................................................................... 28-29

FVIR System Operational Checklist ............................................................................................................................................ 29

TROUBLESHOOTING CHART ..................................................................................................................................................... 30-31

PILOT LIGHT TROUBLESHOOTING FLOWCHART ......................................................................................................................... 32

STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART ................................................................................33-34

REPAIR PARTS ILLUSTRATION ....................................................................................................................................................... 35

................................. 27

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe

B Draft Hood C Anode (Not Shown) D Hot Water Outlet E Insulation F Gas Supply Piping G Manual Gas Shut-off Valve H Ground Joint Union I Sediment Trap

(Z) ROOF JACK**

3-12 PITCH OR LESS

TERMINATION

(ROOF JACK)

TO VENT

(Z) ROOF JACK**

5-12 PITCH OR LESS

J Inner Door K Outer Door L Union M Inlet Water Shut-off Valve N Cold Water Inlet O Inlet Dip Tube (Not Shown) P Temperature-Pressure Relief Valve Q Rating Plate

R Flue Baffle

Gas Control/Temperature Knob

VAC

Igniter

S Gas Control Valve/Thermostat T Drain Valve U Manifold/Burner Assembly V Flue W Metal Drain Pan X Piezo Igniter (bottom, Left-hand Y

Side of Gas Control Valve/Thermostat) Base-Ring Filter

Roof Jack (Various Models)

(S) GAS CONTROL VALVE/

THERMOSTAT

120°F

Mark

Conversion Fitting

Status Light

Temperatures shown are approximates and may vary.

DISCHARGE PIPE

(DO NOT CAP

OR PLUG.)

INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM*

DRAIN LINE MUST PASS THROUGH THE STRUCTURAL FLOOR AND DISCHARGE EXTERNAL TO THE BUILDING

MAIN BURNER

THERMOPILE

(U) MANIFOLD/BURNER ASSEMBLY

MANIFOLD DOOR

VACUUM RELIEF

VALVE*

INSTALL PER

LOCAL CODES

* INSTALL IN ACCORDANCE WITH LOCAL CODES.

* SEDIMENT TRAP AS REQUIRED BY LOCAL CODES.

* SECURE WATER HEATER TO FLOOR

AND WALL AS DESCRIBED IN THIS MANUAL.

PILOT TUBE

IGNITER WIRE

MANIFOLD TUBE

* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.

** ROOF JACK NOT FURNISHED.

FIGURE 1.

* INSTALLATION SHOULD COMPLY

WITH THE “ENCLOSURE INSTALLATION” SECTION OF THIS MANUAL.

INSTALLING YOUR GAS WATER HEATER

Important Information About Your Water Heater

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments. Please review the Installation Checklist section and make any required installation upgrades or changes. IMPORTANT: This water heater is shipped from the factory as a natural gas unit. However, it may be converted to use LP gas. See the Gas Conversion section for more information.

Consumer Information

• The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local and state codes, installations shall comply with the “National Fuel Gas Code,” ANSI Z223.1 (NFPA 54)

-current edition.

Manufactured home manufacturers: The installation must conform to “The Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280.”

These publications are available as follows:

The “National Fuel Gas Code” is available through The Canadian Standards Association, 8501 East Pleasant Valley Rd, Cleveland, Ohio 44131 or The National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

“The Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280” is available through The U.S. Department of Housing and Urban Development (HUD), 451 7th Street S.W., Washington, DC 20410. Offices are also located throughout the United States.

Check your phone listings for the local authorities having jurisdiction over your installation.

• For California installation, this water heater must be braced,

anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California’s Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95811. Instructions can also be downloaded to your computer at www.dsa.dgs.ca.gov/Pubs.

• Massachusetts Code requires this water heater to be

installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

• Complies with 40 Ng/J NOx requirements of Texas and

most California AQM Districts.

Consumer Responsibilities

• Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires. See Figures 1, 9, and 10.

Examine the location to ensure the water heater complies

with the installation instructions in this manual.

• Do not discard this manual. You or future users of this water heater will need it for future reference.

• Service to the FVIR System should only be performed by a qualified technician. Examples of a qualified technician include: licensed plumbers, authorized gas company personnel, and authorized service personnel.

• IMPORTANT: 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 technician perform the installation of this water heater.

• A rating plate identifying your water heater can be found on the front of your water heater. When referring to your water heater, always have the information listed on the rating plate readily available. Retain your original receipt as proof of purchase.

Unpacking the Water Heater

WARNING

Excessive Weight Hazard

Use two or more people to move and install the water heater. Failure to do so can result in injury (including back injury).

IMPORTANT: Do not remove any permanent instructions, labels, or the data label from either the outside of the water heater or on the inside of water heater panels.

• Remove exterior packaging and place installation components aside.

• Inspect all parts for damage prior to installation and start-up.

• Completely read all instructions before attempting to assemble and install this product.

• After installation, dispose of/recycle all packaging materials.

DANGER

Do not use this water heater with any gas other than the one listed on the data plate unless the water heater has been properly converted.

Refer to the “Gas Conversion” section of this manual to convert from one gas to another. Failure to use the correct gas can cause problems which can result in death, serious bodily injury or property damage. If you have any questions or doubts, consult your gas supplier or gas utility company. Water heaters using bottled propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas water heater will not function safely on bottled propane or liquefied petroleum gas (LPG) and a propane gas water heater will not function safely on natural gas.

Location Requirements

WARNING

If ﬂ ammable liquids or vapors have spilled or leaked in the area of the water heater, leave the area immediately and call the ﬁ re department from a neighbor’s home. Do not attempt to clean the spill until all ignition sources have been extinguished.

Carbon Monoxide Poisoning Hazard

Do not install this water heater in any occupied space of the manufactured (mobile) home.

Doing so can result in carbon monoxide poisoning and death.

The FVIR System is designed to reduce the risk of ﬂ ammable vapor-related ﬁ res. The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special ﬂ ame-arrestor. The burning vapors literally “burn themselves out” without escaping back into the room. In the event of a ﬂ ammable vapor incident, the FVIR System disables the water heater by shutting off the gas supply to the water heater’s burner and pilot, preventing re-ignition of any remaining ﬂ ammable vapors in the area. This will not prevent a possible ﬁ re/explosion if the igniter is depressed and ﬂ ammable vapors have accumulated in the combustion chamber with the pilot light off. If you suspect a ﬂ ammable vapor incident has occurred, do not use this appliance. Do not attempt to light this appliance, or depress the igniter button if you suspect ﬂ ammable vapors have accumulated inside or outside the appliance. Immediately call a qualiﬁ ed technician to inspect the appliance. Water heaters subjected to a ﬂ ammable vapors incident will show a discoloration on the ﬂ ame-arrestor and require replacement of the entire water heater.

WARNING

FLAMM ABLES

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.

Read and follow water heater warnings and instructions.

Do not use or store ﬂ ammable products such as gasoline, solvents, or adhesives in the same room or area near the water heater. If such ﬂ ammables 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 ﬂ ammable substances are in use.

Flammable Vapors

WARNING

Fire or Explosion Hazard

• Read instruction manual before installing, using or servicing water heater.

• Improper use may result in fire or explosion.

• Maintain required clearances to combustibles.

Keep combustibles such as boxes, magazines, clothes, etc. away from the water heater area.

Site Location

• DO NOT install this water heater in any occupied space of the manufactured (mobile) home. There shall be no openings between the occupied space of the manufactured (mobile) home and the water heater enclosure.

• The water heater must be installed indoors and in a vertical position on a level surface. Do not install in bathrooms, bedrooms, or any occupied room normally kept closed.

• 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.

• The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces 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 rating 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, fireplaces, 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.

• If the water heater is located in an area that is subjected to lint and dirt, it may be necessary to periodically clean the base-ring filter and flame-arrestor (see Cleaning the Combustion Chamber and Flame-arrestor).

• See also “Enclosure Installations” later in this manual.

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)-current edition. Manufactured home manufacturers must conform with “The Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280”.

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 ﬂ oors of the structure. Due to the normal corrosive action of 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 tank due to corrosion if not repaired. If the homeowner is uncomfortable with making the repair, a qualiﬁ ed technician should be contacted. 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. NOTE: The pan must not restrict combustion air ﬂ ow. Locate the water heater near an adequate drain (Figure 1). In cold climates, it is recommended that the drain pipe be terminated at an adequate drain inside the building. The piping should be at least 3/4” ID and pitched for proper drainage.

Securing Water Heater to Floor and Wall

The water heater must be secured to the ﬂ oor and to the wall of the enclosure as described below. See also “Enclosure Installations.”

1. After properly locating the water heater, fasten it to the ﬂ oor with the brackets and screws that were provided

(Figure 3). Simply pre-drill each screw location in the

l drain pan and water heater jacket with a 1/8” drill bit.

meta

Because of installation variances, these brackets can be located at any points around the circumference of the jacket. However, they should be spaced apart at equal distances.

CAUTION: When making pilot holes in the water heater itself, ensure that you drill only the outer jacket. Also, to prevent leaks in the metal drain pan, seal each drill location with a heavy bead of silicone sealant.

2. Secure the top of the water heater with the provided bracket

and screws or install other acceptable means of support (e.g., support strap).

SCREW

BOTTOM OF WATER HEATER

SCREW

BRACKET

METAL DRAIN PAN

AT LEAST 2” GREATER THAN THE DIAMETER OF THE WATER HEATER.

PIPED TO AN ADEQUATE DRAIN

SEE FIGURE 1

FIGURE 2.

Water heater life depends upon water quality, water usage, water temperature 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 metal 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 metal 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 metal drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected.

• Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the drain pan.

• Water supply shut-off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.

• Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

FIGURE 3.

Clearances and Accessibility

NOTE: Minimum clearances from combustible surfaces are stated on the label adjacent to the gas control valve/thermostat 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 three inches (76.2mm) in any direction; or if in an alcove or closet installation, the entire floor must be covered by the panel.

• Figure 4 may be used as a reference guide to locate the

specific clearance locations. A minimum of 24 inches of front clearance should be provided for inspection and service.

VENT

TOP

CEILING

SIDES

BACK

TOP VIEW

SIDES

FRONT 24” MINIMUM FOR SERVICE

FIGURE 4.

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 ensure 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.

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

GAS CONVERSION

This water heater is originally shipped for use with N atural Gas but can be converted to LP (Propane) Gas by following the

instructions outlined below. To convert this water heater you must change both the conversion fitting in the gas control valve/ thermostat AND manifold/burner assembly (supplied). Both the gas valve and the manifold burner assembly must be correct for the type of gas used. If you are unsure about converting this water heater to use a different type of gas, contact a qualified person such as a plumber or your gas supplier.

1. Contact your gas company to determine the type of gas supplied to your home.

2. Check the setting of the conversion fitting in the gas control valve (see diagram).

3. Check the label on the manifold burner assembly door.

4. Make sure both the conversion fitting (figure 6) and the manifold burner assembly (see door label) are for the type of gas supplied to your home.

5. If you are converting this water heater from Natural to LP or from LP to Natural follow these steps:

• Remove manifold burner assembly (see instructions on page 10)

• Install correct conversion manifold burner assembly (see instructions on page 10).

• Convert the gas control valve/thermostat to same type of gas (see instructions on page 10).

• Place sticker next to data plate showing the type of gas this water heater has been converted to.

GAS CONVERSION (Con’t)

IGNITER WIRE

RED WIRE (LEFT SIDE)

PILOT

UBE MANIFOLD TUBE

IGNITER BUTTON

IGNITER LEAD WIRE

WHITE

WIRE

(RIGHT

SIDE)

WARNING

For your safety, the following procedures should be performed by a qualified technician as it involves disconnection of gas piping and leak testing.

Do not connect a natural gas water heater to an L.P. gas supply.

Do not connect an L.P. gas water heater to a natural gas supply.

A. Remove the Manifold/Burner Assembly

1. Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position, then proceed to turn it off.

2. On the lower front of the water heater, locate the gas control valve/thermostat.

3. Turn the gas control/temperature knob to the “OFF” position. With the unit shut-off, allow sufficient time for the water heater to cool before performing any maintenance.

4. Remove the outer door.

5. Remove the two screws securing the installed manifold door assembly to the combustion chamber (Figure 5).

6. Disconnect the following from the gas control valve/thermostat: pilot tube, igniter wire, and manifold tube. See Figure 5.

7. Using needle nose pliers, disconnect the white and red thermopile wires from the gas control valve/thermostat (Figure 5).

8. Grasp the manifold tube and push down slightly to free the manifold tube and pilot tube.

9. Carefully remove the manifold/burner assembly from the burner compartment. NOTE: Be sure not to damage internal parts.

B. Convert the Gas Control Valve/Thermostat

1. Remove the cap (shown in Figure 6).

2. Remove the conversion fitting by turning it counter-clockwise with a flathead screwdriver.

3. Thread the opposite end of the conversion fitting into the opening by turning it clockwise, then tighten it with a flathead screwdriver.

a. LP GAS: If you are converting the unit to use LP gas

(propane), verify that “LP” is marked on the exposed end

GAS CONTROL VALVE/THERMOSTAT CONNECTIONS

of the fitting. “LP” must face outward (toward you.) See Figure 6. If “NAT” faces outward, repeat step 2.

b. NATURAL GAS: If you are converting the unit to use

natural gas, verify that “NAT” is marked on the exposed end of the fitting. “NAT” must face outward (toward you.) See Figure 6. If “LP” faces outward, repeat step 2.

4. Replace the cap.

C. Install the Conversion Manifold/Burner

Assembly

1. Check the door gasket for damage or imbedded debris prior to installation.

2. Inspect the view port for damage and replace as required.

3. Insert the conversion manifold/burner assembly into the burner compartment, making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber.

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 that secure the manifold/burner assembly door to the combustion chamber, then tighten them securely. There should be no space between the gasket part of the manifold door and the combustion chamber. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber.

6. Reconnect the manifold tube and pilot tube to the gas control valve/thermostat (Figure 5). Do not cross-thread or apply any thread sealant to the fittings. IMPORTANT: If you were supplied with a new ferrule nut in a parts kit, follow these steps to connect the pilot tube:

A.) Install the ferrule nut into the gas valve at the pilot tube

location, hand tight only. B.) Insert the pilot tube into the ferrule nut until the tube bottoms out, then tighten the nut with a 7/16” wrench until the crimp connection seals to the pilot tube. C.) Continue to tighten until the nut is tight in the gas valve.

7. Connect the white and red thermopile wires to the gas control valve/thermostat. See Figure 5.

8. Reconnect the igniter wire.

9. Turn the gas supply on and follow the Lighting Instructions.

10. With the main burner lit, check for leaks at the manifold and pilot connections by brushing on an approved non-corrosive leak detection solution. If such a solution is not available, use a mixture of hand dish washing soap and water (one part soap to 15 parts water). Bubbles forming indicate a leak. Correct any leak found.

11. Verify proper operation; replace outer door.

GAS CONTROL/ TEMPERATURE KNOB

PIEZO IGNITER BUTTON PILOT TUBE

VIEWPORT

OUTER DOOR NOT SHOWN

MANIFOLD SCREW (2)

VAC

MANIFOLD COMPONENT BLOCK

THERMOPILE

WIRE

CONNECTIONS

MANIFOLD TUBE

THERMAL SWITCH

MANIFOLD DOOR

GAS CONTROL VALVE/THERMOSTAT

CONVERSION FITTING

CAP

NATURAL GAS: “NAT” FACES OUTWARD (TOWARD YOU).*

LP GAS: “LP” FACES OUTWARD (TOWARD YOU).*

* ORIENTATION MAY VARY. FITTING TO BE TIGHT.

FIGURE 6.FIGURE 5.

GAS SUPPLY

WARNING

Explosion Hazard

• Use a new CSA approved gas supply line.

• Install a shut-off valve.

• Do not connect a natural gas water heater to an L.P. gas supply.

• Do not connect an L.P. gas water heater to a natural gas supply.

• Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.

Gas Requirements

IMPORTANT: Read the rating 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 rating plate located near the gas control valve/thermostat. 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

MANUAL GAS SHUT-OFF VALVE

GROUND JOINT UNION

CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT

3” MINIMUM

DRIP LEG

FIGURE 7.

Gas Pressure

WARNING

Explosion Hazard

• Gas leaks can not always be detected by smell.

• Gas suppliers recommend that you use a gas detector approved by UL or CSA.

• For more information, contact your gas supplier.

• If a gas leak is detected, follow the “What to do if you smell gas” instructions on the cover of this manual.

The 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)-current edition. Manufactured home m anufacturers m ust conform with “The Manufac tured Home Construction and Safety Standard, Title 24 CFR, Part 3280”.

Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials. Consult the “National Fuel Gas Code” for the recommended gas pipe size of other materials.

NOTE: Use pipe joint compound or teﬂ on tape marked as be- ing resistant to the action of petroleum [Propane (L.P.)] gases. (See Figure 7.)

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 control valve/ thermostat and the manual shut-off valve. This is to allow easy removal of the gas control valve/ thermostat.

4. Turn the gas supply on and check for leaks. Test all connections by brushing on an approved noncorrosive leak-detection solution. Bubbles will show a leak. Correct

any leak found.

IMPORTANT: The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater’s rating 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 and 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 qualiﬁ ed technician after installation of the gas piping system. While purging the gas piping system of air, ensure that the fuel is not spilled in the area of the water heater installation, or any source of ignition. If the fuel is spilled while purging the piping system of air follow the “WHAT TO DO IF YOU SMELL GAS” instructions on the cover of this manual.

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