Reliance 650YBVIS, 640YBVIS User Manual

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Instruction Manual

RESIDENTIAL GAS WATER HEATERS

DIRECT VENT GAS MODELS

NOT FOR USE IN MANUFACTURED (MOBILE) HOMES

LOW LEAD

NTENT

• For Your Safety •

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS PURCHASED. IF YOU ARE UNSUCCESSFUL, PLEASE WRITE TO THE COMPANY LISTED ON THE RATING PLATE ON THE WATER HEATER.

KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE

WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.

1013 PART NO. 321350-002

SAFE INSTALLATION, USE AND SERVICE

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

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

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situ-

DANGER

WARNING

CAUTION

ation which, if not avoided, will result in injury or death.

WARNING Indicates a potentially hazardous situ-

ation which, if not avoided, could result in injury or death.

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

CAUTION used without the safety alert symbol

CAUTION

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

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 water heater can cause low-level exposure to some of the substances included in the Act.

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

• Qualiﬁ ed Installer: A qualiﬁ ed installer must have ability equivalent to a licensed tradesman in the ﬁ elds 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 ﬁ red water heaters. The qualiﬁ ed installer must also be familiar with the design features and use of ﬂ ammable 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 ﬁ elds 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 ﬁ red 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.

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

IMPORTANT DEFINITIONS

GENERAL SAFETY

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE 2

IMPORTANT DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL SAFETY 3 TABLE OF CONTENTS 4 INTRODUCTION 5

PREPARING FOR THE INSTALLATION . . . . . . . . . . . . . . 5

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS 6 TYPICAL INSTALLATION 7

GET TO KNOW YOUR WATER HEATER . . . . . . . . . . . . . 7

REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 7

MIXING VALVE USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

LOCATING THE NEW WATER HEATER 9

FACTS TO CONSIDER ABOUT THE LOCATION . . . . . . . 9

INSULATION BLANKETS . . . . . . . . . . . . . . . . . . . . . . . . . 10

VENT TERMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLING THE NEW WATER HEATER 11

REQUIRED ABILITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

INSPECT SHIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

WATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

T&P VALVE AND PIPE INSULATION (IF SUPPLIED). . . 12

TEMPERATURE-PRESSURE RELIEF VALVE . . . . . . . . 12

WATER (POTABLE) HEATING AND SPACE HEATING . . . . 14

CLOSED WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 14

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SEDIMENT TRAPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

FILLING THE WATER HEATER . . . . . . . . . . . . . . . . . . . . 16

VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

HIGH ALTITUDE INSTALLATIONS. . . . . . . . . . . . . . . . . . 17

COMBUSTION AIR AND VENTILATION . . . . . . . . . . . . . 17

VENT TERMINAL CLEARANCES . . . . . . . . . . . . . . . . . . 17

DV TERMINATION SAFETY COVER. . . . . . . . . . . . . . . . 17

VENT CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

LOCATING CLEARANCE HOLE FOR VENT. . . . . . . . . . 18

HIGH RISE VENT ARRANGEMENT . . . . . . . . . . . . . . . . 18

STANDARD VENT ARRANGEMENT . . . . . . . . . . . . . . . . 19

VENT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECURING VENT TERMINATION ASSEMBLY TO THE EX-

TERIOR WALL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

UNCOMPRESSING THE CORRUGATED TUBING. . . . . 19

VENT RESTRICTER PLATE . . . . . . . . . . . . . . . . . . . . . . 19

OFFSET VENT ARRANGEMENT. . . . . . . . . . . . . . . . . . . 20

TEMPERATURE REGULATION 22

TEMPERATURE REGULATION. . . . . . . . . . . . . . . . . . . . 22

OPERATING THE TEMPERATURE CONTROL SYSTEM 22 FOR YOUR INFORMATION 23

EXTERNAL DAMAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

START UP CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 23

OPERATIONAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . 24

MAINTENANCE 25

VENTING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . 25

PILOT AND MAIN BURNER. . . . . . . . . . . . . . . . . . . . . . . 25

BURNER FLAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

REPLACING THE MANIFOLD/BURNER ASSEMBLY. . . 26

PIEZOELECTRIC IGNITER SYSTEM . . . . . . . . . . . . . . . 26

TESTING THE IGNITER SYSTEM. . . . . . . . . . . . . . . . . . 26

REMOVING AND REPLACING THE GAS CONTROL

VALVE/THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

REMOVING THE MANIFOLD/BURNER ASSEMBLY . . . 27 REMOVING THE BURNER FROM THE MANIFOLD/BURN-

ER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

REPLACING THE PILOT/THERMOPILE ASSEMBLY. . . 28

TEMPERATURE & PRESSURE RELIEF VALVE. . . . . . . 29

DRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CATHODIC PROTECTION - ANODE . . . . . . . . . . . . . . . . 29

DRAIN VALVE WASHER REPLACEMENT . . . . . . . . . . . 29

ANODE ROD MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 30

LEAKAGE CHECKPOINTS 31

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TROUBLESHOOTING GUIDELINES 32 RESIDENTIAL GAS WARRANTY 34

INTRODUCTION

Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. Abbreviations Found In This Instruction Manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• AHRI - Air Conditioning, Heating and Refrigeration Institute

• LLC - Low Lead Content

This gas-ﬁ red water heater is design certiﬁ ed by American Na- tional Standard ANSI Z21.10.1/CSA 4.1 (current edition).

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section, page 3 of this manual ﬁ rst and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. This manual contains instructions for the installation, operation, and maintenance of the gasﬁ red water heater. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the ﬁ rst few pages, READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

2. The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA. This publication is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the local gas utility or the manufacturer whose name appears on the rating plate.

4. 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 ﬁ res, see Figures 1 and 2. Examine the location to ensure the water heater complies with the “Locating the New Water Heater” section in this manual.

5. For California installation, this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. Correct installation procedure instructions may be obtained from California’s Ofﬁ ce 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.

6. Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00. For more information see next page.

7. This water heater is suitable for combination water (potable) heating and space heating and not suitable for space heating applications only.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

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

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

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂ oor level. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

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

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

KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the

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

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

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

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

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

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

2. A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ﬂ ue gases, but identiﬁ es “special venting systems,” the following requirements shall be satisﬁ ed by the manufacturer:

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

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

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.that the discharge pipe be terminated at an adequate drain inside the building.

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER REPLACEMENT PARTS

Replacement parts may be ordered through authorized servicers or distributors. When ordering parts, provide complete model and serial numbers (see rating plate), quantity and name of part desired (as listed in Figure 1). Standard hardware items may be purchased locally.

COLD WATER

INLET PIPE

UNION

INLET DIP TUBE

TEMPERATURE AND PRESSURE RELIEF VALVE

VACUUM RELIEF

VALV E

INSTALL PER

LOCAL CODES.

PILOT TUBE

THERMOPILE CONNECTOR

HOT WATER

OUTLET PIPE

ANODE

TRIM PLATE

(OUTSIDE)

TRIM PLATE

(INSIDE)

INLET VALVE

THERMAL

EXPANSION TANK

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

PILOT / THERMOPILE ASSEMBLY SCREW

WHITE

WIRE

FLUE BAFFLE

GAS SUPPLY

LINE

MAIN MANUAL

GAS SHUTOFF

VALV E

GROUND-JOINT

UNION

SEDIMENT

TRAP (DIRT

LEG

DISCHARGE PIPE (DO NOT CAP OR PLUG)

GAS CONTROL VALV E/ THERMOSTAT

DRAIN VALVE

METAL DRAIN PAN

6” MAXIMUM AIR GAP

IGNITER WIRE

MANIFOLD

COMPONENT

BLOCK

List of status codes are shown at top of gas control valve/thermostat.

RETAINER CLIP

MANIFOLD DOOR

BURNER AND OTHER FITTINGS NOT SHOW

FOR CLARITY.

OUTER DOOR

ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMER.

FIGURE 1

FLOOR DRAIN

MIXING VALVE USAGE

MIXING VALVE

NON-TEMPERED WATER SUPPLY

SUGGESTED PIPING

ARRANGEMENT FOR

TOP CONNECTIONS

TEMPERED POTABLE WATER

SHUT-OFF VALVE

COLD WATER INLET

NON-TEMPERED WATER RETURN

TEMPERATURE-PRESSURE RELIEF VALVE

GAS SUPPLY

DISCHARGE PIPE (DO NOT CAP OR PLUG)

CERTAIN MODELS ARE EQUIPPED WITH SIDE PLUMBING CONNECTIONS FOR SPACE HEATING.

DRAIN VALVE

METAL DRAIN PAN

6” MAXIMUM

AIR GAP

TO SUITABLE DRAIN

FIGURE 2

This water heater has been design certiﬁ ed as complying with American National Standard/CSA Standard for water heaters and is considered suitable for:

Water (Potable) Heating and Space Heating: All models are considered suitable for water (potable) heating and space heating. Not suitable for space heating only.

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the inﬁ rm, or physically/mentally handicapped. If anyone using hot water in your home ﬁ ts into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisﬁ es your hot water needs, a means such as a *Mixing Valve, should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. Consult a Qualiﬁ ed Installer or Service Agency. Follow mixing valve manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

LOCATING THE NEW WATER HEATER

FACTS TO CONSIDER ABOUT THE LOCATION

Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation.

Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed:

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

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

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

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

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

Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the ﬂ ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper ﬂ oor. When such locations cannot be avoided, a metal drain pan should be installed under the water heater. Metal drain pans are available at your local hardware store. Such a metal drain pan must have a minimum length and width of at least 2 in. greater that the water heater dimensions, a maximum height of 1.75 in. and must be piped to an adequate drain.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a 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:

This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the water heater extending beyond the full width and depth of the water heater by at least 3 in. in any direction, or if the water heater is installed in an alcove or closet, the entire ﬂ oor must be covered by the panel. Failure to heed this warning may result in a ﬁ re hazard.

• Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.

INSULATION BLANKETS

VENT TERMINATION

Insulation blankets available to the general public for external use on gas water heaters are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank water heaters. Your Water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions (See Figure 1 for identiﬁ ca- tion of components mentioned below). Failure to follow these instructions can result in ﬁ re, asphyxiation, serious personal injury or death.

Before installing water heater determine placement of vent termination.

Make certain to observe vent location limitations, see Figures 3 & 15.

Minimum clearances between the water heater and combustible and noncombustible construction are: 0 in. from sides, 0 in. from back, 4 in. from front of jacket to closet door and 20 in.* from top of jacket to combustible and noncombustible material. Minimum vent clearance: 1 in.**. Provide 3 ft. front clearance for servicing and adequate clearance between the jacket top & ceiling for servicing the ﬂ ue vent area, see Figure 3.

* This clearance (20 in.) is required only to accomodate the minimum vent radius.

** Where the wall is combustible and the wall thickness is over 14 in., 1 in. clearance to combustible surfaces around the vent terminal is needed. The ﬁ rst 14 in. is zero clearance.

• Do not cover the outer door, thermostat or temperature & pressure relief valve.

• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

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

Make certain the vent locations comply with the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or local codes. There is some important information shown in Figure

15. For a second or more direct vent unit, the distance between vent terminals must be a minimum of 12 in..

FIGURE 3

INSTALLING THE NEW WATER HEATER

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR SUPPLY, VENTING AND GAS SUPPLY ARE REQUIRED.

INSPECT SHIPMENT

There may be hidden damage caused in transit. Check to be certain all parts of the venting system, as listed below, are present.

CAUTION!!! IF THERE ARE ANY DAMAGED PARTS, DO NOT INSTALL THIS WATER HEATER. REPORT ANY SHORTAGE TO YOUR DISTRIBUTOR OR DAMAGE TO YOUR CARRIER.

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

All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

GENERAL

The installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54. The code is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

WATER PIPING

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the inﬁ rm, or physically/men- tally handicapped. If anyone using hot water in your home ﬁ ts into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisﬁ es your hot water needs, a means such as a *mixing valve, should be used at the hot water taps used by these people or at the water heater, see Figure 2. Valves for reducing point of use temperature by mixing cold and hot water are also available:

Consult a Qualiﬁ ed Installer or Service Agency. Follow manufac- turer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

When the system requires water for space heating at temperatures higher than required for domestic water purposes, a mixing valve must be installed. Please refer to Figure 2 for suggested piping arrangement.

Water supply systems may, because of such events as high line pressure, frequent cut-offs, the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back ﬂ ow preventers, etc. to control these types of problems. When these devices are not equipped with an internal by-pass, and no other measures are taken, the devices cause the water system to be closed.

As water is heated, it expands (thermal expansion). In a closed system, the volume of water will grow. As the volume of water increases, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

A properly-sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank.

NOTE: To protect against untimely corrosion of hot and cold water ﬁ ttings, it is strongly recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe.

All gas piping must comply with local codes and ordinances or with the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54 whichever applies. Copper and brass tubing and ﬁ ttings (except tin lined copper tubing) shall not be used.

4. Locate the hot water (outlet) & cold water (inlet) pipes to the water heater.

5. Locate the slit running the length of a section of pipe insulation.

6. Spread the slit open and slip the insulation over the cold water (inlet) pipe. Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe. Also, ensure that the base of the insulation is ﬂ ush with the water heater. Once seated, secure the insulation with duct tape, electrical tape, or equivalent.

7. Repeat steps 5 and 6 for the hot water (outlet) pipe.

8. Add additional sections of pipe insulation as needed.

HOT WATER

OUTLET

UNION

3/4” SWEAT

FITTING

DRAIN VALVE

FLOOR DRAIN

FIGURE 4

COLD WATER

INTLET

SHUTOFF VALV E

UNION

3/4” SWEAT FITTING

TEMPERATURE AND PRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

METAL DRAIN PAN

6” MAXIMUM AIR GAP

Figure 4 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4“ NPT water connections.

T&P Relief Valve Insulation (Outlet opening on underside)

Manual Relief Lever

T&P Relief Valve

T&P Relief Valve Drain Line

FIGURE 5

TEMPERATURE-PRESSURE RELIEF VALVE

Explosion Harzard

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NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. Do not solder the cold water supply line directly to the cold water inlet. It will harm the dip tube and damage the tank.

T&P VALVE AND PIPE INSULATION (IF SUPPLIED)

1. Locate the temperature and pressure relief valve on the water heater (also known as a T&P relief valve). See Figure 5.

2. Locate the slit running the length of the T&P relief valve insulation.

3. Spread the slit open and ﬁ t the insulation over the T&P relief valve. See Figure 5. Apply gentle pressure to the insulation to ensure that it is fully seated on the T&P Relief Valve. Once seated, secure the insulation with duct tape, electrical tape, or equivalent. IMPORTANT: The insulation and tape must not block the discharge opening or hinder access to the manual relief lever (Figure 5). Ensure a discharge pipe is installed into the T&P valve discharge opening per the instructions in this manual.

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

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

If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certiﬁ ed as indicated in the above paragraph. The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate.

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

The temperature-pressure relief valve must be installed directly into the ﬁ tting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only within 6 in. above, or at any distance below the structural ﬂ oor. Be certain that no contact is made with any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances. Excessive length, over 30 ft., or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve, see Figures 4 or 9.

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

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

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

The Discharge Pipe:

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

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

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

• Must terminate a maximum of six inches above a ﬂ oor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.

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

WATER (POTABLE) HEATING AND SPACE HEATING

CLOSED WATER SYSTEM

1. All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

2. Toxic chemicals, such as those used for boiler treatment, shall NEVER be introduced into this system.

3. This unit may NEVER be connected to any existing heating system or component(s) previously used with a non-potable water heating appliance.

4. When the system requires water for space heating at temperatures higher than required for domestic water purposes, a mixing valve must be installed, see Figure 6 for suggested piping arrangement.

5. This water heater is suitable for combination water (potable) heating and space heating and not suitable for space heating applications only.

TYPICAL MIXING VALVE INSTALLATION

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

A closed system will exist if a back-ﬂ ow preventer (check valve), pressure reducing valve, or other similar device is installed in the cold water line between the water heater and the street main (or well). Excessive pressure may develop due to the thermal expansion of heated water causing premature tank failure or intermittent relief valve operation. This type of failure is not covered by the limited warranty. An expansion tank may be necessary in the cold water supply to alleviate this situation, see Figure 1. Contact the local plumbing authority. If the temperature and pressure relief valve on the appliance discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. DO NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE.

The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass should 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.

EXPANSION TANK

COLD WATER INLET

COIL

EVA

AIR

SHUT-OFF

VALVE

CHECK VALVE †

(1/8” HOLE

DRILLED IN CLAPPER)

FLOW CONTROL

PUMP

AIR

†

OUT

HANDLER

†

VACUUM RELIEF VALVE

UNION

TEMP/ PRESSURE RELIEF VALV E

HANDLER

SEE NOTE ‡

SHUT-OFF

VALV E

100 FT. MAX.

DEVELOPED

DISTANCE FROM

WATER HEATER

TO FAN COIL

TEMPERED WATER TO FIXTURES (MUST MEET TEMPS LISTED IN MASS. CODE 248 CMR

MUST BE VERTICAL TO REMOVE A

MIXING VALVE (MUST BE INSTALLED BELOW TOP OF WATER HEATER AS PER MANUFACTURER’S RECOMMENDATIONS)

WATER HEATER ACCEPTED BY THE BOARD FOR INSTALLATION IN MASSACHUSETTS.

MASSACHUSETTS INSTALLATION REQUIREMENTS:

1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS

2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR

3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.

† REQUIRED FOR MASSACHUSETTS. ‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.

IR BUBBLES

FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.

& 780 CMR).

†

)

†

CHECK

VALVE

UNION

HOT

WATER

OUT

Figure 6

GAS PIPING

WARNING

Explosion Hazard

Have a qualified technician make sure that the L.P. gas operating pressure does not exceed 13” water column (3.237 kilopascals).

Failure to do so can result in death, explosion, or fire.

Make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5 kPa) for natural and propane gas (L.P.). The minimum inlet gas pressure shown on the rating plate is that which will permit ﬁ ring at rated input.

If the gas control valve is subjected to pressures exceeding 1/2 psi (3.5 kPa), the damage to the gas control valve could result in a ﬁ re or explosion from leaking gas.

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

A gas line of sufﬁ cient size must be run to the water heater. Consult the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54 and your gas supplier concerning pipe size.

There must be:

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

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

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

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

When installed at elevations above 7,700 feet, input rating should be reduced at the rate of 4 percent for each 1,000 feet above sea level which requires replacement of the burner oriﬁ ce in accordance with the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local gas supplier for further information.

Failure to replace the standard oriﬁ ce with a high altitude oriﬁ ce when installed could result in improper and inefﬁ cient operation of the water heater, producing carbon monoxide gas in excess of safe limits, which could result in serious injury or death. Contact your gas supplier for any speciﬁ c changes which may be required in your area.

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

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

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

Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 7 and 8.

Gas piping with ﬂ exible connector.

FIGURE 7

Gas piping with all black iron pipe to gas control.

FIGURE 8

SEDIMENT TRAPS

HOT WATER

OUTLET

UNION

DRAIN VALVE

FLOOR DRAIN

COLD WATER

INTLET SHUTOFF VALV E

UNION

TEMPERATURE AND PRESSURE RELIEF VALVE

DISCHARGE PIPE (DO NOT CAP OR PLUG)

METAL DRAIN PAN

6” MAXIMUM AIR GAP

FIGURE 9

A sediment trap (dirt leg) shall be installed as close to the inlet of the water heater as practical at the time of water heater installation. The sediment trap (dirt leg) shall be either a tee ﬁ tting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap (dirt leg). If a tee ﬁ tting is used, it shall be installed in conformance with one of the methods of installation shown in Figures 7 and 8.

Contaminants in the gas lines may cause improper operation of the gas control valve that may result in ﬁ re or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a sediment trap (dirt leg) must be incorporated in the piping. The sediment trap (dirt leg) must be readily accessible. Install in accordance with the “Gas Piping” section. Refer to the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54.

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 ﬁ lled with water. Water must ﬂ ow from the hot water faucet before turning “ON” gas to the water heater.

To ﬁ ll the water heater with water:

1. Close the water heater drain valve by turning the handle clockwise ( water heater.

2. 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.

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

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

). The drain valve is on the lower front of the

VENTING

NEVER OPERATE THE WATER HEATER UNLESS IT IS VENTED TO THE OUTDOORS AND HAS ADEQUATE AIR SUPPLY TO AVOID RISKS OF IMPROPER OPERATION, FIRE, EXPLOSION OR ASPHYXIATION.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND

VENTILATING AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST BE PROVIDED FOR SAFE OPERATION.

HIGH ALTITUDE INSTALLATIONS

Installations above 7,700 ft. require replacement of the burner oriﬁ ce in accordance with the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54. Failure to replace the oriﬁ ce could result in improper and inefﬁ cient operation of the appli- ance, producing carbon monoxide gas in excess of safe limits, which could result in serious personal injury or death. Contact your gas supplier for any speciﬁ c changes which may be re- quired in your area.

FIGURE 10

Be sure venting is properly connected to prevent escape of dangerous ﬂ ue gases which could cause deadly asphyxiation.

COMBUSTION AIR AND VENTILATION

When determining the installation location for a direct vent water heater, snow accumulation and drifting should be considered in areas where applicable.

VENT TERMINAL CLEARANCES

The vent system must terminate so that proper clearances are maintained as cited in local codes or the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54 as follows:

DV TERMINATION SAFETY COVER

A Safey cover (see Figure 11) is available to prevent accidental contact with the vent terminal. Contact your Customer Service Department for ordering information.

FIGURE 11

VENT CONNECTIONS

After the location for the vent terminal has been selected as outlined in Figures 3 & 15, use the following illustrations for installation:

7 in. DIAMETER

(SEE TEXT)

BOTTOM OF HEATER

FIGURE 13

HIGH RISE VENT ARRANGEMENT

When the height H (From vent terminal center line to bottom of heater) is over 80 in. , it is a high rise vent arrangement. In this case the minimum distance “D” from the center of the water heater to the outside wall surface is 22 in., and the maximum height of “H” is 12 ft..

FIGURE 12

LOCATING CLEARANCE HOLE FOR VENT

Cut a clearance hole, approximately 7 in. in diameter, through the exterior wall for the vent assembly. The recommended height is 68 in. for 40 gal. models and 76 in. for 50 gal., 50 gal. Hi-Input and 75 gal. models, as measured from the hole center to bottom of water heater. The maximum height recommended is 80 in. or in compliance with Figure 14. Where the wall is combustible and the wall thickness is over 14 in., 1 in. clearance to combustible surfaces around the vent terminal is needed. The ﬁ rst 14 in. is zero clearance.

*Minimum 9 in. for appliances with 10,000 btuh (3 Kw) to 50,000 btuh (15 Kw) inputs and 12 in. for appliances greater than 50,000 btuh (15 Kw) to a window or door that may be opened

TO BOTTOM OF HEATER

Minimum 18 in.

above grade or

anticipated snow

12 in.

level

FIGURE 14

10 in. (REF)

WALL THICKNESS

12 in.

from soffit

Minimum

12 in. from sides, above or below a permanently

closed window or door

VENT TERMINAL AIR SUPPLY INLET

1. Permitted only if veranda, porch, deck or balcony is fully opened on a minimum of two sides beneath the floor.

2. A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

Minimum

2 ft.

from outside

corner

AREA WHERE TERMINAL IS NOT PERMITTED

Minimum 9 in. for appliances with 10,000 btuh (3 Kw)

to 50,000 btuh (15 Kw) inputs and 12 in. for appliances greater

than 50,000 btuh (15 Kw) to a non mechanical air supply inlet

into building or combustion air inlet to another appliance

FIGURE 15

Minimum 12 in.

under veranda, porch,

deck or balcony

(see footnote 1)

Minimum

3 ft.

above if within

10 ft.

horizontally to

a mechanical air

supply inlet

STANDARD VENT ARRANGEMENT

UNCOMPRESSING THE CORRUGATED TUBING

3.6 in.

2.6 in.

17 in. MIN.,*

80 in. MAX.

2.1 in.

FIGURE 16

WALL

* If the horizontal distance is less than 30 in., the restricter plate must be installed (see Figure 21). NOTE: The length of “unstretched” corrugated tube could cause the length of the vent run to exceed the minimum. In this case cut off a piece of the corrugated tube to acheive the 17 in. minimum vent length.

VENT ASSEMBLY

The vent tube and terminal can be assembled as shown in Figure 17. There are springs fastened inside the corrugated tube. When the vent tubes are pulled to a required length, the springs will still be equally spaced.

1. Pull the inner corrugated tube towards the water heater and leave some length over the water heater’s center for bending.

2. Pull the outer corrugated tube toward the water heater and leave it 1 in. shorter than the inner corrugated tube.

3. Make sure there are two springs evenly spaced at the bend in the tube.

4. Use metal hangers to keep venting level or with a slope upward from the heater to terminal.

SPRING

REDUCER

FIGURE 19

Bend both the corrugated tubes toward the water heater’s ﬂ ue connection.

SPRING

CLAMP

FIGURE 17

SECURING VENT TERMINATION ASSEMBLY TO THE EXTERIOR WALL.

Some models are supplied with trim plates which may be used to cover the holes in the wall (see Figures 1 and 18). Slide one trim plate (if supplied) over the outer corrugated tube, then insert the outer corrugated tube through the clearance hole from exterior wall. Secure the trim plate to the exterior wall, then secure the vent terminal to the exterior wall with 4 screw anchors (included) appropriate for the type of wall construction. Caulk the junction of the vent terminal base plate and the exterior wall with exterior type sealant (not included). Slide the trim plate (inside) over the outer corrugated tube and fasten the trim plate to the interior wall. Caulk the junction of the outer corrugated tube and the trim plate (inside) with suitable sealant.

TRIM PLATE

(INSIDE)

SEALANT

FIGURE 20

VENT RESTRICTER PLATE

For short horizontal vent runs (see Figure 16) place the restricter plate over the ﬂ ue tube reducer before connecting the inner cor- rugated tube to the ﬂ ue tube reducer. DO NOT use the restricter plate if the horizontal run is greater than 30 in..

UPPER AIR INLET BOX

FLUE TUBE

REDUCER

FIGURE 21

RESTRICTER PLATE

TRIM PLATE (OUTSIDE)

FIGURE 18

Pull and connect the inner corrugated tube to the water heater’s ﬂ ue tube reducer with hi-temp red silicone (included) and gear clamp. Make sure this connection is tight and leak proof. *The sealant between the inner corrugated tube and water heater’s ﬂ ue tube reducer must be hi-temp red silicone or other material suitable for 600°F continuous service.

FIGURE 22

Apply hi-temp red silicone (included) around the collar on air manifold box. Pull corrugated vent tube all the way on to collar and secure with one sheet metal screw (approx. 3/4 in. up from edge of vent tube. Pull gear clamp past screw and tighten.

OFFSET VENT ARRANGEMENT

CONDITION 1:

Where a straight vent arrangement is impossible, a horizontal 90 degree maximum bend can be made. Use the water heater casing outer diameter as a template to form the corrugated tube.

TOP VIEW

90° MAXIMUM BEND

FIGURE 24

CONDITION 2:

Where ﬂ oor joists impede venting, a rise or drop to complete the vent termination is possible. All installations require 1 in. clearance to combustibles. NOTE: A. The maximum horizontal vent length of 80 in. minus wall

thickness should be considered when installing an offset vent arrangement.

B. Do not combine condition 1 (Figure 24) with condition 2

(Figure 25) in the same installation.

C. The maximum allowable drop from vent center-line to vent

termination center-line (Figure 25) is 7.25 in..

FIGURE 23

>1 in.

“H”

SEE

CHART

>1 in.

7.25 in. MAX

MODELS

40 gal. 68 in. 50 gal. 76 in. 50 gal. Hi-INPUT 76 in.) 75 gal. 76 in.

FIGURE 25

WALL 10 in.

(REF)

RECOMMENDED MINIMUM “H”

FOR YOUR SAFETY READ BEFORE LIGHTING

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

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

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

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

FLAMMABLE

BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED

WITH WATER AND AIR PURGED FROM ALL LINES

A. This appliance has a pilot which is lit by a piezoelectric spark gas ignition system. Do not open the

inner door of the appliance and try to light the pilot by hand.

B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor

because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

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C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not

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repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately contact a qualified installer

or service agency to replace a flooded water heater. Do not attempt to repair the unit! It must be replaced!

LIGHTING INSTRUCTIONS

Gas Control & Temperature Knob

GAS CONTROL

Status Light

Igniter

FIGURE 'A'

120°F

Mark

"OFF" POSITION

FIGURE 'B'

120°F

Mark

"PILOT" POSITION

CONTROL KNOB

FIGURE 'C'

120°F

Mark

"ON" POSITION

MAIN BURNER

THERMOPILE

PILOT

FIGURE 'D'

1. STOP! It is imperative that you read all safety warnings before lighting the pilot.

2. Turn the gas control/temperature knob counterclockwise to the "OFF" position.

3. Wait ten (10) minutes to clear out any gas. If you then smell gas, STOP! Follow “ B” in the safety information above on this label. If you do not smell gas, go to the next step.

4. Turn the gas control/temperature knob clockwise to “PILOT”. See Figure ‘B’.

5. Press the gas control/temperature knob all the way in and hold it in. The knob should travel in about 6mm (1/4 inch) if it is set to "PILOT" correctly. While holding the gas control/temperature knob in, click the igniter button continuously (about once a second) for up to 90 seconds or until Status Light begins to blink.

6. When the status light starts blinking, release the gas control/temperature knob. Set the gas control/temperature knob to the desired setting. See Figure ‘C’.

If the status light does not start blinking within 90 seconds, repeat steps 2 through 5 up to THREE (3)

times, waiting 10 minutes between lighting attempts.

The circuitry in this advanced gas valve requires that you wait 10 minutes between lighting attempts. If the status light turns a solid color, release the gas control/temperature knob and repeat steps 2

through 5 (waiting 10 minutes before attempting to relight the pilot). If the status light does not start blinking after three lighting attempts, turn the gas control/temperature knob to the "OFF" position and call a qualified service technician or your gas supplier.

DANGER:

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

Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting

information.

TO TURN OFF GAS TO APPLIANCE

1. Turn the gas control/temperature knob counterclockwise to the "OFF" position. The status light will stop blinking and stay on for a short time after the water heater is turned off. See Figure ‘A’.

TEMPERATURE REGULATION

TEMPERATURE ADJUSTMENT

Valves for reducing the point-of-use temperature by mixing cold and hot water are available (see Figure 2). Also available are inexpensive devices that attach to faucets to limit hot water temperatures. Contact a licensed plumber or the local plumbing authority. NOTE: During low demand periods, 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 (e.g., 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.

The thermostat is adjusted to the pilot position 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 at the “HOT” setting. Align the knob with the desired water temperature as shown in Figure 26. There is a hot water scald potential if the thermostat is set too high. NOTE: Temperatures shown on the gas control valve/thermostat are approximates. The actual temperature of the heated water may vary. IMPORTANT: Adjusting the thermostat past the 120°F mark on the temperature dial will increase the risk of scald injury. Hot water can produce ﬁ rst degree burns within:

Time for Permanent

Burns 2nd & 3rd

Degree (Most

Severe Burns)

Water Tem-

perature (°F)

Time for 1st Degree

Burn (Less Severe

Burns)

110 (normal shower temp.)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seconds 25 seconds

140 2 seconds 5 seconds

149 1 second 2 seconds

154 instantaneous 1 seconds

U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978

GAS CONTROL VALVE/THERMOSTAT SETTINGS

GAS CONTROL/ TEMPERATURE KNOB

IGNITER

STATUS LIGHT

120°F MARK

91°F MARK

FIGURE 26

130°F MARK

140°F MARK

150°F MARK

155°F MARK

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance. 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.

OPERATING THE TEMPERATURE CONTROL SYSTEM

WATER TEMPERATURE ADJUSTMENT

The water temperature setting can be adjusted from 55°F to 155°F. Turn the Gas Control Valve/Temperature Knob to the desired setting/temperature. NOTE: The temperatures indicated are approximates. The actual temperature of the heated water may vary.

OPERATING MODES AND SETTINGS

Standard Mode - The controller adjusts the water heater to maintain the temperature set by the user. Vacation Setting - The Vacation setting (VAC) sets the controller at approximately 55°F. This setting is recommended when the water heater is not in use for a long period of time. This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy.

FOR YOUR INFORMATION

EXTERNAL DAMAGE

Do not operate the water heater until it has been fully checked out by a qualiﬁ ed technician, if the water heater:

• Has been exposed to ﬁ re or damage.

• Displays evidence of sooting.

• Produces steam or unusually hot water.

If the water heater has been ﬂ ooded it must be replaced.

START UP CONDITIONS

NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER. DO NOT ATTEMPT TO OPERATE HEATER WITH COLD WATER INLET VALVE CLOSED.

CONDENSATE

Whenever the water heater is ﬁ lled with cold water, some con- densate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensate. This usually happens when:

a. A new water heater is ﬁ lled with cold water for the ﬁ rst time. b. Burning gas produces water vapor in water heaters, par-

ticularly high efﬁ ciency models where ﬂ ue temperatures are lower.

c. Large amounts of hot water are used in a short time and the

reﬁ ll water in the tank is very cold.

Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a “sizzling” or “frying” noise.

Because of the suddenness and amount of water, condensate water may be diagnosed as a “tank leak”. After the water in the tank warms up (about 1-2 hours), the condition should disappear.

Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up.

An undersized water heater will cause more condensation. The water heater must be sized properly to meet the family’s demands for hot water including dishwashers, washing machines and shower heads.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed system, the volume of water will grow. As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up.

The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not

covered under the limited warranty.

STRANGE SOUNDS

Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not necessarily represent harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. See “Condensate” in this section.

Excessive condensate may be noticed during the winter and early spring months when incoming water temperatures are at their lowest.

Good venting is essential for a gas ﬁ red water heater to operate properly as well as to carry away products of combustion and water vapor.

SMOKE/ODOR

It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.

OPERATIONAL CONDITIONS

SMELLY WATER

In each water heater there is installed at least one anode rod (see parts section) for corrosion protection of the tank. Certain water conditions will cause a reaction between this rod and the water. The most common complaint associated with the anode rod is one of a “rotten egg smell” in the hot water. The smell is a result of four factors which must all be present for the odor to develop:

a. A concentration of sulfate in the supply water. b. Little or no dissolved oxygen in the water. c. A sulfate reducing bacteria which has accumulated within the

water heater (this harmless bacteria is nontoxic to humans).

d. An excess of active hydrogen in the tank. This is caused by

the corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater models by replacing the anode(s) with one of less active material, and then chlorinating the water heater tank and all water lines. Contact the local water heater supplier or service agency for further information concerning an Anode Replacement Kit and this chlorination treatment.

If the smelly water persists after the anode replacement and chlorination treatment, we can only suggest that chlorination or aeration of the water supply be considered to eliminate the water problem.

Do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided.

“AIR” IN HOT WATER FAUCETS

HYDROGEN GAS: 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 ﬂ am- mable and explosive. To prevent the possibility of injury under these conditions, we recommend the hot water faucet, located farthest away, be opened for several minutes before any electrical appliances which are connected to the hot water system are used (such as a dishwasher or washing machine). If hydrogen gas is present, there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened. There must be no smoking or open ﬂ ame near the faucet at the time it is open.

HIGH WATER TEMPERATURE SHUT OFF SYSTEM

This water heater is equipped with an automatic gas shut-off system. This system works when high water temperatures are present. Turn “OFF” the entire gas supply to the water heater. The high temperature shut-off is built into the gas control valve. It is non-resettable. If the high temperature shut-off activates, the gas control valve must be replaced. Contact your gas supplier or service agency.

MAINTENANCE

FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS RECOMMENDED THAT THIS HEATER BE CHECKED ONCE A YEAR BY A COMPETENT SERVICE PERSON.

USERS OF THIS WATER HEATER SHOULD BE AWARE THAT GAS COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE GAS CARRYING COMPONENTS OF THIS WATER HEATER SHOULD BE INSPECTED FOR PROPER OPERATION PERIODICALLY BY A QUALIFIED SERVICE TECHNICIAN.

VENTING SYSTEM INSPECTION

At least once a year a visual inspection should be made of the venting system. You should look for:

1. Obstructions which could cause improper venting. The combustion and ventilation air ﬂ ow must not be obstructed.

2. Damage or deterioration which could cause improper venting or leakage of combustion products.

Be sure the vent piping is properly connected to prevent escape of dangerous ﬂ ue gasses which could cause deadly asphyxia- tion.

Obstructions and deteriorated vent systems may present serious health risk or asphyxiation.

a ﬂ ooded water heater. Do not attempt to repair the unit! It must be replaced! At least once a year a visual inspection should be made of the main burner and the pilot assembly for proper ﬂ ame characteris- tics. This can be done by removing the Outer Door and viewing the main burner operation through the Viewport on the Inner Door, see Figure 1. The main burner should provide complete combustion of gas, ignite rapidly, give reasonably quiet operation, and cause no excessive ﬂ ame lifting from the burner ports. If the proper ﬂ ame characteristics are not evident (see Figure 1), make sure that the ﬂ ow of combustion and ventilation air is not blocked in the venting system. You should also check for sooting. Soot is not normal and will impair proper combustion. A visual inspection of the main burner and pilot assembly should also be done at least once a year, see Figure 1. Soot build-up indicates a problem that requires correction before further use. Turn “OFF” gas to water heater and leave off until repairs are made, because failure to correct the cause of the sooting can result in a ﬁ re causing death, serious injury, or property damage. If proper ﬂ ame characteristics are not evident, check for accumu- lation of lint or other foreign material that restricts or blocks the air openings in the heater or burner.

BURNER FLAMES

Inspect the burner ﬂ ames through the viewport and compare them to the drawings in Figure 27. A properly operating burner should produce a soft blue ﬂ ame. Blue tips with yellow inner cones are satisfactory. The tips of the ﬂ ame may have a slight yellow tint. The ﬂ ame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored ﬂ ame. Contact a qualiﬁ ed service technician if the ﬂ ame is not satisfactory.

TIPS MAY HAVE A YELLOW TINT

YELLOW INNER

CONES ARE

SATISFACTORY

CORRECT FLAME

SOFT BLUE

FIGURE 27

INCORRECT FLAME LAZY

YELLOW

Chemical vapor corrosion of the ﬂ ue and vent system may occur if air for combustion contains certain chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, bleach and process chemicals are typical compounds which are potentially corrosive.

If after inspection of the vent system you found sooting or deterioration, something is wrong. Call the local gas utility to correct the problem and clean or replace the ﬂ ue and venting before resuming operation of the water heater.

PILOT AND MAIN BURNER

Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a ﬂ ooded water heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a qualiﬁ ed installer or service agency to replace

SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES CORRECTION BEFORE FURTHER USE. CONSULT WITH A QUALIFIED SERVICE TECHNICIAN. Should the main burner or burner air openings require cleaning, turn the gas control knob to “OFF” position and allow the burner to cool. Remove the burner and clean with a soft brush. Clean main burner oriﬁ ce with a suitable soft material.

REPLACING THE MANIFOLD/BURNER ASSEMBLY

WARNING

Explosion Hazard

Tighten both manifold door screws securely.

Remove any fiberglass between gasket and combustion chamber.

Replace viewport if glass is missing or damaged.

Replace manifold component block if missing or removed.

Replace door gasket if damaged.

Failure to do so can result in death, explosion, or fire.

PIEZOELECTRIC IGNITER SYSTEM

The piezoelectric igniter system consists of the igniter button, electrode, and wire. The pilot is ignited by an electric spark generated when the igniter button is pressed. (See Figure 30).

THERMOPILE

PILOT

VAC

ELECTRODE

WIRE TO ELECTRODE

IGNITER BUTTON

FIGURE 30

PILOT/ THERMOPILE BRACKET

TESTING THE IGNITER SYSTEM

Turn off the gas to the water heater at the manual gas shut-off valve. Watch the electrode tip while activating the igniter. A visible spark should jump from the electrode. To avoid shock, do not touch the burner or any metal part on the pilot or pilot assembly. If no spark is visible, check the wire connections and make sure the electrode is not broken. Replace the igniter if defective. Dirt and rust on the pilot or electrode tip can prevent the igniter spark. Wipe clean with a damp cloth and dry completely. Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or ﬁ ne grit sandpaper.

REMOVING AND REPLACING THE GAS CONTROL VALVE/THERMOSTAT

Important: This water heater has a resettable thermal switch installed. Do not attempt to disable or modify this feature in any way. Use only factory authorized replacement parts.

REMOVING THE GAS CONTROL VALVE/THERMOSTAT:

1. Turn the gas control/temperature knob to the “OFF” position (Figure 19A).

2. Turn off the gas at the manual shut-off valve on the gas supply pipe (Figure 3).

3. Drain the water heater. Refer to the section of “Draining and Flushing” and follow the procedure.

4. Disconnect the igniter wire from the igniter lead wire. Use needle nose pliers to disconnect the red (+) and white (-) thermopile wires. Disconnect the pilot tube (7/16” wrench) and manifold tube (3/4” wrench) at the gas control valve/thermostat (Figure 22). NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube.

5. Refer to “Gas Piping” (Figure 3) and disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas control valve/thermostat.

6. To remove the gas control valve/thermostat, thread a 4” section of gas pipe into the inlet and use it to turn the gas control valve/thermostat (counterclockwise). Do not use a pipe wrench or equivalent to grip body. Damage may result, causing leaks. Do not insert any sharp objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result.

REPLACING THE GAS CONTROL VALVE/THERMOSTAT:

To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/thermostat, thread a 4” section of gas pipe into the inlet and use it to turn the gas control valve/thermostat (clockwise). DO NOT OVER TIGHTEN; damage may result. Be sure to use approved Teﬂ on® tape or pipe joint compound on the gas piping connections and ﬁ tting on the back of the gas control valve that screws into the tank. Be sure to remove the pilot ferrule nut from the new gas control valve/thermostat. Turn the main gas supply on and check the gas supply connections for leaks. Correct any leak found. Next, light the pilot and main burner, then check the manifold tube and pilot tube connections for leaks. Correct any leak found. Use an approved noncorrosive 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) or childrens’ soap bubble solution. Bubbles forming indicate a leak. Be sure tank is completely ﬁ lled with water before lighting and activating the water heater. Follow the “Lighting Instructions” on page 21. If additional information is required, reference the number on the cover of this manual for service information. TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company

REMOVING THE MANIFOLD/BURNER ASSEMBLY

1. Turn the gas control/temperature knob to the “OFF” position (Figure 22).

2. Before performing any maintenance, it is important to 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 (Figure 3).

3. With the unit shut-off, allow sufﬁ cient time for the water heater to cool before performing any maintenance.

GAS CONTROL/ TEMPERATURE KNOB

VAC

IGNITER BUTTON

IGNITER LEAD WIRE

IGNITER WIRE

FIGURE 22

PILOT TUBE

WHITE WIRE

RED WIRE

MANIFOLD TUBE

4. Remove the outer door.

5. Disconnect the following from the gas control valve/thermostat: pilot tube (7/16” wrench), igniter wire (from the igniter lead wire), and manifold tube (3/4” wrench). See Figure 22.

NOTE: L.P. Gas systems use reverse (left-hand) threads on

the manifold tube.

6. Use needle nose pliers to disconnect the thermopile wire from the gas control valve/thermostat (Figure 22).

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

8. Remove the screws (1/4” nut driver) securing the manifold/ burner assembly to the combustion chamber. See Figure

23.

9. Carefully remove the manifold/burner assembly from the combustion chamber. BE SURE NOT TO DAMAGE ANY INTERNAL PARTS.

GAS CONTROL/ TEMPERATURE

KNOB

PIEZO IGNITER

BUTTON

PILOT TUBE

VIEWPORT

OUTER DOOR NOT SHOWN

MANIFOLD COMPONENT

BLOCK

GAS CONTROL

VALVE/THERMOSTAT

FIGURE 23

THERMOPILE

WIRE

CONNECTIONS

MANIFOLD

TUBE

MANIFOLD SCREW (2)

MANIFOLD

DOOR

REMOVING THE BURNER FROM THE MANIFOLD/ BURNER ASSEMBLY

NATURAL GAS (LOW NOX) & L.P. GAS BURNER

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 (Figure 24).Important: DO NOT remove the oriﬁ ce.

SCREWS

BURNER (BOTTOM VIEW)

FIGURE 24

PILOT ASSEMBLY (BOTTOM VIEW)

REPLACING THE PILOT/THERMOPILE ASSEMBLY

1. Remove the manifold door assembly as described in “Removing the Manifold/Burner Assembly” section.

2. Remove the burner to access the pilot/thermopile assembly. Remove and keep the screws securing the burner to the manifold (Figure 24).

Important: DO NOT remove the oriﬁ ce.

3. Remove the screw securing the pilot/thermopile assembly to the pilot bracket and keep for reuse later (Figure 25).

4. Lift the retainer clip straight up from the back of the manifold component block (using a ﬂ at-blade screwdriver), then remove the manifold component block from the manifold door (Figure

25). Important: Be careful not to bend or alter the position of the pilot tube. It will be used as a bending template for the new pilot assembly. Note the placement/order of the wires in the manifold component block.

5. Lift the pilot/thermopile assembly (including the igniter wire) from the manifold assembly.

THERMOPILE CONNECTOR

WHITE WIRE

IGNITER CONNECTOR

PILOT

THERMOPILE

PILOT/THERMOPILE

ASSEMBLY

PILOT TUBE NOT SHOWN FOR CLARITY

FIGURE 26

7. Route the new pilot tube, igniter wire and thermopile wire through the opening in the manifold door. See Figure 25.

8. Using the pilot screw removed earlier, attach the new pilot/thermopile assembly. Reattach the burner to the manifold using the screws removed earlier. Note: Make sure the burner scoop is oriented to the pilot side of the manifold tube (Figure 24).

9. Reinstall the manifold component block in the manifold door. Ensure that the pilot tube and wires are positioned as shown in Figure 27.

MANIFOLD

COMPONENT

BLOCK

PILOT TUBE

IGNITER WIRE

MANIFOLD

COMPONENT

BLOCK

THERMOPILE CONNECTOR

WHITE

WIRE

PILOT / THERMOPILE ASSEMBLY SCREW

RETAINER CLIP

MANIFOLD DOOR

BURNER AND OTHER FITTINGS NOT SHOW

FOR CLARITY.

FIGURE 25

6. Read this step carefully before proceeding. Using the old pilot/pilot tube assembly as a guide, bend the new pilot tube to match the old one. Make only the bends closest to the pilot before going to the next step.

PILOT TUBE PASSES

THROUGH TOP HOLE OF MANIFOLD COMPONENT BLOCK

(LARGEST HOLE)

IGNITER WIRE PASSES THROUGH CENTER OF

MANIFOLD

COMPONENT BLOCK

(SMALLEST HOLE)

THERMOPILE WIRES

PASS THROUGH

BOTTOM HOLE OF

MANIFOLD

COMPONENT BLOCK

FIGURE 27

10. Carefully bend the new pilot tube to match the bend of the manifold tube.

Note: When bending, DO NOT crimp or crease the pilot tube.

11. Before you proceed to the next step, install the new brass ferrule nut in the gas control valve/thermostat’s pilot tube opening, HAND TIGHT ONLY.

12. Install the manifold/burner assembly. Refer to the “Replacing the Manifold/Burner Assembly” section for instructions.

TEMPERATURE & PRESSURE RELIEF VALVE

CATHODIC PROTECTION - ANODE

At least once a year, the temperature and pressure relief valve, Figure 1, must be checked to ensure that it is in operating condition. Lift the lever at the top of the valve several times until the valve seats properly and operates freely. If water does not ﬂ ow, remove the valve and inspect for obstruc- tions or corrosion. Have a qualiﬁ ed service agent replace with a new valve of the recommended size as necessary. Do not attempt to repair the valve, as this could result in improper operation and a tank explosion. In areas with poor water conditions, it may be necessary to inspect the T&P valve more frequently.

THE WATER PASSING OUT OF THE VALVE DURING THIS CHECKING OPERATION MAY BE EXTREMELY HOT. AVOID CONTACT AND DISCHARGE SAFELY TO PREVENT WATER DAMAGE.

DRAINING

The anode rod within the tank is designed to be slowly consumed cathodically, minimizing corrosion in the glass-lined tank. A hydrogen sulﬁ de (rotten egg) odor may result if water contains high sulfate and/or minerals. Chlorinating the water supply should minimize the problem. (See EXTENDED NON-USE PERIODS).

NOTE: Anode must remain installed (except for inspection) to avoid shortening tank life. See LIMITED WARRANTY. Replace as necessary.

DRAIN VALVE WASHER REPLACEMENT

(See Figure 28)

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

2. Follow “Draining” instructions.

3. Turning counterclockwise ( the screw handle.

4. Remove the washer and put the new one in place.

5. Screw the handle and cap assembly back into the drain valve and retighten using a wrench. DO NOT OVER TIGHTEN.

6. Follow instructions in the “Filling The Water Heater” section.

7. Check for leaks.

8. Follow the lighting instructions in the “Lighting” section to restart the water heater.

), remove the hex cap below

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 shutoff valve.

2. Open a nearby hot water faucet until the water is no longer hot.

3. Close the cold water inlet valve.

4. Connect a hose to the drain valve and terminate it to an adequate drain or external to the building.

5. Open the water heater drain valve and allow all of the water to drain from the tank. Flush the tank with water as needed to remove sediment.

6. Close the drain valve, reﬁ ll the tank, and restart the heater as directed in this manual.

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.

FIGURE 28

ANODE ROD MAINTENANCE

Each water heater contains at least one anode rod, which will slowly deplete (due to electrolysis) prolonging the life of the water heater by protecting the glass-lined tank from corrosion. Adverse water quality, hotter water temperatures, high hot water usage, hydronic heating devices, and water softening methods can increase the rate of anode rod depletion. Once the anode rod is depleted, the tank will start to corrode, eventually developing a leak.

Certain water conditions will cause a reaction between the anode rod and the water. 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. IMPORTANT: Do not remove this rod permanently as it will void any warranties. A special anode rod may be available if water odor or discoloration occurs. NOTE: 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 inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement.

To replace 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 a nearby hot water faucet to purge air from water system. Check for any leaks and immediately correct any if found.

7. Restart the water heater as directed in this manual. See the Repair Parts Illustration for anode rod location.

NOTE: Artiﬁ cially softened water requires the anode rod to be inspected annually. The following are typical (but not all) signs of a depleted anode rod:

• The majority of the rods diameter is less than 3/8 in..

• Signiﬁ cant sections of the support

EXPOSED SUPPORT WIRE

wire (approx. 1/3 or more of the anode rod’s length) are visible.

If the anode rod show signs of either or both it should be replaced. NOTE: Whether re-installing or replacing the anode rod, check for any leaks and

PITTED ANODE ROD

immediately correct if found.

EXPOSED SUPPORT WIRE

FIGURE 29

LEAKAGE CHECKPOINTS

SERVICE

If a condition persists or you are uncertain about the operation of the water heater contact a service agency.

Use this guide to check a “Leaking” water heater. Many suspected “Leakers” are not leaking tanks. Often the source of the water can be found and corrected.

If you are not thoroughly familiar with gas codes, your water heater, and safety practices, contact your gas supplier or qualiﬁ ed installer to check the water heater.

Read this manual ﬁ rst. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water.

Never use this water heater unless it is completely ﬁ lled with water. To prevent damage to the tank, the tank must be ﬁ lled with water. Water must ﬂ ow from the hot water faucet before turning “ON” gas to the water heater.

A. Water at the vent assembly is water vapor which has con-

densed out of the combustion products. This is caused by a problem in the vent. Contact the gas utility.

B. *Condensation may be seen on pipes in humid weather or

pipe connections may be leaking.

C. *The anode rod ﬁ tting may be leaking (anode is located under

the plastic plug and isulation).

D. Small amounts of water from temperature-pressure relief

valve may be due to thermal expansion or high water pressure in your area.

E. *The temperature-pressure relief valve may be leaking at the

tank ﬁ tting.

F. Water from a drain valve may be due to the valve being

slightly opened. G. *The drain valve may be leaking at the tank ﬁ tting. H. Combustion products contain water vapor which can con-

dense on the cooler surfaces of the tank. Droplets form and

drip onto the burner or run on the ﬂ oor. This is common at the

time of start-up after installation and when incoming water is

cold. I. Water in the water heater bottom or on the ﬂ oor may be from

condensation, loose connections, or the relief valve. DO

NOT replace the water heater until a full inspection of all pos-

sible water sources is made and necessary corrective steps

taken.

FIGURE 30

Leakage from other appliances, water lines, or ground seepage should also be checked.

* To check where threaded portion enters tank, insert cotton

swab between jacket opening and ﬁ tting. If cotton is wet,

follow “Draining” instructions in the “Periodic Maintenance”

section and then remove ﬁ tting. Put pipe dope or Teﬂ on

on the threads and replace. Then follow “Filling the Water

Heater” instructions in the “Installing the New Water Heater”

section.

tape

TROUBLESHOOTING GUIDELINES

PROBLEM POSSIBLE CAUSE(S) CORRECTION

1. Pilot not lit

2. Thermostat set too low

3. No gas

BURNER WILL NOT IGNITE

SMELLY WATER 1. Sulfur in the water 1. Replace the anode with a special anode

BURNER FLAME YELLOW-

LAZY

PILOT WILL NOT LIGHT OR

REMAIN LIT

HIGH OPERATION COSTS

PILOT FLAME TOO SMALL

INSUFFICIENT HOT WATER

SLOW HOT WATER RECOV-

ERY

4. Dirt in the gas lines

5. Pilot line clogged

6. Main burner line clogged

7. Defective thermopile

8. Defective gas control/thermostat

1. Low gas pressure

2. Flue clogged

3. Main burner line clogged

4. Obstruction in main burner oriﬁ ce

1. Air in gas line

2. No gas

3. Dirt in gas lines

4. Pilot line or oriﬁ ce clogged

5. Defective thermopile

6. Cold drafts

7. Gas control/thermostat ECO switch open

8. Defective igniter or electrode

9. Low gas pressure

1. Thermostat set too high

2. Sediment or lime in tank

3. Water heater too small for job

4. Wrong piping connections

5. Leaking faucets

6. Gas leaks

7. Wasted hot water

8. Long runs of exposed piping

9. Hot water piping in exposed wall

10. Leaks or cracks in dip tube

1. Pilot line or oriﬁ ce clogged

2. Low gas pressure

3. Defective pilot

1. Thermostat set too low

2. Sediment or lime in tank

3. Water heater too small

4. Wrong piping connections

5. Leaking faucets

6. Wasted hot water

7. Long runs of exposed piping

8. Hot water piping in outside wall

9. Low gas pressure

1. Insufﬁ cient secondary air

2. Flue clogged

3. Low gas pressure

4. Improper calibration

5. Gas control/thermostat set too low

6. Water heater too small

7. Wrong piping connections

8. Wasted hot water

1. Light pilot

2. Turn temp. dial to desired temperature

3. Check with gas utility company

4. Notify utility-install trap in gas line

5. Clean, locate source and correct

6. Clean, locate source and correct

7. Replace thermopile

8. Replace gas control/thermostat

1. Check with gas utility company

2. Clean, locate source and correct

3. Clean, locate source and correct

4. Clean or replace oriﬁ ce

1. Bleed the air from the gas line

2. Check with gas utility company

3. Notify utility-install sediment trap (dirt leg) in gas line

4. Clean, locate source and correct

5. Replace thermopile

6. Locate source and correct

7. Replace gas control/thermostat

8. Replace igniter or pilot assembly

9. Check with gas utility company

1. Set temperature dial to lower setting

2. Drain/Flush-Provide water treatment if needed

3. Install adequate size heater

4. Correct piping-dip tube must be in cold inlet

5. Repair faucets

6. Check with utility-repair at once

7. Advise customer

8. Insulate piping

9. Insulate piping

10. Check dip tube. Replace if faulty

1. Clean, locate source and correct

2. Check with gas utility company

3. Replace pilot

1. Turn temperature dial to desired setting

2. Drain/ﬂ ush-provide water treatment if need- ed

3. Install adequate size heater

4. Correct piping-dip tube must be in cold inlet

5. Repair faucets

6. Advise customer

7. Insulate piping

8. Insulate piping

9. Check with gas utility company

1. Provide ventilation to water heater. Check ﬂ ue way, ﬂ ue bafﬂ e and burner

2. Clean ﬂ ue, locate source and correct

3. Check with gas utility company

4. Replace gas control/thermostat

5. Turn temperature dial to desired setting

6. Install adequate size heater

7. Correct piping-dip tube must be in cold inlet

8. Advise customer

PROBLEM POSSIBLE CAUSE(S) CORRECTION

1. Excessive water pressure

2. Heater stacking

DRIP FROM RELIEF VALVE

THERMOSTAT FAILS TO

SHUT OFF

COMBUSTION ODORS

SMOKING AND CARBON

FORMATION (SOOTING)

CONDENSATION

BURNER FLAME FLOATS

AND LIFTS OFF PORTS

BURNER FLAME TOO HIGH 1. Oriﬁ ce too large 1. Replace with correct oriﬁ ce

FLAME BURNS AT ORIFICE

3. Closed water system

4. Temperature setting too high

1. Defective gas control/thermostat

2. Improper calibration

1. Insufﬁ cient secondary air

2. Flue clogged

3. Heater installed in a conﬁ ned area

1. Insufﬁ cient secondary air

2. Low gas pressure

3. Flue clogged

4. Defective gas control/thermostat

5. Heater installed in a conﬁ ned area

6. Burner ﬂ ame yellow-lazy

1. Temperature setting too low

2. Water heater too small

1. Oriﬁ ce too large

2. High gas pressure

3. Flue clogged

4. Cold drafts

1. Defective gas control/thermostat

2. Low gas pressure

3. Oriﬁ ce not properly installed

1. Use a pressure reducing valve and relief valve

2. Lower the thermostat setting

3. See “Closed System/Thermal Expansion”

4. Decrease the temperature setting

1. Replace gas control/thermostat

2. Replace gas control/thermostat

1. Provide ventilation to water heater. Check ﬂ ue way, ﬂ ue bafﬂ e, burner

2. Clean, locate source and correct

3. Provide fresh air ventilation

1. Provide ventilation to water heater. Check ﬂ ue way, ﬂ ue bafﬂ e, burner

2. Check with gas utility company

3. Clean, locate source and correct

4. Replace gas control/thermostat

5. Provide fresh air ventilation

6. See “Burner Flame Yellow-Lazy”

1. Increase the temperature setting

2. Install adequate size heater

1. Replace with correct oriﬁ ce

2. Check with gas utility company

3. Clean ﬂ ue and burner-locate source & cor- rect

4. Locate source and correct

1. Replace gas control/thermostat

2. Check with gas utility company

3. Reinstall the oriﬁ ce

RESIDENTIAL GAS WARRANTY

LIMITED RESIDENTIAL GAS WARRANTY

THIS WARRANTY IS APPLICABLE TO THE ORIGINAL OWNER ONLY in accordance with the warranty terms and conditions speciﬁ ed below.

Reliance Water Heater Company (the warrantor) will furnish the ORIGINAL OWNER, 1) a replacement Reliance water heater of equivalent size and current model if the glasslined tank in this water heater leaks and, 2) a replacement part for any component part which fails. Sacriﬁ cial anode rods are consumable maintenance parts and are excluded from warranty coverage.

THE RELIANCE WATER HEATER COMPANY REPLACEMENT MODEL OR PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY. The warranty period will be determined by the original date of purchase of the water heater, or in the absence of a Bill of Sale verifying said date, from the date of manufacture indicated on rating plate afﬁ xed to this water heater. This warranty is not transferrable and applies to models listed below:

If the glass-lined tank in this water heater shall prove upon examination by the warrantor to have leaked due to natural corrosion from potable water therein, during the stated warranty period, the warrantor will supply a complete new Reliance water heater of equivalent size and current model. Should governmental regulations or industry standards prohibit the Manufacturer from furnishing a comparable model replacement under this warranty, the Owner will be furnished with the closest comparable water heater meeting the then current governmental regulations and industry standards. A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards.

MODEL SERIES: Tank Parts

606 6-year 6-year

When the water heater has been used for other than single family residential application;

1. The tank warranty shall be reduced to 1 year for 6 year models.

2. The parts warranty (excluding anode rods) shall be reduced to 1 year for all models.

CONDITIONS AND EXCEPTIONS

This warranty shall apply only when the water heater is installed and operated in accordance with 1) all local ﬁ re codes and plumbing codes, ordinances and regulations, 2) the printed instructions provided with it, 3) good industry practices, and 4) proper safety practices such as but not limited to a properly sized drain pan piped to an adequate drain if installed in an area where leakage from the tank or its connections would result in damage to the area adjacent to the heater. In addition, a new temperature and pressure relief valve, certiﬁ ed by the Canadian Gas Association must have been properly installed and piped to the nearest drain.

This warranty shall apply only when the heater is:

• owned by the original purchaser;

• installed for indoor operation only;

• used at temperatures not exceeding the maximum calibrated setting of its thermostat;

• used at water pressure not exceeding the working pressure shown on the heater;

• ﬁ lled with potable water, free to circulate at all times and with the tank free of damaging water sediment or scale deposits;

• used in a non-corrosive and non-contaminated atmosphere;

• used with factory approved anode(s) installed;

• in its original installation location;

• in the United States, its territories or possessions, and Canada;

• sized in accordance with proper sizing techniques for residential water heaters;

• bearing a rating plate which has not been altered, defaced or removed except as required by the warrantor;

• used in an open system or in a closed system with a properly sized and installed thermal expansion tank;

• operated with properly installed sediment trap (dirt leg) in the gas supply line;

• ﬁ red with the fuel for which it was factory built;

• ﬁ red at the factory rated input;

• operated with the inner and outer combustion chamber doors in place and all factory seals to combustion chamber intact.

• installed with no attempted, nor actual modiﬁ cation or alteration of the water heater’s design in any way, including but not limited to, the attachment of non-company approved appliances or equipment, including any additional aftermarket equipment introduced into the sealed system.

Any accident to the water heater or any part thereof (including freezing, ﬁ re, ﬂ oods, or lightning), any misuse, abuse or alteration of it, any operation of it in a modiﬁ ed form, any

operation of the water heater on desalinated (deionized) water, or any damage caused by attempts to repair tank leaks or parts, will void this warranty. This warranty does not cover water heaters replaced for cosmetic reasons or for reasons of noise, taste, odor, discolored and/or rusty water. This warranty does not apply to water heaters used to heat pools, whirlpools or hot tubs or used for space heating where its sizing does not conform with speciﬁ cations of the heating component manufacturer.

CLAIM PROCEDURE

Any claim under this warranty should be initiated by contacting:

Reliance Water Heater Company 500 Tennessee Waltz Parkway Ashland City, Tennessee 37015. Phone: 1-800-365-4054

This warranty gives you speciﬁ c legal rights, and you may have other rights which vary under the laws of each state. If any provision of this warranty is prohibited or invalid under applicable state law, that provision shall be ineffective to the extent of the prohibition or invalidity without invalidating the remainder of the affected provision or the other provisions of this warranty.

SERVICE AND LABOR RESPONSIBILITY

UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR ALL OTHER COSTS. Such costs may include but are not limited to: a. Labor charges for service, removal, or reinstallation of the

water heater or part thereof.

b. Shipping and delivery charges for forwarding the new wa-

ter heater or replacement part from the nearest distributor and returning the claimed defective heater or part to such distributor.

c. All cost necessary or incidental for handling and adminis-

trative charges, and for any materials and/or permits required for installation of the replacement heater or part.

LIMITATION ON IMPLIED WARRANTIES

Replacement Parts may be ordered through authorized servicers or retailers or by contacting:

Reliance Water Heater Company 500 Tennessee Waltz Parkway Ashland City, Tennessee 37015. Phone: 1-800-821-2017

The warrantor will only honor replacement with identical or similar water heater or parts thereof, which are manufactured by the warrantor.

DISCLAIMERS

NO EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE HEATER OR THE INSTALLATION, OPERATION, REPAIR OR REPLACEMENT OF THE HEATER OR PARTS. THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE, LOSS OF USE OF THE UNIT, INCONVENIENCE, LOSS OR DAMAGE TO PERSONAL PROPERTY, OR OTHER CONSEQUENTIAL DAMAGE. THE WARRANTOR SHALL NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.

Implied warranties, including any warranty of merchantability imposed on the sale of this heater under state law are limited to one year duration for the heater or any of its parts. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

MPORTANT INFORMATION

Model Number

Serial Number

INSTALLATION INFORMATION

Date Installed

Company’s Name

Street or P.O. Box

City, State, and Zip Code

Phone Number

Plumber’s Name

500 TENNESSEE WALTZ PARKWAY

ASHLAND CITY, TN 37015

Phone: 800-821-2017 • Fax: 800-644-9306

www.reliancewaterheaters.com

Reliance 650YBVIS, 640YBVIS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual