Reliance 650NBRT, 940NKCT, 640NBRBT, 1240NACS, 1240NACT Use & Care Guide

...

Installation Instructions and Use & Care Guide

RESIDENTIAL GAS WATER HEATERS

FVIR

(FLAMMABLE VAPOR IGNITION RESISTANT)

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

GAS WATER HEATER

FOR POT ABLE W A TER HEATING ONLY .

NOT FOR USE IN MOBILE HOMES.

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

• Safety Instructions

• Installation

• Operation

INSTALLER:

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

OWNER:

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

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

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

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

SMELL GAS” instructions.

• Care and Maintenance

• Troubleshooting

• Parts List

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

— Do not store or use gasoline or other

flammable vapors and liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

— Installation and service must be

performed by a qualified installer, service agency or the gas supplier.

LOW LEAD

COMPLIANT

ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE RELIANCE CUSTOMER CARE CENTER AT 1-800-365-4054 OR WWW.RELIANCEWATERHEATERS.COM.

PRINTED IN THE U.S.A. 1013 PART NO. 320385-002

TABLE OF CONTENTS

Water Heater Safety .............................................................................................................................................................................. 1

Safe Installation, Use and Service ...................................................................................................................................................... 3

Safety Precautions ............................................................................................................................................................................ 3-4

Typical Installation ............................................................................................................................................................................... 5

Installing your Gas Water Heater ..................................................................................................................................................... 6-8

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

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

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

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

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

Site Location ............................................................................................................................................................................ 7

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

State of California .................................................................................................................................................................... 8

Gas Supply ....................................................................................................................................................................................... 9-10

Gas Requirements .................................................................................................................................................................... 9

Gas Piping ............................................................................................................................................................................... 9

Gas Pressure ........................................................................................................................................................................... 9

Gas Pressure Testing ............................................................................................................................................................... 9

LP Gas Only ........................................................................................................................................................................... 10

Combustion Air and Ventilation ....................................................................................................................................................11-15

Unconfined Space ...................................................................................................................................................................11

Confined Space ......................................................................................................................................................................11

All Air from Inside the Building ............................................................................................................................................... 12

All Air from Outdoors .............................................................................................................................................................. 12

Louvers and Grilles ........................................................................................................................................................... 12-13

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

Draft Hood Installation ...................................................................................................................................................... 13-14

Vent Pipe Size ....................................................................................................................................................................... 14

Vent Connectors .................................................................................................................................................................... 14

Chimney Connection .............................................................................................................................................................. 14

Vertical Exhaust Gas Vent ................................................................................................................................................ 14-15

Water System Piping ..................................................................................................................................................................... 15-18

Piping Installation .............................................................................................................................................................. 15-16

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

Temperature & Pressure Relief Valve .................................................................................................................................... 17

T&P Relief Valve and Pipe Installation .................................................................................................................................. 17

Important Information About this Water Heater ...............................................................................................................................18

Operating Your Water Heater ........................................................................................................................................................ 19-25

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

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

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

Emergency Shutdown ............................................................................................................................................................ 21

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

Operating the Temperature Control System .....................................................................................

Draining and Flushing ............................................................................................................................................................. 24

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

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

Maintenance of Your Water Heater .............................................................................................................................................. 25-29

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

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

Removing the Burner from the Manifold/Burner Assembly ................................................................................................... 25

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

External Inspection & Cleaning of the Base-Ring Filter ........................................................................................................ 27

Cleaning the Combustion Chamber and Flame-arrestor ....................................................................................................... 27

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

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

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

Removing and Replacing the Gas Control Valve/Thermostat ............................................................................................... 28

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

Troubleshooting Checklist ........................................................................................................................................................... 29-30

Pilot Light Troubleshooting Flowchart ............................................................................................................................................ 31

Status Light and Diagnostic Code Troubleshooting Chart ........................................................................................................ 32-33

Notes ........................................................................................................................................................................................... 34-35

Repair Parts ................................................................................................................................................................................... 36-37

Warranty .......................................................................................................................................................................................... 38-39

Operational Conditions ..................................................................................................................................................... 22-24

...................................... 22

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 water heater to warn you and

others of a potential 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 situation which, if not avoided, will

DANGER

WARNING

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 appliance can cause low-level exposure to some of the substances included in the act.

result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

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

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

IMPORTANT DEFINITIONS

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

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

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

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

• Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning

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

FLAMM ABLES

SAFETY PRECAUTIONS

WARNING

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

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

Flammable Vapors

Read and follow water heater warnings and instructions.

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

Fire or Explosion Harzard

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

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

Use only gas shown on rating plate.

Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Fire or Explosion Harzard

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

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

faucet in kitchen for several minutes before using electrical appliances.

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

air stops.

After extended period of non-use,

purge gases from hot water system.

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe

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

* INSTALL IN ACCORDANCE WITH LOCAL CODES.

* SEDIMENT TRAP AS REQUIRED BY LOCAL CODES.

TO VENT

TERMINATION ON

ROOF

INSTALL THERMAL EXPANSION

TANK IF WATER HEATER IS

CLOSED WATER SYSTEM

J Inner Door K Outer Door L Union M Inlet Water Shut-off Valve N Cold Water Inlet O Inlet Dip Tube P Temperature-Pressure Relief Valve Q Rating Plate

R Flue Baffle

(S) GAS CONTROL VALVE/

THERMOSTAT

INSTALLED IN A

VAC

S Gas Control Valve/Thermostat T Drain Valve U Manifold/Burner Assembly V Flue W Metal Drain Pan X Piezo Igniter Y Base-Ring Filter

Gas Control/Temperature Knob

120°F

Status

Mark

Light

VACUUM RELIEF

VALVE

*INSTALL PER

LOCAL CODES

DISCHARGE PIPE

(DO NOT CAP OR PLUG.)

Igniter

Temperatures shown are approximates and may vary.

(U) MANIFOLD/BURNER ASSEMBLY

MAIN BURNER

THERMOPILE

MANIFOLD DOOR

6” MAXIMUM

AIR GAP

PILOT TUBE

IGNITER WIRE

MANIFOLD TUBE

* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.

FLOOR DRAIN

INSTALLING YOUR GAS WATER HEATER

Important Information About This Water Heater

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments. Please review the Installation Checklist found at the end of the installation instructions section and make any required

installation upgrades or changes.

Consumer Information

This water heater is design-certified by CSA International as a Category I, non-direct vented water heater which takes its combustion air either from the installation area or from air ducted to the unit from the outside.

This water heater must be installed according to all local and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition. This is available from the following: CSA America, Inc.

8501 East Pleasant Valley Road Cleveland, OH 44131

National Fire Protection Agency 1 Batterymarch Park Quincy, MA 02269

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

Consumer Responsibilities

Unpacking the Water Heater

WARNING

Excessive Weight Hazard

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

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

• Remove exterior packaging and place installation components aside.

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

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

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

This manual has been prepared to acquaint you with the installation, operation, and maintenance of your gas water heater and provide important safety information in these areas.

Read all of the instructions thoroughly before attempting the installation or operation of this water heater.

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

Service to the FVIR System should only be performed by a qualified technician.

Examples of a qualified technician include: licensed plumbers, authorized gas company personnel, and authorized service personnel.

IMPORTANT: The manufacturer and seller of this water heater will not be liable for any damages, injuries, or deaths caused by failure to comply with the installation and operating instructions outlined in this manual.

If you lack the necessary skills required to properly install this water heater, or you have difficulty following the instructions, you should not proceed but have a qualified technician perform the installation of this water heater. Massachusetts code requires this water heater to be installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2.00 and 5.00.

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

Location Requirements

WARNING

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home. Doing so can result in carbon monoxide poisoning and death.

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

WARNING

FLAMM ABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other flammable

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

Read and follow water heater warnings and instructions

Do not use or store flammable products such as gasoline, solvents, or adhesives in the same room or area near the water heater. If such flammables must be used, all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished. Open the doors and windows for ventilation while flammable substances are in use.

Flammable Vapors

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

WARNING

Fire or Explosion Hazard

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

• Improper use may result in fire or explosion.

• Maintain required clearances to combustibles.

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

Site Location

• Select a location near the center of the water piping system. The water heater must be installed indoors and in a vertical position on a level surface. DO NOT install in bathrooms, bedrooms, or any occupied room normally kept closed.

• Locate the water heater as close to the chimney or gas vent as practical. Consider the vent system piping and combustion air supply requirements when selecting the water heater location. The venting system must be able to run from the water heater to termination with minimal length and elbows.

• Locate the water heater near the existing gas piping. If installing a new gas line, locate the water heater to minimize the pipe length and elbows.

• The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e., attics, basements, etc.) may require insulation of the water piping and drain piping to protect against freezing. The drain and controls must be easily accessible for operation and service. Maintain proper clearances as specified on the rating plate.

• Do not locate the water heater near an air-moving device. The operation of air-moving devices such as exhaust fans, ventilation systems, clothes dryers, fireplaces, etc., can affect the proper operation of the water heater. Special attention must be given to conditions these devices may create. Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling (Figure 1B).

• If the water heater is located in an area that is subjected to lint and dirt, at least once annually, clean the base-ring filter and flame-arrestor. Refer to the “Maintenance of your Water Heater” section.

NOTE: This water heater must be installed according to all local and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition.

IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of water, the tank will eventually leak after an extended period of time. Also any external plumbing leak, including those from improper installation, may cause early failure of the tank due to corrosion if not repaired. If the homeowner is uncomfortable with making the repair a qualified technician should be contacted. A suitable metal drain pan should be installed under the water heater as shown below, to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank. The pan must limit the water level to a maximum depth of 1-3/4” and be two inches wider than the heater and piped to an adequate drain. NOTE: The pan must not restrict combustion air flow. Locate the water heater near a suitable indoor drain. Outside drains are subject to freezing temperatures which can obstruct the drain line. The piping should be at least 3/4” ID and pitched for proper drainage.

METAL DRAIN PAN

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

FIGURE 1A.

PIPED TO AN ADEQUATE DRAIN

Water heater life depends upon water quality, water usage, water temperature and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

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

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

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

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

EXHAUST FAN

REVERSE FLOW OF GASES

FIGURE 1B.

Clearances and Accessibility

NOTE: Minimum clearances from combustible surfaces are stated on the rating plate adjacent to the gas control valve/ thermostat of the water heater.

The water heater is certified for installation on a combustible floor.

• IMPORTANT: If installing over carpeting, the carpeting

must be protected by a metal or wood panel beneath the water heater. The protective panel must extend beyond the full width and depth of the water heater by at least three inches (76.2mm) in any direction; or if in an alcove or closet installation, the entire floor must be covered by the panel.

• Figure 2 may be used as a reference guide to locate

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

VENT

TOP

CEILING

SIDES

BACK

TOP VIEW

SIDES

FRONT 24” MINIMUM FOR SERVICE

FIGURE 2.

State of California

NOTE: The water heater must be braced, anchored, or strapped to avoid moving during an earthquake. Contact local utilities for code requirements in your area, visit http:// www.dsa.dgs.ca.gov, or call 1-916-445-8100 and request instructions.

GAS SUPPLY

WARNING

Explosion Hazard

• Use a new CSA approved gas supply line.

• Install a shut-off valve.

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

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

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

Gas Requirements

IMPORTANT: Read the rating plate to be sure the water heater is made for the type of gas you will be using in your home. This information will be found on the rating plate located near the gas control valve/thermostat. If the information does not agree with the type of gas available, do not install or light. Call your dealer.

NOTE: An odorant is added by the gas supplier to the gas used by this water heater. This odorant may fade over an extended period of time. Do not depend upon this odorant

as an indication of leaking gas.

Gas Piping

The gas piping must be installed according to all local and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.

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

NOTE: Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases (See Figure 3.)

1. Install a readily accessible manual shut-off valve in the gas supply line as recommended by the local utility. Know the location of this valve and how to turn off the gas to this unit.

2. Install a sediment trap (if not already incorporated as part of the water heater) as shown. The sediment trap must be no less than three inches long for the accumulation of dirt, foreign material, and water droplets.

3. Install a ground joint union between the gas control valve/thermostat and the manual shut-off valve. This is to allow easy removal of the gas control valve/ thermostat.

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

Correct any leak found.

Manual Gas

Shut-off Valve

Ground

Joint

Union

Check with local

utility for

minimum height

3” Minimum

Drip Leg

FIGURE 3.

6” Maximum Air Gap

Gas Pressure

WARNING

Explosion Hazard

• Gas leaks can not always be detected by smell.

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

• For more information, contact your gas supplier.

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

IMPORTANT: The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater’s rating plate. The minimum supply pressure is for the purpose of input

adjustment.

Gas Pressure Testing

IMPORTANT: This water heater and its gas connection must be leak tested before placing the appliance in operation.

• If the code requires the gas lines to be tested at a pressure exceeding 14” W.C., the water heater and its manual shut-off valve must be disconnected from the gas supply piping system and the line capped.

• If the gas lines are to be tested at a pressure less than 14” W.C., the water heater must be isolated from the gas supply piping system by closing its manual shut-off valve.

NOTE: Air may be present in the gas lines and could prevent the pilot from lighting on initial start-up. The gas lines should be purged of air by a qualified technician after installation of the gas piping system. While purging the gas piping system of air, insure that the fuel is not spilled in the area of the water heater installation, or any source of ignition. If the fuel is spilled while purging the piping system of air follow the “WHAT TO DO IF YOU SMELL GAS” instructions on the cover of this manual.

LP Gas Only

WARNING

Explosion Hazard

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

Examples of a qualified person include: licensed plumbers, authorized gas company personnel, and authorized service personnel.

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

Liquefied petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at floor level. Basements, crawl spaces, closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page.

When your L.P. tank runs out of fuel, turn off the gas at all gas appliances including pilot lights. After the tank is reﬁ lled, all appliances must be re-lit according to their manufacturer’s instructions.

COMBUSTION AIR & VENTILATION

WARNING

Carbon Monoxide Warning

Water heater must be vented to outdoors. Vent must be installed by a qualified technician using

the installation instructions. Examples of a qualified technican include: gas

technicians, authorized gas company personel, and authorized service persons.

Failure to so do can result in death or carbon monoxide poisoning.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation (not limited to the following) will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air:

• beauty shops

• photo processing labs

• buildings with indoor pools

• water heaters installed in laundry, hobby, or craft rooms

• water heaters installed near chemical storage areas

Combustion air must be free of acid-forming chemicals such as sulfur, fluorine, and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint, and varnish removers, refrigerants, and many other commercial and household products. When burned, vapors from these products form highly corrosive acid compounds. These products should not be stored or used near the water heater or air inlet.

Combustion and ventilation air requirements are determined by the location of the water heater. The water heater may be located in either an open (unconfined) area or in a confined area or small enclosure such as a closet or small room. Confined spaces are areas with less than 50 cubic feet for each 1,000 BTUH of the total input for all gas-using appliances.

Unconfined Space

A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTUH of the total input for all gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTUH inputs.

TABLE 3

Minimum

BTUH Input

30,000 188 9 x 21

45,000 281 14 x 20

60,000 375 15 x 25

75,000 469 15 x 31

90,000 563 20 x 28

105,000 657 20 x 33

120,000 750 25 x 30

135,000 844 28 x 30

IMPORTANT:

• The area must be open and be able to provide the proper air requirements to the water heater. Areas that are being used for storage or contain large objects may not be suitable for water heater installation.

• Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly. In this situation, outside air openings should be sized the same as for a confined space.

• Modern home construction usually requires supplying outside air into the water heater area.

Square Feet with 8’ Ceiling

Typical Room

with 8’ Ceiling

Confined Space

For the correct and proper operation of this water heater, ample air must be supplied for the combustion, ventilation, and dilution of flue gases. Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 4.

The size of each opening (free area) is determined by the total BTUH input of all gas utilization equipment (i.e., water heaters, furnaces, clothes dryers, etc.) and the method by which the air is provided. The BTUH input can be found on the water heater rating plate. Additional air can be provided by two methods:

1. All air from inside the building.

2. All air from outdoors.

PERMANENT

OPENINGS TO

HE OUTSIDE OR

ADDITIONAL

ROOMS WITHIN

THE BUILDING

12” MAXIMUM

CLOSET

OTHER

CONFINED

SPACE

fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside.

Ductwork must be of the same cross-sectional area as the free area of the opening to which they connect. The minimum dimension of rectangular air ducts cannot be less than three inches.

The size of each of the two openings is determined by the method in which the air is to be provided. Refer to Table 4 to calculate the minimum free area for each opening. Figures 6, 7, 8A and 8B are typical examples of each method.

Louvers and Grilles

12” MAXIMUM

FIGURE 4.

In calculating free area for ventilation and combustion air supply openings, consideration must be given to the blocking effect of protection louvers, grilles, and screens.

All Air from Inside the Building

When additional air is to be provided to the confined area from additional room(s) within the building, the total volume of the room(s) must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area. If you are unsure that the structure meets this requirement, contact your local gas utility company or other qualified agency for a safety inspection. Each of the two openings shall have a minimum free area of 1 square inch per 1,000 BTUH of the total input rating of all gas utilization equipment in the confined area, but not less than 100 square inches (Figure 5).

These devices can reduce airflow, which in turn may require larger openings to achieve the required minimum free area. Screens must not be smaller than 1/4” mesh. If the free area through a particular design of louver or grille is known, it should be used in calculating the specified free area of the opening. If the design and free area are not known, it can be assumed that most wood louvers will allow 20 - 25% of free area while metal louvers and grilles will allow 60 - 75% of free area.

Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation.

Keep louvers and grilles clean and free of debris or other obstructions.

TABLE 4

CONFINED

SPACE

Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply - All Air from Outdoors Only.

Based on total BTUH input rating for all utilizing equipment within the conﬁ ned space.

PERMANENT

OPENINGS

1 SQUARE INCH/1000

BTUH

(MINIMUM

100 SQ. IN.)

FIGURE 5.

All Air from Outdoors

Opening Source

*D irec t t o o utd oors 1 sq. in, per 4000 BTUH F igu r e 6

Ver tic al Duc t s 1 sq. in, per 4000 BTUH Fi gure 7

Ho r izo ntal D ucts 1 sq. in, per 2000 BTUH Figu re 8A

Si ngl e O p eni ng 1 sq. in, per 3000 BTUH Figu re 8B

Example: A water heater with an input rating of 50,000 BTUH using horizontal ducts would require each opening to have a minimum free area of 25 square inches.

Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25 sq. in.

These openings connect directly with the outdoors through

a ventilated attic, a ventilated crawl space, or through an

Minimum Free Area

Per Open i n g (sq. i n .) Refe rence Dr a wing

outside wall.

Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The

Consult the local codes of your area for specific ventilation and combustion air requirements.

GABLE VENT

TO OUTDOORS

INSTALL ABOVE

INSULATION

CONFINED

SPACE

ALTERNATE

AIR INLET

1 SQ. INCH PER

4000 BTUH

ALL AIR FROM OUTDOORS: INLET AIR FROM VENTILATED

CRAWL SPACE/OUTLET AIR TO VENTILATED ATTIC

OUTLET

AIR TO

ATTIC 1 SQ.

INCH PER

4000 BTUH

INLET AIR FROM

THE CRAWL SPACE

OPEN

FOUNDATION

VENT

FIGURE 6.

GABLE VENT TO OUTDOORS

INSTALL ABOVE INSULATION

OUTLET AIR

CONFINED SPACE

ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC

TO ATTIC 1 SQ. INCH PER 4000 BTUH

INLET AIR DUCT 1 SQ. INCH PER 4000 BTUH

12” MAXIMUM

FIGURE 7.

1 SQ. INCH PER 2000 BTUH

CONFINED SPACE

OUTLET

INLET

OUTDOOR

AIR DUCTS

ALTERNATIVE OPENING LOCATION

CONFINED SPACE

ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING

1 SQ. INCH PER 3000 BTUH

FIGURE 8B.

Vent Pipe System

This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels. Air for combustion is taken from the immediate water heater location or is ducted in from the outside (see “Combustion Air and Ventilation”).

This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit.

The vent pipe must be installed according to all local and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition. The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere.

IMPORTANT: The use of vent dampers is not recommended by the manufacturer of this water heater. Although some vent dampers are certified by CSA International, this certification applies to the vent damper device only and does not mean they are certified for use on this water heater.

U.L. recognized fuel gas and carbon monoxide (CO) detectors are recommended in all applications and should be installed using the manufacturer’s instructions and local codes, rules, or regulations.

IMPORTANT: If you lack the necessary skills required to properly install this venting system, you should not proceed, but get help from a qualified technician.

Draft Hood Installation

SHEET METAL SCREWS (FOUR PROVIDED)

LEGS

DRAFT HOOD

1 SQ. INCH PER 2000 BTUH

ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS

FIGURE 8A .

SLOT

JACKET TOP

INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED.

FIGURE 9

LEGS

SLOT

Align the legs of the draft hood with the slots provided. Insert the legs and secure the draft hood to the water heater’s top with the four screws provided as shown in Figure 9. Do not alter the draft hood in any way. If you are replacing an existing water heater, be sure to use the draft hood supplied with this water heater.

Vent Pipe Size

It is important that you follow the guidelines in these instructions for sizing a vent pipe system. If a transition to a larger vent size is required, the vent transition connection must be made at the draft hood outlet.

Vent Connectors

1. Type B, Double wall, U.L. Listed Vent Pipe.

2. Single wall Vent Pipe. Maintain the manufacturer’s specified minimum clearance

from combustible materials when using type B double wall vent pipe.

Vent connectors made of type B, double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained.

Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe.

IMPORTANT: Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces, crawl spaces or any confined or inaccessible location. A single wall metal vent connector cannot pass through any interior wall.

When installing a vent connector, please note the following (See Figures 10-12):

• Install the vent connector avoiding unnecessary bends, which create resistance to the flow of vent gases.

• Install without dips or sags with an upward slope of at least 1/4-inch per foot.

• Joints must be fastened by sheet metal screws or other approved means. It must be supported to maintain clearances and prevent separation of joints and damage.

• The length of the vent connector cannot exceed 75% of the vertical vent height.

• The vent connector must be accessible for cleaning, inspection, and replacement.

• Vent connectors cannot pass through any ceiling, floor, firewall, or fire partition.

• It is recommended (but not mandatory) that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system.

IMPORTANT: Existing vent systems must be inspected for obstructions, corrosion, and proper installation.

Chimney Connection

IMPORTANT: Before connecting a vent to a chimney, make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition.

• The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases.

• The connector must be firmly attached and sealed to prevent it from falling out.

• To aid in removing the connector, a thimble or slip joint may be used.

• The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney (Figure 10).

LISTED LINED CHIMNEY

2 FT. MINIMUM ABOVE ANY OBJECT WITHIN 10FT. HORIZONTALLY

DO NOT EXTEND VENT BEYOND EDGE OF CHIMNEY

VENT CONNECTOR

SUPPORT STRAP

MAINTAIN CLEARANCE*

3 FT. MINIMUM

SEAL

SLOPE

UP 1/4 IN.

PER FT.

MINIMUM

CHIMNEY TERMINATION VENT SYSTEM

FIGURE 10.

Do not terminate the vent connector in a chimney that has not been certified for this purpose. Some local codes may prohibit the termination of vent connectors in a masonry chimney.

Vertical Exhaust Gas Vent

Vertical exhaust gas vents must be installed with U.L. listed type B vent pipe according to the vent manufacturer’s instructions and the terms of its listing.

It must be connected to the water heater’s draft hood by a listed vent connector or by directly originating at the draft hood opening.

Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer’s instructions.

Gas vents must be supported to prevent damage, joint separation, and maintain clearances to combustible materials (Figures 11 and 12).

IMPORTANT: This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases.

An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent (Figure 12).

Common (combined) venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation. CAUTION: DO NOT common vent this water heater with any power vented appliance.

Figures 10-12 are examples of vent pipe system installations and may or may not be typical for your specific application. Consult the “National Fuel Gas Code”, NFPA 54, ANSI Z223.1-current edition and the guidelines set forth by prevailing local codes.

LISTED VENT CAP

WATER SYSTEM PIPING

2 FT. MINIMUM ABOVE ANY OBJECT

3 FT. MINIMUM

SUPPORT STRAP

*MAINTAIN CLEARANCE

VENT

CONNECTOR

SLOPE UP

1/4 IN. PER FT.

MINIMUM

VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE.

FIGURE 11.

MAINTAIN MANUFACTURER’S SPECIFIED MINIMUM CLEARANCE

SUPPORT STRAP

*MAINTAIN CLEARANCE

VENT

CONNECTOR

SLOPE UP

1/4 IN. PER FT.

MINIMUM

Maintain vent pipe clearance requirements to local, state

SEAL

VENTING THROUGH A CHIMNEY WITH

TYPE B DOUBLE WALL VENT PIPE.

FIGURE 12.

WITHIN 10 FT. HORIZONTALLY

TYPE B DOUBLE WALL VENT PIPE

**MAINTAIN SPECIFIED CLEARANCE

LISTED VENT CAP

**MAINTAIN SPECIFIED CLEARANCE

VENT CONNECTOR

UNUSED CHIMNEY FLUE OR MASONRY ENCLOSURE

and/or the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition.

NFPA 211, Standard for Chimneys, Fireplaces, Vents, and

Solid Fuel-Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly. Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections.

Piping Installation

Piping, fittings, and valves should be installed according to the installation drawing (Figure 13). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation.

The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass may need to be installed in the cold water inlet line. This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures.

IMPORTANT: Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts. If solder connections are used, solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings.

IMPORTANT: Always use a good grade of joint compound and be certain that all fittings are drawn up tight.

1. Install the water piping and fittings as shown in Figure

13. Connect the cold water supply (3/4” NPT) to the cold water inlet fitting. Connect the hot water supply (3/4” NPT) to the hot water outlet fitting.

IMPORTANT: Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes. Do not remove the inserts within the heat traps.

2. The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement.

3. The manufacturer of this water heater recommends installing a mixing valve or an anti-scald device in the domestic hot water line as shown in Figure 14. These valves reduce the point-of-use temperature of the water by mixing cold and hot water and are readily available for use.

4. If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified under Closed System/Thermal Expansion.

5. Install a shut-off valve in the cold water inlet line. It should be located close to the water heater and be easily accessible. Know the location of this valve and how to shut off the water to the heater.

6. A temperature and pressure relief valve must be installed in the opening marked “Temperature and Pressure (T & P) Relief Valve” on the water heater. A discharge line must be added to the opening of the T&P Relief Valve. Follow the instructions under Temperature and Pressure Relief Valve.

7. After piping has been properly connected to the water heater, remove the aerator at the nearest hot water faucet. Open the hot water faucet and allow the tank to completely fill with water. To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained. Close the faucet and check all connections for leaks.

HOT WATER OUTLET

UNION

” MINIMUM

METAL DRAIN PAN 1 3/4” DEPTH MAXIMUM

IN A CLOSED SYSTEM, USE A

THERMAL EXPANSION TANK

COLD WATER

SUPPLY TO FIXTURES

MAIN WATER SUPPLY

COLD WATER

INLET VALVE (SHUT-OFF VALVE)

TEMPERATURE AND PRESSURE RELIEF VALV DISCHARGE PIPE

DO NOT CAP OR PLUG

DRAIN LINE 3/4” ID MINIMUM

6” MAXIMUM AIR GAP

FLOOR DRAIN

PRESSURE REDUCING

VALVE WITH BYPASS

MASSACHUSSETTS: INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142.

Please note the following:

• The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping.

• Use only pumps, valves, or fittings that are compatible with potable water.

• It is recommend that only full flow ball or gate valves are used in water piping installations. The use of valves that may cause excessive restriction to water flow is not recommended.

• Use only 95/5 tin-antimony or other equivalent solder. Any lead based solder must not be used.

• Piping that has been treated with chromates, boiler seal, or other chemicals must not be used.

• Chemicals that may contaminate the potable water supply must not be added to the piping system.

UNTEMPERED HOT WATER

HOT WATER OUTLET

FIGURE 13.

TEMPERED WATER

TO FIXTURES

COLD

WATER

INLET

MIXING VALVE

(SET TO 120°F)

FOLLOW THE MIXING

VALVE MANUFACTURER’S

INSTRUCTIONS

Closed System/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.

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

FIGURE 14.

T emperature and Pressure Relief Valve

Explosion Harzard

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TEMPERATURE AND PRESSURE RELIEF (T&P) VALVE (OPTIONAL TOP T&P RELIEF VALVE NOT SHOWN)

1” MINIMUM

METAL DRAIN PAN

DRAIN

For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF VALVE” (see Figure 15). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22. The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater. The valve’s relief pressure must not exceed the working

pressure of the water heater as stated on the rating plate.

IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater. Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not place any valve between the relief valve and the tank.

The Temperature & Pressure Relief Valve:

• Must not be in contact with any electrical part.

• Must be connected to an adequate discharge line.

• Must not be rated higher than the working pressure shown on the rating plate of the water heater.

The Discharge Line:

DISCHARGE PIPE

DO NOT CAP OR PLUG

DRAIN LINE 3/4” ID MINIMUM

6” MAXIMUM AIR GAP

FIGURE 15.

• Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line.

• Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line.

• Must terminate a maximum of six inches above a floor 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.

• Must be capable of withstanding 250°F (121°C) without distortion.

• Must be installed to allow complete drainage of both the valve and discharge line.

T&P Relief Valv e and P ipe Insulation (Some Models)

1. Locate the temperature and pressure relief valve on the water heater (also known as a T&P relief valve). See Figure 16.

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

3. Spread the slit open and fit the insulation over the T&P relief valve. See Figure 16. 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 or tape should not block

or cover the T&P relief valve drain opening. Also, the insulation or tape should not block or hinder access to the manual relief lever (Figure 16). Ensure that a discharge pipe is installed into the T&P valve discharge opening per the instructions in this manual.

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 flush 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.

T&P RELIEF VALVE INSULATION

MANUAL RELIEF

LEVER

T&P RELIEF

VALVE

T&P RELIEF VALVE

DRAIN LINE

FIGURE 16.

IMPORTANT INFORMATION ABOUT THIS WATER HEATER

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes.

Questions? Contact Residential Technical Assistance by referencing the phone number on the front of the Installation Instructions and Use & Care Guide.

Installation Checklist

Water Heater Location

Water heater location is important and can affect system performance. Please check the following:

□ Installation area free of corrosive elements and flammable

materials.

□ Centrally located with the water piping system.

Located as close to the gas piping and vent pipe system as possible.

□ Located indoors and in a vertical position. Protected

from freezing temperatures.

□ Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted floor.

□ Provisions made to protect the area from water

damage. Metal drain pan installed and piped to an adequate drain.

□ Sufficient room to service the water heater. See

“Clearances and Accessibility” section of this manual.

□ Water heater not located near an air moving device. □ Is the installed environment dirty (excessive amounts

of lint, dirt, dust, etc.)? If so, the flame arrestor located on the bottom of the water heater will need to be cleaned periodically. Refer to the “Maintenance of your Water Heater” section of this manual for information on cleaning the flame arrestor.

Combustion Air Supply and Ventilation

Check for sufficient combustion air supply. Insufficient air for the combustion of gas will result in the flame becoming “lazy”, thereby allowing heat to build up in the combustion chamber. This excessive heat will cause a thermal switch on the door assembly to trip. Is the water heater installed in a closet or other small, enclosed space? If so:

□ Are there openings for make-up air to enter and

exit the room/area?

□ Are the openings of sufficient size? Remember,

if there are other gas-fired or air-consuming appliances in the same room, you need more make-up air. Refer to the “Location Requirements” section of this water heater manual for specific requirements.

Fresh air not taken from areas that contain negative pressure producing devices such as exhaust fans, fireplaces, etc.

□ Is there a furnace/air handler in the same room

space as the water heater? If so, has a return air duct system been attached that exits the room? If so, check for leaks on the air duct system. If no air duct system is present, correct immediately

by contacting a local Heating, Ventilation, AirConditioning & Refrigeration (HVAC-R) authorized service provider.

□ Fresh air supply free of corrosive elements and

flammable vapors.

□ Fresh air openings sized correctly with consideration

given to the blocking effect of louvers and grilles.

□ Ductwork is the same cross-sectional area as the

openings.

Vent Pipe System

Check for proper drafting at the water heater draft hood. Refer to the “Checking the Draft” section of this manual for the test procedure. If the procedure shows insufficient draft is present, please check the following.

□ Draft hood properly installed. □ Vent connectors securely fastened with screws and

supported properly to maintain six inch clearance.

□ Vent connector made of approved material and

sized correctly.

□ Vent pipe system installed according to all local

and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.

□ Flue baffle properly positioned in the flue tube. □ Check the vent system for restrictions/obstructions

and check the vent termination height. Refer to the “Air Supply and Ventilation” section of this water heater manual for specific requirements.

□ Recheck for sufficient combustion air supply.

Water System Piping

□ Temperature and pressure relief valve properly

installed with a discharge line run to an open drain and protected from freezing.

□ All piping properly installed and free of leaks. □ Heater completely filled with water. □ Closed system pressure build-up devices installed. □ Mixing valve (when applicable) installed

per manufacturer’s instructions (see “Water Temperature Regulation” section).

Gas Supply and Piping

□ Gas type is the same as that listed on the water

heater data plate.

□ Gas line equipped with shut-off valve, union, and

sediment trap.

□ Adequate pipe size and approved pipe material. □ An approved noncorrosive leak detection solution

used to check all connections and fittings for possible gas leaks. If such a solution is not available, use a mixture of dish washing soap and water (one part soap to 15 parts water) or children’s soap bubble solution. Bubbles forming indicate a leak. Correct any leak found.

TEFLON ® is a registered trademark of E.I. Du Pont De Nemours and

Company.

OPERATING YOUR WATER HEATER

Lighting Instructions

Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 23.) Make sure the tank is completely filled with water before lighting the pilot. Check the rating plate near the gas control valve/ thermostat for the correct type of gas. Do not use this water heater with any gas other than the one listed on the rating plate. If you have any questions or doubts, consult your gas supplier or gas utility company.

WARNING

Explosion Hazard

Replace view port if glass is missing or damaged.

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

Lighting the Pilot:

1. Read and follow the lighting instructions on the water heater’s label.

2. Turn the Control Knob to Pilot. Press the Knob in fully and hold it in. (The knob will travel in about 1/4-inch if it is set to Pilot correctly.)

3. Click the Igniter button continuously for up to 90 seconds or until the Status Light begins to blink.

If the Status Light does not begin to blink after 90 seconds, STOP. Wait 10 minutes before attempting to relight the Pilot. Repeat these steps 2-3 times, if necessary.

The circuitry in this gas valve requires that you wait 10 minutes between lighting attempts.

If the Status Light blinks, release the Control Knob and turn it to the desired setting. (“Hot” is approximately 120°F).

If the Status Light Does Not Blink:

1. Wait 10 minutes before another lighting attempt.

2. If the Status Light did not blink, repeat the lighting procedure by following the lighting instructions on the water heater’s label. Remove the outer door. The Control Knob must be set to Pilot and held in continuously while clicking the igniter button (about once per second for up to 90 seconds). To observe the Pilot, remove the outer door and look through the view port (sight glass). See Figure 23.

3. Continue clicking the Igniter button (for up to 90 seconds) until Pilot lights.

4. Once the Pilot is lit, continue to hold the Control Knob in until the Status Light begins to blink.

5. Release Control Knob and set Knob to desired temperature setting. (“Hot” is approximately 120°F.)

6. Replace the outer door.

If the Pilot Does Not Light:

1. Wait 10 minutes before another lighting attempt. If the pilot does not light, the Igniter may not be

sparking or the unit may not be getting gas (or for a new installation, there may still be air in the gas line).

Each time you click the igniter button, you should be able to see the spark by looking through the view port. See Figure 23. (You may have to darken the room lights to see the spark.) You do not have to push the

Control Knob in to check the Igniter button. Simply look through the sight glass while clicking the Igniter button and look for a spark. If you can’t see a spark when the Igniter button is clicked, check the wiring connections from the Igniter button and make sure that they are tight.

2. If you see the Igniter spark, try relighting the pilot by following the instructions on the water heater’s label. Ensure that the gas supply is tuned on. There may be air in the gas line, and several lighting attempts may be needed to completely fill the line with gas and successfully light the pilot.

If the Pilot Lights but the Status Light Does Not Blink:

1. If the pilot lights, continue to hold the Control Knob in until the Status Light blinks. If the pilot is lit and remains lit for 90 seconds and the Status Light still does not blink, the thermopile connections may be loose, the thermal switch may need to be reset, or the thermopile may be defective.

2. Remove the outer door.

3. Press the reset button on the thermal switch (Figure 23).

4. If switch clicks, it may have tripped. Do not light the Pilot if flammable vapors are present. Check flame arrestor for signs of discoloration (which could be caused by flammable vapors). If the flame arrestor is discolored, do not attempt to relight the Pilot. Have the water heater inspected by a qualified service technician.

5. Check the wiring connections from the thermopile and the thermal switch to the gas control valve/thermostat. Ensure that all wiring connections are tight. See Figure 23.

6. Replace the outer door.

7. Wait 10 minutes and try to light the Pilot according to the instructions on the water heater’s label.

8. While clicking the Igniter button continuously, the Control Knob must be set to Pilot and held in until the Status Light blinks. Once the Status Light blinks, release the Control Knob and set the Knob to the desired temperature setting. (“Hot” is approximately 120°F.)

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING:

If you do not follow these instructions exactly, a

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

FLAMMABLE

BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES

Use only your hand to push in or turn the gas control

This appliance has a pilot which is lit by a piezo-

electric spark gas ignition system. Do not open the inner door of the appliance and try to light the pilot by hand.

BEFORE LIGHTING

smell all around the appliance

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

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's

phone. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department.

knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified

service technician. Force or attempted repair may result in a fire or explosion.

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! DO NOT USE THIS APPLIANCE IF THERE HAS

BEEN AN IGNITION OF VAPORS. Immediately call a qualified service technician to inspect the appliance. Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater.

LIGHTING INSTRUCTIONS

Gas Control/Temperature Knob

Status Light

120°F

120°F Mark

Mark

FIGURE 'A'

FIGURE 'B'

120°F

120°F Mark

Mark

FIGURE 'C'

120°F

120°F Mark

Mark

MAIN BURNER

THERMOPILE

VAC

Igniter

GAS CONTROL

"OFF" POSITION

"PILOT" POSITION

CONTROL KNOB

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" setting.

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 1/4 inch (6.35 mm) 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/

TO TURN OFF GAS TO APPLIANCE

"ON" POSITION

PILOT

FIGURE 'D'

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 "OFF" and call a qualified service technician or your gas supplier.

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.

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

Checking the Draft

Water Temperature Regulation

WARNING

Burn Hazard

Do not touch vent. Doing so can result in burns.

After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft (Figure 17). Make sure all other appliances in the area are operating and all doors are closed when performing the draft test. Pass a match flame around the relief opening of the draft hood. A steady flame drawn into the opening indicates proper draft.

DRAFT HOOD

RELIEF

OPENIN

ATCH

FIGURE 17.

If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and/or air supply requirements.

Burner Flames

Inspect the burner flames through the viewport and compare them to the drawings in Figure 18. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored flame. Contact a qualified technician if the flame is not satisfactory.

FIGURE 18.

Emergency Shut Down

IMPORTANT: Should overheating occur or the gas supply fails to shut off, turn off the water heater’s manual gas control valve and call a qualified technician.

Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death.

Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting valves are available.

Read instruction manual for safe temperature setting.

Due to the nature of the typical gas water heater, the water temperature in certain situations may vary up to 30°F (16.7 °C) higher or lower at the point of use such as, bathtubs, showers, sink, etc.

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 infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing 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. See Figure 14. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, see Figure 19A. Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater.

Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower.

NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is recommended by most dishwasher manufacturers.

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 19A. 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 first degree burns within:

Water

Temperature °F

110 116 116 122 131 140 149 154

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

GAS CONTROL VALVE/THERMOSTAT SETTINGS

GAS CONTROL/TEMPERATURE KNOB

Time for 1st

Degree Burn

(Less Severe Burns)

(normal shower temp.)

(pain threshold)

35 minutes

1 minute 5 seconds 2 seconds

1 second

Instantaneous

STATUS LIGHT

120°F

MARK

Time for

Permanent Burns 2nd & 3rd Degree (Most Severe Burns)

45 minutes

5 minutes

25 seconds

5 seconds 2 seconds

1 second

Water Temperature Adjustment

The water temperature setting can be adjusted from 55°F to 155°F. Turn the Gas Control/Temperature Knob to the desired setting/temperature.

NOTE:

• Some models are certified for 180°F outlet temperatures. See the Data Plate on the front of the water heater for the maximum outlet temperature.

• 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.

VAC

IGNITER

FIGURE 19A.

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

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

VAC

FIGURE 19B.

Status Light Code

Normal Flashes:

• 0 Flashes Indicates Control Off/Pilot Out.

• 1 Flash Indicates Normal Operation.

• A solid light indicates that the gas control valve/thermostat is shutting down.

Diagnostic Flashes: If the water heater is not working, look for the following

diagnostic flashes after lighting the pilot. For more details, see “

Status Light and Diagnostic Code Troubleshooting Chart 2 Flashes Indicates Thermopile Voltage Low 4 Flashes Indicates Overheat Failure 5 Flashes Indicates Sensor Failure 7 Flashes Indicates Electronic Control Failure 8 Flashes See “Status Light and Diagnostic Code

Troubleshooting Chart.”

Operational Conditions

Condensation

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

a. A new water heater is filled with cold water for the first time.

b. Burning gas produces water vapor in water heaters, par-

ticularly high efficiency models where flue temperatures are lower.

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

the refill 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.

.”

Excessive condensation can cause pilot outage due to water running down the flue tube onto the main burner and putting out the pilot.

Because of the suddenness and amount of water, condensation 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

machines and shower heads.

Excessive condensation 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 fired water heater to operate properly as well as to carry away products of combustion and water vapor.

demands for hot water including dishwashers, washing

It is always recommended that a suitable metal drain pan be installed under the water heater to protect the area from water damage resulting from normal condensation production, a leaking tank or piping connections. Refer to the “Location Requirements” section.

Water Heater Sounds

During the normal operation of the water heater, sounds or noises may be heard. These noises are common and may result from the following:

1. Normal expansion and contraction of metal parts during periods of heat-up and cool-down.

2. Condensation causes sizzling and popping within the burner area and should be considered normal.

3. Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank failure. Drain and flush the tank as directed under the “Draining and Flushing” section.

Smoke/Odor

The water heater may give off a small amount of smoke and odor during the initial start-up of the unit. This is due to the burning off of oil from metal parts of a new unit and will disappear after a brief period of operation.

Safety Shut-off

This water heater is designed to automatically shut-off in the event of the following:

1. The pilot flame is extinguished for any reason.

2. The water temperature exceeds 189°F (87°C) for 155°F models or 199°F (93°C) for 180°F models. See the data plate for your model.

3. Excessive combustion chamber temperatures.

4. The ignition of flammable vapors. A thermopile is used to determine if a pilot flame is

present, and will shut off the gas supply to the main burner and the pilot if the flame is absent. This unit is also equipped with a thermal switch, designed to shut off the gas supply in the event the heater has been exposed to flammable vapors (spilled gasoline or paint fumes, for example), poor combustion caused by insufficient combustion air, or improper venting. If the switch opens, check the flame arrestor for signs of high temperature (blue or black discoloration), and inspect your installation for any problems with venting or combustion air. (See Pilot Light Troubleshooting Flowchart). Reset the switch by depressing the small button in the center of the switch.

IMPORTANT: Correct any issues prior to resetting the

switch. Reference the number on the cover of this manual for service information.

The gas control valve\thermostat includes a temperature limiting ECO (Energy Cut Off) system that will shut off the water heater if the water temperature exceeds 189°F (87°C) for 155°F models or 199°F (93°C) for 180°F models. See the data plate for your model.

Should the water temperature get too high, the diagnostic status light will flash a code (4 flashes), indicating an overtemperature condition and the main burner will be shut off. If a high temperature condition occurs, turn the main gas supply OFF and have the water heater repaired by a qualified service technician. Contact your local dealer for service information.

Anode Rod/Water Odor

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 sulfide 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 filtration equipment from a water conditioning company to successfully eliminate all water odor problems.

Artificially 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.

NOTE: Artificially 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”.

• Significant sections of the support 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

EXPOSED SUPPORT WIRE

re-installing or replacing the anode rod, check for any leaks and immediately correct if found.

In replacing the anode:

1. Turn off gas supply to the

PITTED ANODE ROD

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

EXPOSED SUPPORT WIRE

FIGURE 20.

procedures). Close drain valve.

4. Remove the old anode rod.

5. Use Teflon® 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.

7. Check for any leaks and immediately correct any if found.

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

TEFLON ® is a registered trademark of E.I. Du Pont De Nemours and Company.

Draining and Flushing

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, refill the tank, and restart the water 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 refilling the tank and should not be confused with a tank leak.

Routine Preventive Maintenance

At least annually, a visual inspection should be made of the venting and air supply system, piping systems, main burner, pilot burner, and flame-arrestor. Check the water heater for the following:

• Obstructions, damage, or deterioration in the venting system. Make sure the ventilation and combustion air supplies are not obstructed.

• Clean any dust or debris from the base-ring filter.

• Soot and/or carbon on the main burner and pilot burner. Contact a qualified technician.

• Leaking or damaged water and gas piping.

• Presence of flammable or corrosive materials in the installation area.

• Presence of combustible materials near the water heater.

• After servicing this water heater, check to make sure it is working properly. (See “Operating Your Water Heater” section of this manual.)

IMPORTANT: If you lack the necessary skills required to properly perform this visual inspection, you should not proceed, but get help from a qualified technician.

It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps:

1. Turn off the gas to the water heater at the manual gas shut-off valve.

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

T emperature and Pressure Relief Valve

Explosion Harzard

• Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code.

• Properly sized temperaturepressure relief valve must be installed in opening provided.

• Can result in overheating and excessive tank pressure.

• Can cause serious injury or death.

Manually operate the temperature and pressure relief valve at least once a year to make sure that it is working

properly. To prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position. See Figure 21. If the valve fails to completely reset and continues to release water, immediately shut off the manual gas control valve and the cold water inlet valve and call a qualified technician.

MAINTENANCE OF YOUR WATER HEATER

TEMPERATURE AND PRESSURE RELIEF VALVE

DISCHARGE LINE TO DRAIN

MANUAL RELIEF VALVE

FIGURE 21.

Replacement Parts

IMPORTANT: The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician.

Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly. When ordering replacement parts, always have the following information ready:

1. model, serial, and product number

2. type of gas

3. item number

4. parts description See Repair Parts Section for a list of available repair parts.

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 sufficient time for the water heater to cool before performing any maintenance.

GAS CONTROL/ TEMPERATURE KNOB

VAC

IGNITER BUTTON

IGNITER LEAD WIRE

IGNITER WIRE

PILOT TUBE

FIGURE 2 2 .

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.

WHITE

WIRE

(RIGHT

SIDE)

RED WIRE (LEFT SIDE)

MANIFOLD TUBE

6. Use needle nose pliers to disconnect the white (-) thermopile wire from the gas control valve/thermostat (Figure 22). Next, disconnect both red thermal switch wires from the thermal switch on the manifold door (Figure 23).

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 VALVE/THERMOSTAT

GAS CONTROL/ TEMPERATURE KNOB

PIEZO IGNITER BUTTON

PILOT TUBE VIEWPORT

OUTER DOOR NOT SHOWN

MANIFOLD SCREW (2)

VAC

MANIFOLD COMPONENT BLOCK

FIGURE 23 .

THERMOPILE AND SWITCH WIRE CONNECTIONS

MANIFOLD TUBE

THERMAL SWITCH

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 orifice.

PILOT ASSEMBLY

(BOTTOM VIEW)

SCREWS

BURNER

(BOTTOM VIEW)

FIGURE 24.

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 orifice.

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 flat-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.

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.

RED (+) THERMAL SWITCH WIRE CONNECTS TO THE GAS CONTROL VALVE\THERMOSTAT.

WHITE (-) THERMOPILE WIRE CONNECTS TO THE GAS CONTROL VALVE\THERMOSTAT.

MANIFOLD

COMPONENT

BLOCK

RED THERMAL SWITCH WIRE CONNECTIONS AT MANIFOLD DOOR

PILOT / THERMOPILE ASSEMBLY SCREW

BURNER AND OTHER FITTINGS NOT SHOW FOR CLARITY.

RED WIRES TO THERMAL SWITCH (2)

IGNITER WIRE

MANIFOLD COMPONENT BLOCK

CONNECTORS

PILOT TUBE

MANIFOLD DOOR

RETAINER CLIP

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.

THERMOPILE

PILOT/THERMOPILE ASSEMBLY

THERMAL SWITCH CONNECTORS (RED WIRES)

IGNITER CONNECTOR

PILOT

CONNECTORS (CONNECT AT GAS CONTROL VALVE/ THERMOSTAT)

THERMOPILE WIRES PASS THROUGH TOP HOLE OF THE MANIFOLD COMPONENT BLOCK

IGNITER WIRE PASSES THROUGH CENTER OF MANIFOLD COMPONENT BLOCK (SMALLEST HOLE)

PILOT TUBE PASSES THROUGH BOTTOM HOLE OF MANIFOLD COMPONENT BLOCK (LARGEST HOLE)

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.

FIGURE 26.

FOR CLARITY, PILOT TUBE NOT SHOWN .

External Inspection & Cleaning of the Base-Ring Filter

Replacing the Manifold/Burner Assembly

1. At least once annually, check the base-ring filter (Figure 28) for any dust or debris that may have accumulated on the filter screen. NOTE: If the water heater is located in an area that is subjected to lint and dirt, it may be necessary to check the base-ring filter more frequently.

2. Follow the Lighting Instructions to turn off the water heater and allow it to cool for 10 minutes before attempting to clean the base-ring filter.

3. Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the filter. NOTE: If unable to inspect or clean the base-ring filter, follow the “Cleaning the Combustion Chamber and Flame-arrestor” instructions.

4. After the base-ring filter has been cleaned, follow the Lighting Instructions to return the water heater to service.

Cleaning the Combustion Chamber and Flame-arrestor

1. Follow procedure outlined in “Removing the Manifold/ Burner Assembly”.

2. Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 28). Use compressed air to clear any dust or debris that may have accumulated in the flame-arrestor.

COMBUSTION CHAMBER

DOOR GASKET

BASE-RING FILTER

3. Reassemble following the procedure under “Replacing the Manifold/Burner Assembly”.

FLAME ARRESTOR

FIGURE 28.

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 follow these instructions can result in death, explosion, or fire.

1. Check the door gasket for damage or imbedded debris prior to installation (Figure 28).

2. Inspect the viewport for damage and replace as required (Figure 23).

3. Insert the new manifold/burner assembly into the burner compartment, making sure that the tab of the manifold tube engages the slot of the bracket inside t h e c o m b u s t i o n c h a m b e r ( F i g u r e 2 9 ) .

4. Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber (Figure 28).

5. Tighten the two screws that secure the manifold/burner assembly to the combustion chamber. (Use a 1/4” nut driver.) There should be no space between the gasket

part of the manifold door and combustion chamber

IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber.

6. Reconnect the manifold tube (3/4” wrench) and pilot tube (7/16” wrench) to the gas control valve/thermostat (Figure 22). Do not cross-thread or apply any thread sealant to the fittings.

IMPORTANT: If you were supplied with a new ferrule nut in a parts kit, follow these steps to connect the pilot tube:

1.) Install the ferrule nut into the gas valve at the pilot tube location, hand tight only. 2.) Insert the pilot tube into the ferrule nut until the tube bottoms out, then tighten the nut with a 7/16” wrench until the crimp connection seals to the pilot tube. 3.) Continue to tighten until the nut is tight in the gas valve.

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

7. Connect the white (-) thermopile wire to the gas control valve/thermostat, then connect the red thermal switch wires to the thermal switch on the manifold door. (Figure 23).

8. Reconnect the igniter wire (Figure 22).

9. Turn on the gas supply to the water heater at the manual gas shut-off valve (Figure 3).

10. Follow the lighting instructions on the front of the water heater. With the main burner lit, check for leaks at the manifold and pilot connections by brushing on 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. Correct any leak found.

11. Verify proper operation, then replace the outer door.

CLOSE-UP INSIDE VIEW OF THE COMBUSTION CHAMBER.

SLOT

TIP

MANIFOLD TUBE

FIGURE 29.

BRACKET

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

T esting 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 fine 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 Teflon® tape or pipe joint compound on the gas piping connections and fitting 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 filled with water before lighting and activating the water heater. Follow the “Lighting Instructions” on page 20.

• 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

FVIR System Operational Checklist

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Flame-arrestor free of debris and undamaged.

4. Manifold component block properly installed.

TROUBLESHOOTING CHART

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER WILL NOT IGNITE

1. Pilot not lit

2. Thermostat set too low

3. Main burner line clogged

4. Non-functioning thermostat

5. Base-Ring Filter blocked with lint/ dust

5. No leaks at pilot and manifold connection.

6. Manifold door screws securely tightened.

7. Depress the button on the thermal switch

1. Light pilot

2. Turn temp. dial to desired temperature

3. Clean, locate source and correct

4. Test Gas Control Valve/Thermostat

5. Clean filter, See “External Inspection & Cleaning of the Base-Ring Filter” section.

6. Heater installed in a confined area

7. FVIR Flame Arrestor blocked with lint/dust.

SMELLY WATER

BURNER FLAME YELLOWLAZY

1. Sulfides in the water 1. Replace the anode with a special anode

1. Insufficient combustion air

2. Low gas pressure

3. Water heater flue or vent system blocked

4. Main burner line clogged

5. Base-Ring Filter blocked with lint/

dust

6. Heater installed in a confined area

7. FVIR Flame Arrestor blocked with lint/dust.

8. Obstruction in main burner orifice

PILOT WILL NOT LIGHT OR REMAIN LIT

1. Non-functioning igniter

2. The thermal switch tripped

3. Wire lead connection at thermal switch loose

4. Thermopile connection loose

5. Air in gas line

6. Low gas pressure

7. N o g as

8. Dirt in gas lines

9. Cold drafts

10. Thermostat temperature limit was exceeded. Status light will blink 4 flashes.

11. Pilot line or orifice clogged

12. Non-functioning thermopile

13. Air for combustion obstructed

14. FVIR Flame Arrestor blocked with lint/dust

15. Flammable vapors incident, FVIR function actuated

16. Base-Ring Filter blocked with lint/ dust

HIGH OPERATION COSTS

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

INSUFFICIENT HOT WATER 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

6. Provide fresh air ventilation

7. Clean filter, See “Cleaning the Combustion Chamber and Flame-Arrestor” section.

1. Provide ventilation to water heater

2. Check with gas utility company

3. Clean, locate source and correct

4. Clean, locate source and correct

5. Clean filter, See “External Inspection & Cleaning of the Base-Ring Filter” section.

6. Proper fresh air ventilation

7. Clean filter, See “Cleaning the Combustion Chamber and Flame-Arrestor” section.

8. Clean or replace orifice

1. Replace igniter pilot assembly

2. See Pilot Light Troubleshooting Flowchart section

3. Remove and reconnect the wire leads at thermal switch, confirm connections are tight and not loose

4. Finger tighten; then 1/4 turn with wrench

5. Bleed the air from the gas line

6. Check with gas utility company

7. Check with gas utility company

8. Notify utility-install dirt trap in gas line

9. Locate source and correct

10. Replace thermostat

11. Clean, locate source and correct

12. Replace thermopile

13. See maintenance section for inspection and cleaning of flame arrester

14. Clean filter, See “Cleaning the Combustion Chamber and Flame-Arrestor” section.

15. Replace water heater, eliminate flammable vapors source. Contact Technical Assistance.

16. Clean filter, See “External Inspection & Cleaning of the Base-Ring Filter” section.

1. Set temperature dial to lower setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

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

5. Repair faucets

6. Check with utility-repair at once

7. A dv i s e c u s t om er

8. Insulate piping

9. Insulate piping

1. Turn temperature dial to desired setting

2. Drain/flush-provide water treatment if needed

3. Install adequate 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

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

SLOW HOT WATER RECOVERY

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. Insufficient combustion air

1. Provide ventilation to water heater. Check flue way, flue baffle, and burner

2. Water heater flue or vent system

2. Clean flue, locate source and correct

blocked

3. Low gas pressure

4. Improper calibration

5. Base-Ring Filter blocked with lint/ dust

3. Check with gas utility company

4. Replace thermostat

5. Clean filter, See “External Inspection & Cleaning of the Base-Ring Filter” section.

6. Clean filter, See “Cleaning the Combustion

6. FVIR Flame Arrestor blocked with

Chamber and Flame-Arrestor” section.

lint/dust.

1. Excessive water pressure

2. Heater stacking

3. Closed water system

1. Use a pressure reducing valve and relief valve

2. Lower the thermostat setting

3. See “Closed System/Thermal Expansion”

1. Thermostat not functioning properly

1. Replace thermostat

2. Replace thermostat

2. Improper calibration

1. Insufficient combustion air

1. Provide ventilation to water heater. Check flue

2. Water heater flue or vent system blocked

way, flue baffle, and burner

2. Clean, locate source and correct

3. Heater installed in a confined area

4. Base-Ring Filter blocked with lint/ dust

3. Provide fresh air ventilation

4. Clean filter, See “External Inspection & Cleaning of the Base-Ring Filter” section.

5. FVIR Flame Arrestor blocked with lint/dust.

1. Insufficient combustion air

5. Clean filter, See “Cleaning the Combustion Chamber and Flame-Arrestor” section.

1. Provide ventilation to water heater. Check flue way, flue baffle, burner

2. Low gas pressure

3. Water heater flue or vent system

2. Check with gas utility company

3. Clean, locate source and correct

blocked

4. Thermostat not functioning properly

5. Heater installed in a confined area

6. Burner flame yellow-lazy

7. Base-Ring Filter blocked with lint/ dust

4. Replace thermostat

5. Provide fresh air ventilation

6. See “Burner Flame Yellow-Lazy”

7. Clean filter, See “External Inspection & Cleaning of the Base-Ring Filter” section.

8. Clean filter, See “Cleaning the Combustion Chamber and Flame-Arrestor” section.

8. FVIR Flame Arrestor blocked with lint/dust.

1. Temperature setting too low 1. Increase the temperature setting. Refer

to the “Condensation” sub-section of this manual’s Troubleshooting Guide.

1. Orifice too large

2. High gas pressure

3. Water heater flue or vent system blocked

1. Replace with correct orifice

2. Check with gas utility company

3. Clean flue and burner-locate source and correct

4. Cold drafts

4. Locate source and correct

1. Orifice too large 1. Replace with correct orifice

FLAME BURNS AT ORIFICE

PILOT FLAME TOO SMALL

1. Thermostat not functioning properly

2. Low gas pressure

1. Pilot line or orifice clogged

2. Low gas pressure

1. Replace thermostat

2. Check with gas utility company

1. Clean, locate source and correct

2. Check with gas utility company

PILOT LIGHT TROUBLESHOOTING FLOWCHART

Section A: Pilot light will not light (new installation).

Is the manual gas shut-off valve, located in the supply line to the water heater, in the on position?

YES

Have you bled all the air from the pilot tube and gas supply line?

YES

Is the igniter producing a spark?

Follow the “Testing the Igniter System” section in this manual.

YES

Turn the manual gas shut-off valve to the on position and follow the lighting

instructions on the front of the water heater.

While repeatedly depressing the igniter button, push in and hold the gas control/ temperature knob until the pilot is lit and maintains a stable flame (status light will blink). It may take up to 90 seconds of pilot operation before status light blinks. Once status light blinks, release the gas control/temperature knob.

Set thermostat to desired temperature.

Section B: Pilot light repeatedly goes out.

Check the Base-Ring Filter and Flame Arrestor for blockage due to lint or dust. Are both the Air Filter and Flame Arrestor clean?

YES

Refer to the “Maintenance of your Water Heater” section of this

manual for information on cleaning the flame arrestor and burner.

Section C: Pilot light will not remain lit.

Complete this section after completing Section B.

Check for insufficient combustion air.

YES

Are the combustion air supply and ventilation openings of sufficient size? See “Combustion Air Supply and Ventilation” section in this manual for requirements.

YES

Does the return air duct for the furnace/ air handler/air conditioner draw its air from the same location as the water heater? See the “Location Requirements” section and the “Combustion Air Supply” section.

YES

Contact a Heating and Air Conditioning service technician to relocate the return air duct. The water heater’s pilot can be extinguished when the heating or cooling system is turned on if the return air duct is in the same location.

If you are still having difficulty keeping the pilot lit, reference the number on the cover of this manual for service information.

Correct size of

openings to allow sufficient air.

Is there proper drafting at the drafthood? See “Checking the Draft” section in this manual.

YES

Check the vent system for restrictions/obstructions and check the vent termination height. Refer to the “Installation Instructions” section of this manual for specific requirements.

Does the flame arrestor show signs of discoloration?

YES

Shut-off the gas supply to the water heater at the manual gas shut-off valve. Use the number on the cover of this manual to contact Customer Service.

Go to section C.

Reassemble the heater, press the thermal

switch, and attempt to return the heater to service. Does the pilot remain lit?

Set to desired temperature.

Does the diagnostic status light on the gas control valve/thermostat give a two flash error code?

Refer to the “Replacing the Pilot Assembly” instructions in the manual.

Reassemble and restore to service.

YES

NOTE: If you are still experiencing difﬁ culties after following

the steps in sections A, B, and C, please use the number on the cover of this manual to contact Customer Service.

THERMAL SWITCH LOCATION

THERMAL SWITCH

FIGURE 31.

STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART

LED STATUS PROBLEM CORRECTIVE ACTION

0 FLASHES (LED NOT LIT) Pilot light is not lit or Thermopile

has not yet reached normal operating temperature.

LIGHT ON (SOLID) Pilot light was recently

extinguished and the Thermopile is cooling down.

1 FLASH (EVERY 3 SECONDS) Normal operation. No corrective action necessary.

2 FLASHES Pilot is lit but the Thermopile is

not producing the required output voltage.

Turn Gas Control Valve/Thermostat knob to OFF. Wait 10 minutes, then attempt to relight Pilot by following the lighting instructions on the water heater’s label. Until the Thermopile reaches its normal operating temperature, the Status Light will not blink, even if the Pilot is lit. It may take up to 90 seconds of continuous Pilot operation before the Thermopile reaches normal operating temperature and the Status Light starts to blink.

If the Status Light does not blink after three lighting attempts, check to make sure unit is getting gas. Remove the outer door. Press reset button. Replace outer door. Turn Gas Control Valve/Thermostat knob to OFF. Wait 10 minutes, then attempt to light Pilot by following the lighting instructions on the water heater’s label. Look through the view port for the Pilot flame. If Pilot is not visible, the spark igniter or gas supply to the Pilot should be checked.

If the Pilot is visible and the Status Light does not blink after 90 seconds of continuous Pilot operation, the Pilot flame may not be heating the Thermopile sufficiently (weak Pilot), the Thermopile may be defective, or wiring connectors may be loose.

NOTE: If the water heater has been operating but has stopped and will not re-light, check the flamearrestor for signs of high temperature (blue or black) discoloration indicating a flammable vapor incident. If you suspect a flammable vapor incident has occurred, do not use this appliance. Immediately call a qualified technician to inspect the appliance. Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater.

Turn Gas Control Valve/Thermostat knob to OFF. Wait 10 minutes for the Thermopile to cool, then attempt to relight Pilot by following the lighting instructions on

the water heater’s label.

NOTE: This gas control valve/thermostat has built-in circuitry that requires waiting 10 minutes between lighting attempts.

Until the Thermopile reaches its normal operating temperature, the Status Light will not blink, even if the Pilot is lit. It may take up to 90 seconds of continuous Pilot operation before the Thermopile reaches normal operating temperature and the Status Light starts to blink.

Turn Gas Control Valve/Thermostat knob to OFF. The Thermopile is probably defective, but loose wiring connections or a weak Pilot flame can also cause this symptom.

STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART (Continued)

LED STATUS PROBLEM CORRECTIVE ACTION

4 FLASHES The Gas Control Valve’s

temperature sensor has detected that the water temperature was too high. Once this condition occurs, the Main Burner and the Pilot Light will be shut off. Since the Pilot light will be off, should this condition occur, this Flash Code will only be displayed immediately after the Pilot has been relit. Turn Gas Control Valve/ Thermostat knob to OFF.

5 FLASHES The temperature sensor

(thermistor) is defective.

7 FLASHES Gas Control Valve failure. Turn Gas Control Valve/Thermostat knob to OFF. Turn

Relight pilot and verify 4 flashes. If 4 flashes are observed, turn Gas Control Valve/Thermostat knob to OFF. Turn Main Gas Supply OFF. Replace the Gas Control Valve/Thermostat. See “Removing and Replacing the Gas Control Valve/Thermostat.”

Turn Gas Control Valve/Thermostat knob to OFF. Replace the temperature sensor (thermistor).

Main Gas Supply OFF. Replace the Gas Control Valve/ Thermostat. See “Removing and Replacing the Gas Control Valve/Thermostat.”

8 FLASHES This condition only appears if the

gas control/temperature knob has been turned off and the thermopile continued to produce electric power. This condition can occur if the thermopile does not cool down as quickly as expected when the unit is shut off. This condition can also occur if the gas control/ temperature knob has been turned off and the pilot continues to operate because the pilot valve is stuck in the open position.

Make sure that the gas control valve/thermostat knob is set to OFF. Wait one minute. Remove the outer door. Look through the sight glass for a pilot flame. If a pilot flame is observed with the gas control valve/thermostat knob set to the OFF position, the pilot valve is stuck open. Turn the main gas supply OFF. Replace the gas control valve/thermostat. For instructions, see “Removing and Replacing the Gas Control Valve/Thermostat.”

If the pilot flame is not observed when the gas control valve/thermostat knob is set to the OFF position, wait 10 minutes for the thermopile to cool, then attempt to relight the pilot by following the lighting instructions on the water heater’s label. If this condition returns, replace the gas control valve/thermostat. See “Removing and Replacing the Gas Control Valve/Thermostat” for instructions.

NOTES

REPAIR PARTS ILLUSTRATION

When ordering repair parts, always give the following information:

1. Model, serial, and product number

2. Type of gas

3. Item number

4. Parts description

Repair Parts List

Item

No.

1 DRAFT HOOD

2 HEAT TRAP (COLD) - SOME MODELS

3 HEAT TRAP (HOT) - SOME MODELS

4 COLD WATER DIP TUBE

5 ANODE ROD

6 TEMPERATURE & PRESSURE RELIEF VALVE

(LOCATED TOP OR SIDE)

7 DRAIN VALVE

8 GAS CONTROL VALVE/THERMOSTAT

(with thermal switch wire lead)

9 OUTER DOOR

10 BASE-RING FILTER

11A* PILOT / THERMOPILE ASSEMBLY KIT (Natural Gas)

11B* PILOT / THERMOPILE ASSEMBLY KIT ( L.P. Gas)

12A* BURNER (Natural Gas)

12B* BURNER (L.P. Gas)

13A* MANIFOLD / BURNER ASSEMBLY (Natural Gas)

13B* MANIFOLD / BURNER ASSEMBLY ( L.P. Gas)

14* MANIFOLD COMPONENT BLOCK

15* MANIFOLD DOOR GASKET

16* VIEWPORT ASSEMBLY

*Pictured on next page.

Parts Description

LEGEND

Special anode rod. (See “Anode Rod / Water Odor” section.)

Temperature and Pressure Relief Valve is required, but may not be factory installed

Unique: FVIR System parts

Listed Parts Kits and Illustrations

Item 11A: Pilot / Thermopile Assembly kit, which contains the pilot / pilot tube assembly, thermopile, and igniter electrode.

(Natural Gas)

Item 11B: Pilot / Thermopile Assembly kit, which contains the pilot / pilot tube assembly, thermopile, and igniter electrode.

(L.P. Gas)

Item 12A: Burner (Natural Gas/Low Nox)

Item 12B: Burner (L.P. Gas)

Item 13A: Manifold / Burner Assembly: contains the door, gasket, manifold tube, pilot / thermopile assembly, manifold

component block, thermal switch, and burner. (Natural Gas/Low Nox)

Item 13B: Manifold / Burner Assembly: contains the door, gasket, manifold tube, pilot / thermopile assembly, manifold

component block, thermal switch, and burner. (L.P. Gas)

Item 14: Contains manifold component block

Item 15: Contains manifold door gasket

Item 16: Contains view port

Item # 11A

Item #11B

Item # 13B

Item # 15 Item # 16

Item # 12A

Item # 12B

Item # 13A

Item # 14

RESIDENTIAL GAS WARRANTY

THIS WARRANTY IS APPLICABLE T O THE ORIGINAL OWNER ONLY in accordance with the warranty terms and conditions speci 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.

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 af xed to this water heater. This warranty is not transferrable and applies to models listed below:

MODEL SERIES: Tank Parts Labor 1212 12-year 12-year 1-year 909 9-year 9-year 1-year 616 6-year 6-year 1-year 606 6-year 6-year ------ 101 1-year 1-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 and 8 year models and to 3 years for 9 and 12 year models.

2. The parts warranty 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  re codes 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, certi 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;

and

 used at water pressure not exceeding the working pressure shown on the heater;   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 drip leg in the gas supply line;

  red with the fuel for which it was factory built;   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.

Any accident to the water heater or any part thereof (including freezing,  re,  oods, or lightning), any misuse, abuse or alteration of it, any operation of it in a modi ed form, any operation of the water heater on desalinated (deionized) water, or any damage caused by attempts to repair tank leaks or 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 speci cations of the heating component manufacturer.

This warranty gives you speci 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.

UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT W A TER 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 water heater or replacement part from the nearest distributor

parts, will void this

SERVICE AND LABOR RESPONSIBILITY

and returning the claimed defective heater or part to such distributor.

c. All cost necessary or incidental for handling and administrative charges, and for any materials and/or permits required for installation of the replacement heater or part.

LIMITATION ON IMPLIED WARRANTIES

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.

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

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. IF THE GLASSLINED TANK IN THIS WATER HEATER SHALL PROVE UPON EXAMINATION BY THE WARRANTOR TO HAVE LEAKED DUE TO NA TURAL CORROSION FROM POT ABLE 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 REGULA TIONS OR INDUSTRY ST ANDARDS 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.

IMPORTANT INFORMATION

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 INST ALLATION, 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 PROPER TY , OR OTHER CONSEQUENTIAL

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 ______________________________

Reliance 650NBRT, 940NKCT, 640NBRBT, 1240NACS, 1240NACT Use & Care Guide

Specifications and Main Features

Frequently Asked Questions

User Manual