Rudd 100 GALLON Installation Manual

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WARNING: This water heater is not suitable

for use in manufactured (mobile) homes!

Gas Residential

Water Heaters

Residential 60, 75 and 100 Gallon

The purpose of this manual is twofold: one, to provide the installer with basic directions and
recommendations for the proper installation and adjustment of the water heater; and two,
for the owner–operator, to explain the features, operation, safety precautions, maintenance and trouble
shooting of the water heater. This manual includes a parts list.

It is imperative that all persons who are expected to install, operate or adjust this water heater read the
instructions carefully so that they may understand how to perform these operations. If you do not
understand these instructions or any terms within it, seek professional advice.

Any questions regarding the operation, maintenance, service or warranty of this water heater should be
directed to the seller from whom it was purchased. If additional information is required, refer to the

section “If You Need Service .....”

Use & Care Manual

With Installation Instructions for the Installer

READ ALL INSTRUCTIONS

BEFORE

U N I T R O L

LIGHTING

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Do not destroy this manual. Please read carefully and keep in a safe place for future reference.

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Recognize this symbol as an indication of Important Safety Information!

California Proposition 65 Warning: This product contains chemicals known to the State of

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California to cause cancer, birth defects or other reproductive harm.

WARNING: If the information in these instructions is not followed exactly, a fire or

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explosion may result causing property damage, personal injury or death.

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FOR YOUR SAFETY!

— Do not store or use gasoline or other

flammable vapors or liquids or other
combustible materials in the vicinity of this or
any other appliance. To do so may result in an
explosion or fire.

— 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.

● If you cannot reach your gas supplier, call

the fire department.

● Do not return to your home until authorized

by the gas supplier or fire department.

— Improper installation, adjustment, alteration,

service or maintenance can cause injury,
property damage or death. Refer to this
manual. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.

● Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s
instructions.

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®

Printed in USA

AP8804-18 (01/05)

Safety Information

Safety Precautions . . . . . . . 3–6

LP Gas Models . . . . . . . . . . . 5

FOR YOUR RECORDS

Write the model and serial numbers here:

#

#

You can find them on a label on the appliance.

Installation Instructions

Location . . . . . . . . . . . . . . . . . 7

Water Connections . . . . . . . . 9

Gas Supply . . . . . . . . . . . . . . 11

Pipe Insulation . . . . . . . . . . . 13

Heat Traps . . . . . . . . . . . . . . 13

Installation Checklist. . . . . . 14

Potable Space Heating . . . . 15

Operating Instructions

Lighting Instructions . . 16 , 17

Water Temperature . . . . . 19, 20

Care and Cleaning

Staple sales slip or cancelled check here.

Proof of the original purchase date is needed to obtain service under
the warranty.

READ THIS MANUAL

Inside you will find many helpful hints on how to use and
maintain your water heater properly. Just a little preventive care
on your part can save you time and money over the life of your
water heater.

You’ll find many answers to common problems in the Before You
Call For Service section. If you review our chart of
Troubleshooting Tips first, you may not need to call for service at
all.

Draining . . . . . . . . . . . . . . . . 21

Burner Inspection . . . . . . . . 22

Extended Shut-Down . . . . . 22

Troubleshooting Tips

Before You Call

For Service. . . . . . . . . . . 23, 24

Customer Service

Parts List . . . . . . . . . . . . . . . 25

If You Need Service . . . . . . 26

2

READ THE SAFETY INFORMATION

Your safety and the safety of others are very important. There
are many important safety messages in this manual and on your
appliance. Always read and obey all safety messages.

This is the safety alert symbol. Recognize this symbol
as an indication of Important Safety Information! This symbol
alerts you to potential hazards that can kill or
hurt you and others.

All safety messages will follow the safety alert symbol and either
the word “DANGER”, “WARNING”, “CAUTION” or
“NOTICE”.

These words mean:

DANGER An imminently hazardous situation that will

result in death or serious injury.

WARNING A potentially hazardous situation that could

result in death or serious injury and/or
damage to property.

CAUTION A potentially hazardous situation that may

result in minor or moderate injury.

Notice: Attention is called to observe a specified

procedure or maintain a specific condition.

IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING.

Be sure to read and understand the entire Use and Care Manual before attempting to install or operate
this water heater. It may save you time and cost. Pay particular attention to the Safety Instructions.
Failure to follow these warnings could result in serious bodily injury or death. Should you have
problems understanding the instructions in this manual, or have any questions, STOP, and get help
from a qualified service technician, or the local electric utility.

DANGER!

INSTALL THE DRAFT HOOD AND PROPERLY VENT THE
WATER HEATER…

Failure to install the draft hood and properly vent the water heater to the outdoors as
outlined in the Venting Section of the Installation Instructions in this manual can result in
unsafe operation of the water heater. To avoid the risk of fire, explosion, or asphyxiation
from carbon monoxide, never operate this water heater unless it is properly vented and
has an adequate air supply for proper operation. Be sure to inspect the vent system for
proper installation at initial start-up; and at least annually thereafter. Refer to the Care
and Cleaning section of this manual for more information regarding vent system
inspection.

WARNING!

Gasoline, as well as other flammable materials and liquids (adhesives, solvents, etc.), and
the vapors they produce are extremely dangerous. Do not handle, use or store gasoline or
other flammable or combustible materials anywhere near or in the vicinity of a water
heater. Be sure to read and follow the warning label pictured below and other labels on
the water heater, as well as the warnings printed in this manual. Failure to do so can
result in property damage, bodily injury or death.

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DANGER

FLAMMABLES

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Vapors from flammable
liquids will explode and
catch fire causing death or
severe burns

Do not use or store flammable
products such as gasoline,
solvents or adhesives in the
same room or area near the
water heater.

Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of children's reach.

Flammable Vapors

Water heater has a main
burner and pilot flame.
The pilot flame:

1. is on all the time and

2. will ignite flammable

Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the

4. can be carried from

flame by air currents.

vapors.

floor and

other rooms to the pilot

Installation:
Do not install water heater
where flammable products will
be stored or used unless the
main burner and pilot flames

Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.

are at least 18" above the
floor. This will reduce, but not
eliminate, the risk of vapors
being ignited by the main
burner or pilot flame.

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IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING.

DANGER!

WATER TEMPERATURE SETTING

Safety and energy conservation are factors to be considered when selecting the water
temperature setting of water heater’s thermostat. Water temperatures above 125°F. can
cause severe burns or death from scalding. Be sure to read and follow the warnings
outlined on the label pictured below. This label is also located on the water heater.

Time/Temperature Relationship in Scalds

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DANGER

HOT

BURN

Water temperature over 125°F can
cause severe burns instantly or
death from scalds.

Children, disabled and elderly are
at highest risk of being scalded.

See instruction manual before
setting temperature at water
heater.

Feel water before bathing or
showering.

Temperature limiting valves are
available, see manual.

Water Temperature Time To Produce a Serious Burn

120°F More than 5 minutes

125°F 11/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 11/2 seconds

155°F About 1 second

Table courtesy of Shriners Burn Institute

The chart shown above may be used as a guide
in determining the proper water temperature for your
home.

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DANGER: Households with small children, disabled,
or elderly persons may require a 120°F. or lower gas control
(thermostat) setting to prevent contact with “HOT” water.

Maximum water temperatures occur just after burner
has shut off. To find hot water temperature being
delivered, turn on a hot water faucet and place a
thermometer in the hot water stream and read the
thermometer.

The temperature of the water in the heater can be
regulated by setting the temperature dial on the front
of the gas control (thermostat). To comply with
safety regulations the gas control (thermostat) was

set at its lowest setting
before water heater was
shipped from the factory.

The illustration at the left

90°F

details the approximate

80°F

water temperature

70°F

for each mark on the gas
control (Thermostat)

60°F

130°F

140°F

150°F

160°F

WARNING

READ ALL INSTRUCTIONS
BEFORE LIGHTING

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120°F

110°F

100°F

Temperature Dial.

Notice: Mixing valves are available for reducing

Temperatures are approximate

point of use water temperature by mixing hot and
cold water in branch water lines . Contact a licensed

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plumber or the local plumbing authority for further
information.

4

DANGER:

Water SCALDS.

Hotter water increases the Potential for Hot

DANGER!

LIQUEFIED PETROLEUM (LP-PROPANE OR BUTANE)
AND NATURAL GAS MODELS

LP and natural gas have an odorant added to aid in detecting a gas leak. Some
people may not physically be able to smell or recognize this odorant. If you are unsure or unfamiliar
with the smell of LP or natural gas, ask the gas supplier. Other conditions, such as “odorant fade”,
which causes the odorant to diminish in intensity, can also hide or camouflage a gas leak.

● Water heaters utilizing LP gas are

different from natural gas models. A
natural gas water heater will not function
safely on LP gas and vice versa.

● No attempt should ever be made to

convert the water heater from natural
gas to LP gas. To avoid possible
equipment damage, personal injury or
fire, do not connect the water heater to a
fuel type not in accordance with the unit
data plate. LP for LP units. Natural gas
for natural gas units. These units are not
certified for any other fuel type.

● LP appliances should not be installed

below grade (for example, in a basement)
if such installation is prohibited by
federal, state and/or local laws, rules,
regulations or customs.

● LP gas must be used with great caution.

It is heavier than air and will collect first
in lower areas making it hard to detect at
nose level.

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DANGER: If a gas leak is present or

suspected:

● Do not attempt to find the cause yourself.

● Do not

● Do not

● Do not

● Leave the house immediately and make

sure your family and pets leave also.

● Leave the doors open for ventilation and

contact the gas supplier, a qualified
service agency or the fire department.

● Stay away from the house (or building)

until the service call has been made, the
leak is corrected and a qualified agency
has determined the area to be safe.

try to light any appliance.

touch any electrical switch.

use any phone in your building.

● Before attempting to light the water

heater, make sure to look and smell for
gas leaks. Use a soapy solution to check
all gas fittings and connections. Bubbling
at a connection indicates a leak that must
be corrected. When smelling to detect an
LP leak, be sure to sniff near the floor
also.

● Gas detectors are recommended in LP &

natural gas applications and their
installation should be in accordance with
the manufacturer’s recommendations
and/or local laws, rules, regulations or
customs.

● It is recommended that more than one

method, such as soapy solution, gas
detectors, etc., be used to detect leaks in
gas applications.

5

IMPORTANT SAFETY INFORMATION.
READ ALL INSTRUCTIONS BEFORE USING.

WARNING!

For your safety, the information in this manual must be followed to minimize the risk of
fire or explosion, electric shock, or to prevent property damage, personal injury, or loss of
life.

FOR INSTALLATIONS IN THE STATE OF CALIFORNIA

California Law requires that residential water heaters must be braced, anchored or
strapped to resist falling or horizontal displacement due to earthquake motions. For
residential water heaters up to 52 gallon capacity, a brochure with generic earthquake
bracing instructions can be obtained from: Office of the State Architect, 400 P Street,
Sacramento, CA 95814 or you may call 916-445-8100 or ask a water heater dealer.

However, applicable local codes shall govern installation. For residential water heaters
of a capacity greater than 52 gallons, consult the local building jurisdiction for acceptable
bracing procedures.

SAFETY PRECAUTIONS

Have the installer show you the location of the gas shut-off valve and how to shut it off if
necessary. Turn off the manual shut-off valve if the water heater has been subjected to
overheating, fire, flood, physical damage or if the gas supply fails to shut off.

● Read this manual entirely before installing

or operating the water heater.

● Use this appliance only for its intended

purpose as described in this Use and Care
Manual.

● Be sure your appliance is properly installed

by a qualified technician in accordance
with the provided installation instructions.

● Do not attempt to repair or replace any part

of your water heater unless it is specifically
recommended in this manual. All other
servicing should be referred to a qualified
technician.

READ AND FOLLOW THIS SAFETY INFORMATION
CAREFULLY.

SAVE THESE INSTRUCTIONS

6

Installing the water heater.

This water heater must be installed in accordance with these instructions, local codes, utility company
requirements, and/or in the absence of local codes, use the latest edition of the American National
Standard/National Fuel Gas Code. A copy can be purchased from either the American Gas Association,
1515 Wilson Blvd., Arlington, VA 22209 as booklet Z223.1 or National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269 as booklet NFPA No. 54.

Location

Max.

2″

Diameter of

water heater

plus 2″ min.

The auxiliary catch pan
installation MUST conform
to local codes.

WARNING: Combustible
construction refers to adjacent
walls and ceilings and should
not be confused with
combustible or flammable
products and materials.
Combustible and/or flammable
products and materials should
never be stored in the vicinity
of this or any gas appliance.

WARNING: If a location in
a garage is the only
alternative, the gas water
heater should be installed so
that the open flame of the pilot
and main burner are no less
than 18″ above the garage
floor, unless specifically
exempted from this by local
code, rule, regulation or custom.

The water heater should not be located
in an area where leakage of the tank or
connections will result in damage to the
area adjacent to it or to lower floors of
the structure.

When such areas cannot be avoided it is
recommended that a suitable catch pan,
adequately drained, must be installed
under the water heater.

The pan must not restrict combustion
air flow to the bottom of the water heater.

Catch pan kits are available from the store
where the water heater was purchased, or
any water heater distributor.

Make certain the floor underneath the
water heater is strong enough to
sufficiently support the weight of the
water heater once it is filled with water.

A gas fired water heater should not be
installed in a space where liquids which
give off flammable vapors are to be used
or stored. Such liquids include gasoline,
LP gas (butane and propane), paint or
adhesives and their thinners, solvents
or removers.

Because of natural air movement in a
room or other enclosed space, flammable
vapors can be carried some distance from
where their liquids are being used or
stored. The open flame of the water
heater’s pilot light or main burner can
ignite these vapors causing an explosion
or fire which may result in severe burns,
death or property damage.

For these reasons installation of a gas fired
water heater in a garage is not desirable.

Raising the gas fired water heater will
reduce, but not eliminate, the possibility
of lighting the vapor of any flammable
liquids which may be improperly stored or
accidentally spilled.

The water heater must be located so it is
not subject to physical damage, for example,
by moving vehicles, area flooding, etc.

● The water heater should be installed as

close as practical to the gas vent or
chimney.

● Long hot water lines should be insulated

to conserve water and energy.

● The water heater and water lines should

be protected from exposure
to freezing temperatures.

● Do not install the water heater in

bathrooms, bedrooms, any occupied
rooms normally kept closed, or in
outdoor unprotected areas.

● Minimum clearance from combustible

construction is 1″ sides and rear; 3″
from front of control; 12″ from the top.
If the clearances stated on the
Instruction/Warning Label, located on
the front of the heater differ, install the
water heater according to the clearances
stated on the label.

● The water heater may be installed on

combustible floors, but not directly on
carpeting. If the water heater must be
installed on carpeting, place a metal or
wood panel beneath the water heater,
extending beyond its full width and
depth at least 3″ in all directions.

● If the water heater is installed in an

alcove or closet, the entire floor must
be covered by a wood or metal panel. A
minimum of 24″ clearance from the
front and top should be available for
adequate inspection and servicing.

Stand kits to raise the water heater 18″
above the floor are available from the store
where the water heater was purchased, or
any water heater distributor. These kits
must comply with local codes.

7

Installing the water heater.

Inspect Shipment

Inspect the water heater for possible damage. Check the markings on the rating plate of
the water heater to be certain the type of gas supplied corresponds to the water heater
requirements.

Combustion and Ventilation Air

Proper operation of the water heater
requires air for combustion and
ventilation. Provisions for combustion
and ventilation air must comply with
referenced codes and standards.

NOTICE: If the water heater is installed in
an unconfined space within a building of
conventional frame, masonry or metal
construction, infiltration air is normally
adequate for proper combustion and
ventilation. If the water heater is installed in
a confined space, provisions for combustion
and ventilation air must be made.

A confined space is one having a volume
of less than 50 cubic feet per 1000 BTUH
of the aggregate input of all appliances
within that space.

The air must be supplied through two
permanent openings of equal area. One
is to be located within 12″ above the floor
and the other is to be located within 12″
below the ceiling.

The minimum net free area of each opening
must not be less than one square inch per
1000 BTUH of the total input rating of all
the appliances in the enclosure (but not
less than 100 square inches),

if each opening communicates with other
unconfined areas inside the building.

Buildings of unusually tight construction
shall have the combustion and ventilation
air supplied from outdoors, or a freely
ventilated attic or crawl space.

If air is supplied from outdoors, directly or
through vertical ducts, there must be two
openings located as specified above and
each must have a minimum net free area
of not less than one square inch per 4000
BTUH of the total input rating of all the
appliances in the enclosure.

If horizontal ducts are used to
communicate with the outdoors, each
opening must have a minimum net free
area of not less than one square inch per
2000 BTUH of the total input rating of all
the appliances in the enclosure. If ducts
are used, the minimum dimensions of
rectangular air ducts shall not be less than
3″.

NOTICE: If the duct openings are to be
covered with a protective screen or grill, the
net free area of the covering material must
be used in determining the size of the
openings. Protective screening for the
openings must not be smaller than 1/4″ mesh
to prevent clogging by lint or other debris.

NOTICE: The water heater
should not be installed near an
air supply containing
halogenated hydrocarbons.

8

Corrosive Atmospheres

The air in beauty shops, dry cleaning
establishments, photo processing labs, and
storage areas for liquid and powdered
bleaches or swimming pool chemicals
often contain such halogenated
hydrocarbons.

An air supply containing halogenated
hydrocarbons may be safe to breathe,
but when it passes through a gas flame
corrosive elements are released that
will shorten the life of any gas burning
appliance.

Propellants from common spray cans or
gas leaks from refrigeration equipment are
highly corrosive after passing through a
flame.

The water heater warranty is voided when
failure of the heater is due to operation in
a corrosive atmosphere.

Thermal Expansion

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Determine if a check valve exists in the
inlet water line. Check with your local
water utility company. It may have been

installed in the cold water line as a separate
back flow preventer, or it may be part of a
pressure reducing valve, water meter or
water softerner. A check valve located in the
cold water inlet line can cause what is
referred to as a “closed water system”. A
cold water inlet line with no check valve or
back flow prevention device is referred to as
an “open” water system.

As water is heated, it expands in volume and
creates an increase in the pressure within the
water system. This action is referred to as
“thermal expansion”. In an “open” water
system, expanding water which exceeds the
capacity of the water heater flows back into
the city main where the pressure is easily
dissapated.

A “closed water system”, however, prevents
the expanding water from flowing back into
the main supply line, and the result of
“thermal expansion” can create a rapid and

dangerous pressure increase in the water
heater and system piping. This rapid pressure
increase can quickly reach the safety setting
of the relief valve, causing it to operate
during each heating cycle. Thermal
expansion, and the resulting rapid and
repeated expansion and contraction of
components in the water heater and piping
system can cause premature failure of the
relief valve, and possibly the heater itself.
Replacing the relief valve will not correct the
problem.

The suggested method of controlling thermal
expansion is to install an expansion tank in
the cold water line between the water heater
and the check valve. The expansion tank is
designed with an air cushion built in that
compresses as the system pressure increases,
thereby relieving the over pressure condition
and eliminating the repeated operation of the
relief valve. Other methods of controlling
thermal expansion are also available. Contact
your installing contractor, water supplier or
plumbing inspector for additional
information regarding this subject.

IMPORTANT: Do not apply
heat to the HOT or COLD
water connections. If sweat
connections are used, sweat
tubing to adapter before
fitting adapter to the cold water
connections on heater. Any
heat applied to the cold water
supply fittings will
permanently damage the dip
tube.

Vacuum Relief Valve

(Not Supplied)

If required, install per local codes

and valve manufacturer’s

instructions.

NOTICE: The National
Fuel Gas Code (NFGC)
mandates a manual gas
shut-off valve: See (NFGC)
for complete instructions.
Local codes or plumbing
authority requirements
may vary from the
instructions or diagrams
provided and take
precedent over these
instructions.

Water Supply Connections

Refer to the illustration below for suggested typical installation. The installation of
unions or flexible copper connectors is recommended on the hot and cold water
connections so that the water heater may be easily disconnected for servicing if
necessary. The HOT and COLD water connections are clearly marked and are 3/4″
NPT on all models. Install a shut-off valve in the cold water line near the water heater.

Typical Installation

Vent connector to

chimney

Heat trap

6″ minimum

Hot water outlet

to fixtures

Temperature and

pressure relief valve

Water Heater Jacket

Manual gas shut-off

To gas supply

Ground joint union

Sediment trap

Thermostatic gas valve

Jacket door

Auxiliary catch pan

Cap

Union

Draft hood

Shut-off

valve

Thermal expansion
tank (if required)

Drain
valve

6″ air gap

Pitch up 1/4″
per foot

Anode

Union

Heat trap
6″ minimum

To cold water
supply

Shut-off valve

Relief valve discharge
line to suitable open
drain.

9