All Models: Maximum supply pressure = 14.0 in. W.C. (3.48 kPa)
Minimum supply pressure, Natural gas = 6 in. W.C. (1.49 kPa).
Minimum pressures must be maintained under both load and no load (static and dynamic) conditions.
FOREWORD
The design of these models comply with the current edition of ANSI
Z21.10.3/CSA 4.3 an automatic storage water heater.
Installation diagrams are found in this manual. These diagrams will serve
to provide the installer with a reference for the materials and method of
piping necessary. It is highly essential that all water and gas piping be
installed as shown on the diagrams.
In addition to these instructions, the equipment shall be installed in
accordance with those installation regulations in force in the local area
where the installation is to be made. These shall be carefully followed
in all cases. Authorities having jurisdiction should be consulted before
installations are made.
The installation must conform with these instructions and the local code
authority having jurisdiction. In the absence of local codes, installations
should comply with the National Fuel Gas Code (ANSI Z223.1/NFPA
54) and the National Electric Code (NFPA 70). These publications are
available from The National Fire Protection Association, 1 Batterymarch
Park, Quincy, MA 02269
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
Abbreviations Found In This Manual:
• CSA-Canadian Standards Association
• ANSI-American National Standards Institute
• NFPA-National Fire Protection Association
• AHRI-Air Conditioning, Heating and Refrigeration Institute
• UL-Underwriters Laboratories
This gas-fired water heater is design certified by Underwriters
Laboratories Inc. under American National Standard/CSA Standard for
Gas Wtare Heaters ANSI Z21.10.3•CSA 4.3 (current edition).
DO NOT USE THIS WA TER HEA TER IF ANY P AR T HAS BEEN UNDER
WATER. Immediately call a qualifi ed service technician to inspect the
water heater and to replace any part of the control system and any gas
control which has been under water.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERATE
HEATER UNTIL ALL CORRECTIVE STEPS HAVE BEEN MADE BY A
QUALIFIED SERVICEMAN.
1. EXTERNAL FIRE.
2. DAMAGE.
3. FIRING WITHOUT WATER.
4. SOOTING.
Heater must be protected from freezing downdrafts during shutdown periods.
PREPARING FOR THE INSTALLATION
1. Read the “General Safety” section, page 3 of this manual fi rst and
then the entire manual carefully. If you don’t follow the safety rules,
the water heater will not operate properly. It could cause DEATH,
SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fi red water heater. It also contains warnings
throughout the manual that you must read and be aware of. All warnings
and all instructions are essential to the proper operation of the water
heater and your safety. Since we cannot put everything on the fi rst few
pages, READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO
INSTALL OR OPERATE THE WATER HEATER.
2. The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installations shall comply with the National Fuel Gas Code ANSI
Z223.1/NFPA 54 current addition. This publication is available from
the CSA International, 8501 East Pleasant Valley Rd., Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
3. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility
or the manufacturer whose name appears on the rating plate.
4. Carefully plan the place where you are going to put the water heater.
Correct combustion, vent action, and vent pipe installation are
very important in preventing death from possible carbon monoxide
poisoning and fi res, see Figures 3 through 8A.
Examine the location to ensure the water heater complies with the
“Locating the New Water Heater” section in this manual.
5. For California installation this water heater must be braced, anchored,
or strapped to avoid falling or moving during an earthquake. See
instructions for correct installation procedures. Instructions may be
obtained from California Offi ce of the State Architect, 400 P Street,
Sacramento, CA 95814.
6. Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
7. Complies with SCAQMD rule #1146.2 and districts having equivalent
NOx requirements.
GROUNDING INSTRUCTIONS
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all cases.
This water heater must be connected to a grounded metal, permanent
wiring system; or an equipment grounding conductor must be run with
the circuit conductors and connected to the equipment grounding terminal
or lead on the water heater, see Figure 5.
4
Page 5
CHEMICAL VAPOR CORROSION
HIGH AL TITUDE INST ALLATIONS
CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF
AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS. SUCH
CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION.
Spray can propellants, cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and sodium chloride (water
softener salt), waxes, and process chemicals are typical compounds which
are potentially corrosive. Do not store products of this sort near the heater.
Also, air which is brought in contact with the heater should not contain
any of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. The limited warranty is voided
when failure of water heater is due to a corrosive atmosphere. (Refer to
the limited warranty for complete terms and conditions.)
EXTENDED NON-USE PERIODS
WARNING
HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM
SERVED BY THIS HEATER THAT HAS NOT BEEN USED FOR A LONG
PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE). HYDROGEN
GAS IS EXTREMELY FLAMMABLE.
these conditions, it is recommended that the hot water faucet be opened
for several minutes at the kitchen sink before using any electrical water
heater connected to the hot water system. If hydrogen is present, there
will probably be an unusual sound such as air escaping through the pipe
as the water begins to fl ow.
OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
WARNING
To reduce the risk of injury under
THERE SHOULD BE NO SMOKING OR
INSULATION BLANKETS
Insulation blankets available to the general public for external use on gas
water heaters are not required for use on this water heater. The purpose
of an insulation blanket is to reduce the standby heat loss encountered
with storage tank water heaters. This water heater meets or exceeds the
current edition of ASHRAE/IES 90.1 standards with respect to insulation
and standby loss requirement making an insulation blanket unnecessary.
Water heaters covered in this manual have been tested and approved for
installation at elevations up to 7,700 feet (2,347 m) above sea level. For
installation above 7,700 feet (2,347 m), the water heater’s Btu input should
be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea
level which requires replacement of the burner orifi ce in accordance with
the National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local
gas supplier for further information.
Failure to replace the standard orifi ce with the proper high altitude orifi ce
when installed at elevations above 7,700 feet (2,347 m) could result in
improper and ineffi cient operation of the water heater, producing carbon
monoxide gas in excess of the safe limits. This could result in serious
injury or death. Contact your local gas supplier for any specifi c changes
that may be required in your area.
WARNING
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions. Failure to follow these instructions can
result in fi re, asphyxiation , serious personal injury or death.
• Do not apply insulation to the top of the water heater, as this will
interfere with safe operation.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
• Do not allow insulation to come within 2" (5cm) of the fl oor to prevent
blockage of combustion air fl ow to the burner.
• Do not cover the instruction manual. Keep it on the side of the water
heater or nearby for future reference.
• Do obtain new warning and instruction labels from manufacturer for
placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it does
not sag, thereby obstructing combustion air fl ow.
The input reduction is primarily achieved by reducing the size of the main
burner orifi ces. To do this, the main burner orifi ces require replacement
with orifi ces sized for the particular installation elevation. Correct orifi ce
sizing and parts may be obtained from your distributor or manufacturer.
When ordering, be sure to state the model number and the altitude of
the location where the water heater is being installed.
Upon completion of derating of the heater, adjustment to the gas pressure
regulator may be required. See CHECKING THE GAS INPUT section
in this manual for inlet and manifold pressure requirements.
Also due to the input rating reduction required at high altitudes, the output
rating of the water heater is also reduced and should be compensated
for in the sizing of the equipment for application.
5
Page 6
CIRCULATING PUMP
A circulating pump is used when a system requires a circulating loop or
there is a storage tank used in conjunction with the heater. Refer to the
piping diagrams at rear of manual for electrical hookup information and
install in accordance with the current edition of the National Electrical
Code ANSI/NFPA No. 70.
Only all bronze circulating pumps are used with commercial water
heaters. Although circulators are oiled and operated by the manufacturer
some circulators must be oiled again before operating. Please refer to
manufacturer’s instructions.
INSTALLATION INSTRUCTIONS
REQUIRED ABILITY
INSTALLATION OR SERVICE OF THIS WATER HEATER REQUIRES
ABILITY EQUIV ALENT TO THAT OF A LICENSED TRADESMAN IN THE
FIELD INVOLVED. PLUMBING, AIR SUPPL Y, VENTING, ELECTRICAL
AND GAS SUPPLY WORK ARE REQUIRED.
LOCATING THE HEATER
WARNING
THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS
GAS WATER HEATERS IN ROOMS, GARAGES OR OTHER AREAS
WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE
DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED
OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL
ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER’S
PILOT OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION.
SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES
IF INSTALLED 18 INCHES (45.7 CM) OR MORE ABOVE THE FLOOR.
THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA
CANNOT BE AVOIDED.
DO NOT INST ALL THIS W A TER HEA TER DIRECTL Y ON A CARPETED
FLOOR. A FIRE HAZARD MA Y RESUL T. Instead the water heater must
be placed on a metal or wood panel extending beyond the full width
and depth by at least 3 inches (7.6 cm) in any direction. If the heater is
installed in a carpeted alcove or closet, the entire fl oor shall be covered
by the panel. Also, see the drain requirements.
THE WATER SUPPLY PRESSURE SHOULD NOT EXCEED 80 PSI
(551.58 kPa). IF THIS OCCURS, A PRESSURE REDUCING VALVE
WITH A BYPASS SHOULD BE PLACED ON THE SUPPLY TO THE
ENTIRE HOUSE IN ORDER TO MAINTAIN EQUAL HOT AND COLD
WATER PRESSURES.
THE HEATER SHOULD BE LOCA TED IN AN AREA WHERE LEAKAGE
FROM THE HEATER OR CONNECTIONS WILL NOT RESULT IN
DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF
THE STRUCTURE.
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE
DRAIN PAN SHOULD BE INSTALLED UNDER THE HEATER. Such
pans should be fabricated with sides at least 2" (5cm) deep, with length
and width at least 2" (5cm) greater than the diameter of the heater
and must be piped to an adequate drain. The pan must not restrict
combustion air fl ow.
Drain pans suitable for these heaters are available from your distributor
or Water Heater Parts Fulfi llment, 125 Southeast Parkway, Franklin,
TN 37068.
For appliance installation locations with elevations above 7700 feet
(610 meters), refer to HIGH ALTITUDE INSTALLATIONS section of this
manual for input reduction procedure.
CLEARANCES
These heaters are approved for installation on combustible fl ooring in a
closet having a ceiling 12" (30.5cm) above top cover and with clearances
to combustible construction of 6" (15.2cm) from fl ue or vent connector, 0"
(0cm) at the sides and rear and 5" (10.2cm) to front to prevent a possible
fi re hazard condition. A minimum of 4" (10.2cm) shall be allowed for
installation of serviceable parts.
HARD WATER
Where hard water conditions exist, water softening or the threshold type
of water treatment is recommended. This will protect the dishwashers,
coffee urns, water heaters, water piping and other equipment.
See MAINTENANCE section for details of tank cleanout procedure.
AIR REQUIREMENTS
REFER TO THE CURRENT EDITION OF THE "NATIONAL FUEL GAS
CODE ANSI Z223.1/NFPA 54.
KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MATERIALS, GASOLINE AND OTHER FLAMMABLES, VAPORS AND
LIQUIDS.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR VENTILATING
AIR.
WARNING
ATTIC AND/OR EXHAUST FANS OPERATING ON THE PREMISES
WITH A WATER HEATER CAN RESULT IN CARBON MONOXIDE
POISONING AND DEATH.
THIS HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT
SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.
WARNING
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER
POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED
ON OR ADJACENT TO THE HEATER. OPEN CONTAINERS OF
FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN
THE SAME ROOM WITH THE HEATER.
When installing the heater, consideration must be given to proper
location. Location selected should be as close to the stack or chimney
as practicable, with adequate air supply and as centralized with the
piping system as possible.
THE HEATER MUST NOT BE LOCA TED IN AN AREA WHERE IT WILL
BE SUBJECT TO FREEZING.
OPERATION OF THESE FANS CAN PRODUCE A NEGA TIVE DRAFT IN
THE AREA OF THE W A TER HEA TER PREVENTING THE PRODUCTS
OF COMBUSTION FROM EXHAUSTING THROUGH THE CHIMNEY
OR VENT PIPE.
The venting of the water heater should be inspected by a qualifi ed service
technician at the time of installation and periodically thereafter to ensure
a down-draft condition does not exist.
WARNING
FOR SAFE OPERATION PROVIDE ADEQUA TE AIR FOR COMBUSTION
AND VENTILATION. AN INSUFFICIENT SUPPL Y OF AIR WILL CAUSE
RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN
AIR CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE. SUCH
A CONDITION OFTEN WILL RESULT IN A YELLOW, LUMINOUS
BURNER FLAME, CAUSING CARBONING OR SOOTING OF THE
COMBUSTION CHAMBER, BURNERS AND FLUE TUBES AND
CREATES A RISK OF ASPHYXIATION.
6
Page 7
Where an exhaust fan is supplied in the same room with a heater,
suffi cient openings for air must be provided in the walls.
UNDERSIZED
OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM
THROUGH THE CHIMNEY, CAUSING POOR COMBUSTION.
SOOTING MAY RESULT IN SERIOUS DAMAGE TO THE HEATER
AND RISK OF FIRE OR EXPLOSION.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATING
AIR. ADEQUATE AIR FOR COMBUSTION AND VENTILATION MUST
BE PROVIDED FOR SAFE OPERATION.
UNCONFINED SPACE
In buildings of conventional frame, brick, or stone construction,
unconfi ned spaces may provide adequate air for combustion, ventilation
and draft hood dilution.
If the unconfi ned space is within a building of tight construction (buildings
using the following construction: weather stripping, heavy insulation,
caulking, vapor barrier, etc.), air for combustion, ventilation and draft hood
dilution must be obtained from outdoors. The installation instructions
for confi ned spaces in tightly constructed buildings must be followed to
ensure adequate air supply.
CONFINED SPACE
When drawing combustion and dilution air from inside a conventionally
constructed building to a confi ned space, such a space shall be provided
with two permanent openings, ONE IN OR WITHIN 12 INCHES (30.5cm)
OF THE ENCLOSURE TOP AND ONE IN OR WITHIN 12 INCHES
(30.5cm) OF THE ENCLOSURE BOTTOM. Each opening shall have a
free area of at least one square inch per 1000 Btuh (2,225mm
2
/Kw) of
the total input of all appliances in the enclosure, but not less than 100
square inches (645 square cm).
If the confi ned space is within a building of tight construction, air for
combustion, ventilation, and draft hood dilution must be obtained
from outdoors. When directly communicating with the outdoors or
communicating with the outdoors through vertical ducts, two permanent
openings, located in the above manner, shall be provided. Each opening
shall have a free area of not less than one square inch per 4000 Btuh
(8,900mm
horizontal ducts are used, each opening shall have a free area of not
less than one square inch per 2000 Btuh (4,450mm
2
/Kw) of the total input of all appliances in the enclosure. If
2
/Kw) of the total
input of all appliances in the enclosure.
VENTING
WARNING
THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST BE
FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULA TION
OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS
OF FIRE AND ASPHYXIATION.
This water heater must be protected from freezing downdrafts.
Remove all soot or other obstructions from the chimney that will retard
a free draft.
Type B venting is recommended with these water heaters.
This water heater must be vented in compliance with all local codes, the
current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and with the Category I Venting Table.
If any part of the vent system are exposed to ambient temperatures below
35 degrees F (2 degrees C) it must be insulated to prevent condensation.
• Do not connect the heater to a common vent or chimney with solid
SINGLE TEMPERATURE
MIXING VALVE APPLICATION FOR TWO TEMPERATURE WATER
WARNING
TEMPERATURE SETTING SHOULD NOT EXCEED SAFE
USE TEMPERATURE AT FIXTURES. SEE TEMPERA TURE
REGULATION ON PAGE 11. IF HIGHER PREHEAT
TEMPERATURES ARE NECESSARY TO OBTAIN
ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD
VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
CIRCULATING RETURN LINE CONNECTIONS
TEMPERED WATER LOOP, IF USED, CONNECT TO POINT "A".
STORED TEMPERATURE WATER LOOP, IF USED, CONNECT TO
COLD WATER INLET
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES.
CAUTION: IF BUILDING COLD WA TER SUPPL Y HAS A BACK-FLOW
PREVENTER, CHECK VALVE OR WATER METER WITH CHECK
VALVE, AN EXPANSION TANK MUST BE PROVIDED.
FIGURE 2.
7
Page 8
fuel burning equipment. This practice is prohibited by many local
building codes as is the practice of venting gas fi red equipment to
the duct work of ventilation systems.
• Where a separate vent connection is not available and the vent
pipe from the heater must be connected to a common vent with an
oil burning furnace, the vent pipe should enter the smaller common
vent or chimney at a point above the large vent pipe.
Excessive pressure may develop in such closed systems, causing
premature tank failure or intermittent relief valve operation. This is not a
warranty failure. An expansion tank or a similar device may be required
in the inlet supply line between the appliance and the meter or valve to
compensate for the thermal expansion of the water.
As water is heated, it expands (thermal expansion). In a closed system, the
volume of water will increase. As the volume of water increases, there will
be a corresponding increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure (leakage). This type
of failure is not covered under the limited warranty. Thermal expansion
can also cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure build up. The
temperature-pressure relief valve is not intended for the constant relief
of thermal expansion. This condition is not covered under the limited
warranty.
A properly-sized thermal expansion tank should be installed on all closed
systems to control the harmful effects of thermal expansion. Contact a
plumbing service agency or your retail supplier reguarding the installation
of a thermal expansion tank.
FIGURE 3.
VENT CONNECTION
Vent connections must be made to an adequate stack or chimney . Size
and install proper size vent pipe. Do not reduce pipe size to less than
that of the blower outlet.
Horizontal runs of vent pipe must have a minimum upward slope
toward the chimney of 1/4 inch per foot (2cm per meter). Dampers or
other obstructions must not be installed in between the heater and the
blower. Be sure that the vent pipe does not extend beyond the inside
wall of the chimney.
Where a continuous or intermittent back draft is found to exist, the
cause must be determined and corrected. A special vent cap may be
required. If the back draft cannot be corrected by the normal methods or
if a suitable draft cannot be obtained, a blower type fl ue gas exhauster
must be employed to assure proper venting and correct combustion.
THERMOMETERS (Not Supplied)
Thermometers should be obtained and fi eld installed as shown in Figure 3.
Thermometers are installed in the system as a means of detecting the
temperature of the outlet water supply.
COMBINATION WATER (POTABLE) HEATING
AND SPACE HEATING
1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
2. These water heaters connot be used in space heating applications
only.
3. Toxic chemicals, such as those used for boiler treatment, shall
NEVER be introduced into this system.
4. This unit may NEVER be connected to any existing heating system
or component(s) previously used with a non-potable water heating
appliance.
5. When the system requires water for space heating at temperatures
higher than required for domestic water purposes, a tempering valve
must be installed. Please refer to installation diagram on page 6 of
this manual for suggested piping arrangements.
CAUTION
A closed system will exist if a check valve (without bypass), pressure
reducing valve (without bypass), or a water meter (without bypass) is
installed in the cold water line between the water heater and street
main (or well).
MIXING VALVES
DANGER
Water heated to a temperature which will satisfy clothes washing, dish
washing, and other sanitizing needs can scald and cause permanent
injury upon contact. Short repeated heating cycles caused by small hot
water uses can cause temperatures at the point of use to exceed the
water heater’s temperature setting by up to 20°F (11°C).
Some people are more likely to be permanently injured by hot water than
others. These include the elderly , children, the infi rm and the physically/
mentally disabled. Table 1 shows the approximate time-to-burn
relationship for normal adult skin. If anyone using hot water provided by
the water heater being installed fi ts into one of these groups or if there
is a local code or state law requiring a certain water temperature at the
point of use, then special precautions must be taken.
In addition to
application a Mixing Valve should be installed at water heater (see Figure 3)
or at hot water taps to further reduce system water temperature.
Mixing valves are available at plumbing supply stores. Consult a Qualifi ed
Installer or Service Agency . Follow mixing valve manufacturer’s instructions
for installation of the valves.
8
using lowest possible temperature setting that
Water temperature over 125°F (52°C)
can cause severe 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 devices such as
mixing valves must be installed when
required by codes and to ensure safe
temperatures at fixtures.
(U.S. Government Memorandum, C.P .S.C., Peter L. Armstrong, Sept. 15, 1978)
WATER
Time for 1
TEMPERED WATER
COLD
INLET
OUTLET
Degree Burns
(Less Severe Burns)
HOT WATER
OUTLET
CHECK
VALV E
TO TANK
INLET
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
12” TO 15”
(30-38 cm)
CHECK
VALV E
MIXING
VALV E
FIGURE 4.
SYSTEM CONNECTIONS
The system installation must conform to these instructions and to the
local code authority having jurisdiction. Good practice requires that all
heavy piping be supported.
RELIEF VALVE
This water heater is equipped with a combination temperature-pressure
relief valve that complies with the standard for relief valves for hot water
supply systems Z21.22-CSA 4.4.
WATER HEATER, THE RELIEF VALVE(S) MUST NOT BE REMOVED
OR PLUGGED.
ASME ratings cover pressure relief capacities. ANSI ratings cover release
rate with temperature actuation.
In addition to the water heater relief valve, each remote storage tank
which may be used in conjunction with this appliance shall also be
installed with a properly sized, rated and approved combination
temperature (ANSI) and pressure (ASME) relief valve(s). This valve
shall comply with the standard for relief valves for hot water supply
systems Z21.22-CSA 4.4.
THE PURPOSE OF RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE
OR TEMPERATURE INTO THE STEAM RANGE, WHICH MAY CAUSE
SCALDING AT FIXTURES, TANK EXPLOSION, SYSTEM OR HEATER
DAMAGE. NO VALVE IS TO BE PLACED BETWEEN THE
VALVE AND TANK.
Your local code authority may have other specifi c relief valve requirements.
A DRAIN LINE MUST BE CONNECTED TO THE RELIEF VALVE TO
DIRECT DISCHARGE TO A SAFE LOCATION TO AVOID SCALDING OR
WATER DAMAGE. THIS LINE MUST NOT BE REDUCED FROM THE
SIZE OF THE VALVE OUTLET AND MUST NOT CONTAIN VALVES,
FOR SAFE OPERATION OF THE
WARNING
RELIEF
RESTRICTIONS NOR SHOULD IT BE LOCATED IN FREEZING AREAS.
DO NOT THREAD OR CAP THE END OF THIS LINE. RESTRICTED OR
BLOCKED DISCHARGE WILL DEFEAT THE PURPOSE OF THE VALVE
AND IS UNSAFE. DISCHARGE LINE SHALL BE INSTALLED TO ALLOW
COMPLETE DRAINAGE OF BOTH THE VALVE AND LINE.
See SERVICE INFORMATION section for procedure and precautions.
The type, size and location of the relief valves must be in accordance
with local codes. The location of the relief valve is shown in Figure 1.
The heater has a factory installed high temperature limit switch.
GAS PIPING
Contact your local gas service company to ensure that adequate gas service
is available and to review applicable installation codes for your area.
Size the main gas line in accordance with Table 4. The fi gures shown
are for straight lengths of pipe at 0.5" W.C. (.125 kPa) pressure drop,
which is considered normal for low pressure systems. Note: Fittings
such as elbows, tees and line regulators will add to the pipe pressure
drop. Also refer to the current edition of the National Fuel Gas Code.
WARNING
The minimum gas supply pressure for input adjustment is 6.0" W.C.(1.49
kPa) for natural gas.
THE HEATER IS NOT INTENDED FOR OPERATION AT HIGHER THAN
14" W.C. (3.49 kPa) SUPPLY PRESSURE. EXPOSURE TO HIGHER GAS
SUPPLY PRESSURE MAY CAUSE DAMAGE TO THE CONTROL WHICH
COULD RESULT IN FIRE OF EXPLOSION.
such as through improper testing of gas lines or emergency malfunction
of the supply system, the control must be checked for safe operation.
Make sure that the outside vents on the supply regulators and the safety
vent valves are protected against blockage. These are parts of the gas
supply system not the heater. V ent blockage may occur during ice storms.
IT IS IMPORT ANT T O GUARD AGAINST GAS V AL VE FOULING FROM
CONTAMINANTS IN THE GAS W AYS. SUCH FOULING MAY CAUSE
IMPROPER OPERATION, FIRE OR EXPLOSION.
IF COPPER SUPPLY LINES ARE USED THEY MUST BE INTERNALLY
TINNED AND CERTIFIED FOR GAS SERVICE. BEFORE ATTACHING THE
GAS LINE, BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE.
TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS SUPPLY
LINE, A SEDIMENT TRAP MUST BE INCORPORA TED IN THE PIPING
(SEE FIG. 5). THE SEDIMENT TRAP MUST BE READIL Y ACCESSIBLE
AND NOT SUBJECT TO FREEZING CONDITIONS. INSTALL IN
ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS
SUPPLIERS. REFER TO THE CURRENT EDITION OF THE NA TIONAL
FUEL GAS CODE.
To prevent damage, care must be taken not to apply too much torque
when attaching gas supply pipe to gas valve inlet.
Apply joint compounds (pipe dope) sparingly and only to the male threads
of pipe joints. Do not apply compounds to the fi rst two threads. Use
compounds resistant to the action of liquefi ed petroleum gases.
BEFORE PLACING THE HEATER IN OPERATION, CHECK FOR GAS
LEAKAGE.
the purpose in locating the leaks.
Use soap and water solution or other material acceptable for
DO NOT USE MA TCHES, CANDLES,
FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE.
FIGURE 5. GAS PIPING AND SEDIMENT TRAP INSTALLATION
PURGING
Gas line purging is required with new piping or systems in which air has
entered.
CAUTION
PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED
IN THIS TYPE GAS SERVICE. TO AVOID RISK OF FIRE OR
EXPLOSION, PURGE DISCHARGE MUST NOT ENTER CONFINED
AREAS OR SPACES WHERE IGNITION CAN OCCUR. THE AREA
MUST BE WELL VENTILA TED AND ALL SOURCES OF IGNITION MUST
BE INACTIVATED OR REMOVED.
GAS METER SIZE — NATURAL GASES ONLY
Be sure the gas meter has suffi cient capacity to supply the full rated gas
input of the water heater as well as the requirements of all other gas fi red
equipment supplied by the meter. If gas meter is too small, ask the gas
company to install a larger meter having adequate capacity.
GAS PRESSURE REGULATOR
The gas pressure regulator is built into the gas valve and is equipped to
operate on the gas specifi ed on model and rating plate. The regulator is
factory adjusted to deliver gas to burner at correct water column pressure
allowing for a nominal pressure drop through the controls.
The minimum gas supply pressure for input adjustment must not be less
than 6" w.c. (1.49 kPa) for natural gas.
Do not subject the combination gas valve to inlet gas pressures of more
than 14.0" w.c. (3.48 kPa) - natural gas. A service regulator is necessary
if higher gas pressures are encountered.
Gas pressure specifi ed in T able 5, refer to fl ow pressure taken at pressure
tap of automatic gas valve while heater is operating.
TABLE 6. GAS PRESSURE
Type of
Gas
Natural
InputManifold Pressure
75,100 Btu/hr
22 KW/hr
4.0 in. W.C.
1.12 kPa
OPERATION
It is recommended that a qualifi ed person perform the initial fi ring of the
heater. At this time the user should not hesitate to ask the individual any
questions which he may have in regard to the operation and maintenance
of the unit.
DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF VALVE
FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY SUPPLY
PRESSURE TESTING EXCEEDING 1/2 PSIG (3.45 kPa). GAS SUPPLY
LINE MUST BE CAPPED WHEN DISCONNECTED FROM THE HEATER
FOR TEST PRESSURES OF 1/2 PSIG (3.45 kPa) OR LESS. THE WATER
HEATER NEED NOT BE DISCONNECTED, BUT MUST BE ISOLATED
FROM THE SUPPLY PRESSURE TEST BY CLOSING THE MANUAL GAS
SHUTOFF VALVE.
TO OPERATE THE HEATER
1. Close the heater drain valve (Figure 1) by turning handle clockwise
.
2. Open a nearby hot water faucet to permit the air in the system to
escape.
3. Fully open the cold water inlet pipe valve (Figure 1) allowing the heater
and piping to be fi lled.
4. Close the hot water faucet as water starts to fl ow.
5. The heater is ready to be operated.
WARNING
DO NOT ATTEMPT TO OPERATE WATER HEATER WITH COLD
WATER INLET VALVE CLOSED.
NEVER OPERATE THE HEATER WITHOUT FIRST BEING CERTAIN IT IS
FILLED WITH WATER AND A TEMPERATURE AND PRESSURE RELIEF
VALVE IS INSTALLED IN THE RELIEF VALVE OPENING OF THE HEATER.
10
Page 11
HEATER WIRING
All electrical work must be installed in the United States in accordance with the current edition of the National Electrical Code ANSI/NFPA No.
70, in Canada, must conform to all local code authority having jurisdiction. AN ELECTRICAL GROUND IS REQUIRED TO REDUCE RISK OF
ELECTRICAL SHOCK OR POSSIBLE ELECTROCUTION.
If any of the original wire as supplied with the appliance must be replaced, use only type 105°C thermoplastic or equivalent, 250°C type F must
be used for the fl ame sensor leads and the spark ignition cable must be high voltage 250°C.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
FIGURE 6. WIRING DIAGRAM AND SCHEMATIC
11
Page 12
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING:If you do not follow these instructions exactly, a fi re or explosion
may result causing property damage, personal injury or loss of life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
A. This appliance does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the fl oor because
some gas is heavier than air and will settle on the fl oor.
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 fi re
department.
C. Use only your hand to push in the control buttons.
Never use tools. If the control buttons will not push
in, don’t try to repair them, call a qualifi ed service
technician. Force or attempted repair may result in a
fi re or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualifi ed service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
OPERATING INSTRUCTIONS
VACATIONVACATION
WARM
COOLER
!
WARNING
ABC
HOTTER
VERY
HOT
1. STOP! Read the safety information above
on this label.
2. Set the thermostat to the lowest setting by fi rst pressing
the COOLER
and HOTTER buttons together
and holding for 1 second. Then press the COOLER
button until the WARM indicator light appears.
3. Turn the "ON/OFF" swich on the blower control to the
"OFF" position.
4. This appliance is equipped with a device which
automatically lights the burner.
DO NOT TRY TO LIGHT THE BURNER BY HAND.
5. Wait fi ve (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow "B" in
the safety information above on this label.
If you don't smell gas, go to next step.
6. Turn on all electrical power to the appliance.
7. Set thermostat to desired setting by fi rst pressing the
COOLER
and HOTTER buttons together and
holding for 1 second. Then press the HOTTER
button.
8. If the appliance will not operate, follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your technician or gas supplier.
9. WATER TEMPERATURE ADJUSTMENT
is approximately 120°F (49°C).
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperatures.
WARNING: TURN OFF ALL ELECTRIC
POWER BEFORE SERVICING
TO TURN OFF GAS TO APPLIANCE
A. Set thermostat to the lowest setting.
B. Turn off all the electric power to the appliance
if service is to be performed.
12
Page 13
TEMPERATURE REGULATION
DANGER
THIS WATER HEATER IS EQUIPPED WITH AN ADJUSTABLE
THERMOSTAT TO CONTROL WATER TEMPERATURE. HOT WATER
TEMPERATURES REQUIRED FOR AUTOMATIC DISHWASHING AND
LAUNDRY USE CAN CAUSE PAINFUL SCALDING WITH POSSIBLE
SERIOUS AND PERMANENT INJURY. THE TEMPERATURE AT WHICH
INJURY OCCURS VARIES WITH THE PERSON’S AGE AND THE TIME
OF THE EXPOSURE. THE SLOWER RESPONSE TIME OF CHILDREN,
AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO
THEM. NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP,
OR TO DRAW THEIR OWN BATH WATER. NEVER LEAVE A CHILD
OR DISABLED PERSON UNATTENDED IN A BATHTUB OR SHOWER.
THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE
THE GENERAL PUBLIC DOES NOT HAVE ACCESS. IF A SUIT ABLE
AREA IS NOT A V AILABLE, A COVER SHOULD BE INST ALLED OVER
THE THERMOSTAT TO PREVENT TAMPERING. Suitable covers
are available through Water Heater Parts Fulfi llment, 125 Southeast
Parkway, Franklin, TN 37068.
(U.S. Government Memorandum, C.P .S.C., Peter L. Armstrong, Sept. 15,1978)
Time for 1st
Degree Burn
(Less Severe Burns)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
.
Display
Temperature Setting
C-Flashing = approx. 160°F (71°C)
C = approx. 150°F (66°C)
B = approx. 140°F (60°C)
A = approx. 130°F (54°C)
= approx. 120°F (49°C)
WARM = approx. 80°F (27°C)
A B C
FIGURE 7.
SETTING THE WATER HEATER TEMPERATURE AT 120°F (49°C)
(APPROX. "
DIAL) WILL REDUCE THE RISK OF SCALDS.
" MARK ON FACE OF THE TEMPERA TURE ADJUSTING
Some States or Provinces
require settings at specifi c lower temperatures.
Figure 6 shows the approximate water temperatures produced at various
thermostat settings. Short repeated heating cycles caused by small hot
water uses can cause temperatures at the point of use to exceed the
thermostat setting by up to 20°F (11°C). If you experience this type of
use you should consider using lower temperature settings to reduce
scald hazards.
Valves for reducing point of use temperature by mixing cold and hot
water are available. Also available are inexpensive devices that attach
to faucets to limit hot water temperatures. Contact a licensed plumber
or the local plumbing authority.
To avoid any unintentional changes in water temperature settings, the
control has a tamper resistant feature for changing the temperature
setting. To change the temperature setting follow these instructions:
It is recommended that lower water temperatures be used to avoid the
risk of scalding. It is further recommended, in all cases, that the water
temperature setting be set for the lowest temperature that satisfi es
your hot water needs. This will also provide the most energy effi cient
operation of the water heater. The water temperature adjustment was
factory set at the lowest temperature. Pressing the "COOLER" button
decreases temperature and pressing the "HOTTER"
button increases
the temperature
1. "Wake Up" the temperature indicators by holding down both the
"COOLER" and "HOTTER" temperature adjustment buttons at
the same time for one second (see Figure 6). One or two of the
temperature indicators will light up. These indicators will only remain
on for 30 seconds if no further buttons are pressed. After 30 seconds
the control will go back to "Sleep" mode.
2. Release both of the temperature adjustment buttons.
A. To decrease the temperature press and release the "COOLER"
button until desired setting is reached.
B. To increase the temperature press and release the "HOTTER"
button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or raise the
temperature setting. The button must be pressed and released for each
temperature change desired.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MAIN MANUAL GAS SHUTOFF VALVE
TO THE APPLIANCE. SEE FIGURE 1 (G).
13
Page 14
CHECKING VENTING
The following steps shall be followed with each appliance connected
to the venting system placed in operation, while any other appliances
connected to the venting system are not in operation.
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch, as
required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54
Installation codes and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.
3. So far as is practical, close all building doors and windows and all
doors between the space in which the water heater(s) connected
to the venting system are located and other spaces of the building.
Turn on all appliances not connected to the venting system. Turn
on all exhaust fans, such as range hoods and bathroom exhausts,
so they shall operate at maximum speed. Close fi replace dampers.
4. Follow the lighting instruction. Place the water heater being
inspected in operation. Adjust thermostat so appliance shall operate
continuously.
5. Test for vent system leakage after 5 minutes of main burner
operation.
6. After it has been determined that each appliance connected to the
venting system properly vents when tested as outlined above, return
doors, windows, exhaust fans, fi replace dampers and any other gas
burning appliance to their previous conditions of use.
7. If improper venting is observed during any of the above tests, the
venting system must be corrected.
WARNING
FAILURE TO CORRECT BACK DRAFTS MAY CAUSE AIR
CONTAMINATION AND UNSAFE CONDITIONS.
HIGH TEMPERATURE LIMIT SWITCH (ECO)
The water heater is equipped with a manual reset type high limit (Energy
Cutoff) sensor. The high limit switch interrupts the main burner gas fl ow
should the water temperature reach 195°F (90°C). The high limit switch
must be manually reset by turning the power to the water heater off for
5 seconds then back on and cannot be reset until the water temperature
drops below 120°F (49°C). It is important that a serviceman be called
to determine the reason for limit operation and thus avoid repeated
thermostat resetting.
FOR YOUR SAFETY AND SATISFACTORY OPERATION, IT IS
RECOMMENDED THA T THIS HEA TER BE CHECKED ONCE A YEAR
BY A COMPETENT SERVICE PERSON.
USERS OF THIS APPLIANCE SHOULD BE AWARE THAT GAS
COMPONENTS WEAR OUT OVER A PERIOD OF TIME. THE GAS
CARRYING COMPONENTS OF THIS APPLIANCE SHOULD BE
INSPECTED FOR PROPER OPERATION PERIODICALLY BY A
QUALIFIED SERVICE TECHNICIAN.
MAIN BURNER AND IGNITER
Check main burner (figure 7) at least every 6 months for proper
fl ame characteristics. The main burner should display the following
characteristics:
BURNER HEAD
ASSEMBLY
BURNER TUBE
ASSEMBLY
H.S.I.
ASSEMBLY
FIGURE 8. MAIN BURNER AND IGNITER ASSEMBLY
1. Provide complete combustion of gas.
2. Cause rapid ignition and carryover of fl ame across entire burner.
3. Give reasonably quiet operation during ignition, burning and extinction.
4. Cause no excessive lifting of fl ames from burner ports.
If preceding burner characteristics are not evident, check for accumulation
of lint or other foreign material that restricts or blocks the air openings
to the heater or burner.
WARNING
SOOT BUILD-UP INDICATES A PROBLEM THAT REQUIRES
CORRECTION BEFORE FURTHER USE. CONSULT WITH A
QUALIFIED SERVICE TECHNICIAN.
Should the main burner or burner air openings require cleaning, remove
the burner and clean with a soft brush. Clean main burner orifi ce with
a suitable soft material.
CHECK FOR GOOD FLOW OF COMBUSTION AND VENTILATING
AIR TO THE UNIT. MAINTAIN A CLEAR OPEN AREA AROUND THE
HEATER AT ALL TIMES. DO NOT STORE COMBUSTIBLES OR
FLAMMABLE LIQUIDS NEAR OR AROUND AN APPLIANCE.
THE ON/OFF SWITCH MUST HA VE BEEN IN THE OFF POSITION FOR
WARNING
AT LEAST 5 MINUTES. This waiting period is an important safety step.
Its purpose is to permit gas that may have accumulated in the combustion
chamber to clear. IF YOU DETECT GAS ODOR A T THE END OF THIS
PERIOD DO NOT PROCEED WITH LIGHTING. RECOGNIZE THAT
GAS ODOR, EVEN IF IT SEEMS WEAK, MA Y INDICATE PRESENCE
OF ACCUMULATED GAS SOMEPLACE IN THE AREA WITH RISK
OF FIRE OR EXPLOSION. SEE THE FRONT PAGE FOR STEPS TO
BE TAKEN.
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO
THE APPLIANCE.
SERVICE INFORMATION
The installer may be able to observe and correct certain problems
which may arise when the unit is put into operation. HOWEVER, it is
recommended that only qualifi ed servicemen, using appropriate test
equipment, be allowed to service the heater.
CHECKING GAS INPUT
For appliance installation locations with elevation above 2000 ft.(610m)
refer to HIGH ALTITUDE INSTALLATIONS section of this manual for
input reduction procedure.
With this heater in operation, determine whether it is receiving the full
rated input of gas. This may be done by timing the gas meter and
measuring gas pressure with a gauge or manometer. When the heater is
operating at full capacity (full gas input) it should consume approximately
1 cubic foot of gas in the time shown in table 6.
TABLE 7
INPUT CHECK TIME REQUIRED TO CONSUME 1 CU. FT. OF GAS
Type of GasBTU Per Cu. Ft.
Natural105050.3 Seconds
14
Time Required To Consume 1 Cu.
Ft. of Gas
Page 15
Use this formula to “clock” the meter. Be sure that other gas consuming
appliances are not operating during this interval.
3,600 X H = Btu/h
T
T = Time in seconds needed to burn one cubic foot of gas.
H = Heating value of gas in Btu’s per cubic foot of gas.
Btuh = Actual heater input rate.
Example:
T = 47.2 seconds/ft
H = 1,050 Btu/ft3 (natural gas)
Btuh = ?
3,600 X 1,050 = 75,100 Btu/h (22Kw)
50.3
3
• T o check UN•LIME for continued use or reuse, place some lime
scale or white chalk into a glass with a small amount of solution. If
the material is vigorously dissolved by the solution, the UN•LIME
can be reused. If not, the UN•LIME has been weakened and
should be replaced.
8. When deliming has been completed, the heater should be fl ushed
for 3 to 5 minutes with fresh water.
• Remove the deliming equipment, install the drain valve, open the
cold water inlet line and allow water to fl ow through heater and out
drain valve. Don’t forget to plug vent and cap opening in Flo-Jug.
9. When fl ushing is completed:
Compare the actual input rate to that given on the heater’s rating plate.
In the example, the full input rate should be 75,100 Btu/h (22 Kw) for
natural gas.
VENT SYSTEM
Examine the venting system every 6 months for obstructions and/or
deterioration of vent piping.
BLOWER MAINTENANCE
For safety and satisfactory operation it is recommended that the blower
be checked once a year by a competent service person.
1. MOTOR - The motor is factory oiled and sealed and requires no
further maintenance.
2. WHEEL - Wheel must be clean of soot, ash or any other coating
which inhibits either rotation or air fl ow. Remove all foreign material
from vent system.
3. The pressure switch is inside the blower control box and is connected
to the blower housing with a tube. This tubing should be soft and
pliable and show no sign of deterioration.
RELIEF VALVE
At least once a year the temperature and pressure relief valve should
be checked to ensure that it is in operating condition. (During manual
operation of this valve, avoid any contact with hot water and take
preventive steps for water damage). Lift the lever at the top of the valve
several times until the valve seats properly and operates freely.
WARNING
THE WA TER P ASSING OUT OF THE V AL VE DURING THIS CHECKING
OPERATION MAY BE EXTREMELY HOT. AVOID CONTACT AND
DISCHARGE SAFELY TO PREVENT WATER DAMAGE.
If the temperature and pressure relief valve on the heater discharges
periodically or continuously, a problem exists. This may be due to
unusually high water temperatures or pressures in the system, or to a
faulty relief valve. Contact your dealer or a qualifi ed service technician
to fi nd the cause of the problem and to correct it. This may also be due
to thermal expansion in a closed water supply system. Contact the water
supplier or local plumbing inspector on how to correct this situation. DO
NOT PLUG THE TEMPERATURE AND PRESSURE RELIEF VALVE.
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO
SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE TO THE
APPLIANCE.
HOT WATER ODOR
• Fill heater being certain to expel air from tank through a nearby
hot water faucet or, if removed, the relief valve opening.
• The heater relief valve can be washed in UN•LIME if it is limed.
• Replace relief valve if removed for deliming.
• Restore gas, oil or electrical supply to heater.
• Check for water leakage.
10. Flo-Jug cleanup:
• Allow scale to separate from UN•LIME and settle on bottom of
Flo-Jug.
• Pour off UN•LIME into plastic container and check for reuse.
• Rinse sediment from Flo-Jug.
DRAINING AND FLUSHING
It is recommended that the tank be drained and fl ushed
every 6 months to remove sediment which may build up
during operation. The water heater should be drained if
being shut down during freezing temperatures. To drain the
tank, perform the following steps:
1. Turn off the gas to the water heater at the manual gas
shut off valve.
2. Open a nearby hot water faucet until the water is no
longer hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to an
adequate drain or external to the building.
5. Open the water heater drain valve and allow all of the
water to drain from the tank. Flush the tank with water
as needed to remove sediment.
6. Close the drain valve, refi ll the tank, and restart the
heater as directed in this manual.
If the water heater heater is going to be shut down for an
extended period, the drain valve should be left open.
iMPORTANT: ccondensation may occur when refi lling the
On occasion, hot water may develop a strong odor. If this occurs drain
the heater completely, fl ush thoroughly, and refi ll. If the problem persists,
chlorination of the heater and replacement of the factory installed
magnesium anode with aluminum anode may correct the condition.
Occasionally water softener companies recommend removal of heater
anodes for odor reasons.
tank and should not be confused with a tank leak.
15
Page 16
CHECKLIST
Before contacting your dealer, check the water heater to see if the apparent
malfunction is caused by some external fault. Consulting this checklist
may eliminate the need for a repair call and restore hot water service.
NOT ENOUGH OR NO HOT WATER
1. Look for leaking or open hot water faucets. Check for excessive
usage.
2. Your gas company can check the gas input to the heater to see that
it is correct. An underfi red heater will not produce hot water at its
normal recovery rate.
3. If the heater was installed when incoming water temperatures were
warm, colder incoming temperatures will create the effect of less
hot water.
4. The thermostat water temperature adjusting dial may be set too low.
5. If you cannot determine the cause of the problems, contact your
dealer.
WATER TEMPERATURE IS TOO HOT
1. The thermostat water temperature adjusting dial may be set too high.
2. If lowering control setting does not reduce the water temperature
contact your dealer.
GAS SMELL AT THE HEATER
1. Close the main shutoff valve in the gas supply pipe near the heater,
see Figure 5 on page 9.
2. Call your gas company.
WATER LEAKAGE IS SUSPECTED
1. Check to see if the heater drain valve is tightly closed.
2. The apparent leakage might be condensation. In warm or humid
locations, condensation can accumulate and run from within the
heater or its piping.
• When a water heater is fi rst installed and fi lled, the bottom of the
tank might condense water. The water accumulation, if excessive,
can drip into the fl oor shield. Also, during normal operation there
may be occasions when large quantities of water are drawn,
chilling the tank bottom. This too can result in condensation.
• Condensation, appearing in the vent pipe (water dripping from
draft diverter) during heater operation is evidence of poor vent
action. Possible causes are too long a vent pipe or improper
chimney operation.
3. If the leakage is from the temperature and pressure relief valve or
its discharge pipe, it may represent a normal condition. However,
see RELIEF VALVE section on page 7. DO NOT PLUG THE
TEMPERATURE AND PRESSURE RELIEF VALVE. Also, the
leakage could be due to unusually high water pressures or
temperatures in the system, or to a faulty relief valve. Your dealer
or a qualifi ed service technician should be called to determine the
cause of the problem and to correct it.
4. If you cannot identify or correct the source of water leakage:
• Close the main shutof f valve in the gas supply pipe at the heater.
See Figure 5, page 9.
• Close the valve which feeds water to the cold water inlet at the
top of the heater.
• Contact your dealer.
WATER HEATER MAKES SOUNDS
1. Occasional excessive condensation, as explained under LEAKAGE,
can cause a sizzling sound as the moisture is vaporized by the gas
fl ame. This is a normal sound and may be disregarded.
2. Sediment and water scale accumulations may cause rumbling
noises. See MAINTENANCE or contact your dealer for details of
fl ushing the heater.
3. If you cannot identify or remedy the condition, contact your dealer.
CONDENSATION
Water vapor can condense on the cooler surfaces of the tank forming
droplets, these drip into the fi re or run out on the fl oor. This is common at
the time of startup after installation, during periods of time when incoming
water is very cold, or the heater may be undersized for the requirements.
Droplets from the bottom of the fl ue may be due to corrosive combustion
products or improper vent. Check with your dealer for more information.
ANODE ROD INSPECTION
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 useage, and water
softening methods can increase the rate of anode rod depletion
the anode rod is depleted, the tank will start to corrode, eventually
developing a leak.
Certain water conditions will cause a reaction between the anode
rod and the water. The most common complaint associated with the
anode rod is a "rotten egg smell" produced from the presence of
hydrogen sulfi de gas dissolved in the water. IMPORTANT: Do not
remove this rod permanently as it will void any warranties. The parts
list includes a special anode rodthat can be ordered if water odor or
discoloration occurs. NOTE: This rod may reduce but not eliminate
water odor problems.
Artifi cially softened water is exceedingly corrosive because the
process substitutes sodium ions for magnesium and calcium ions. The
use of a water softener may decrease the life of the water heater tank.
The anode rod should be inspected after a maximum of three years
and annually thereafter until the condition of the anode rod dictates its
replacement. NOTE: Artifi cially softened water requires the anode rod
to be inspected annually.
The following are typical (but not all) signs of a depleted anode rod:
* The majority of the rods diameter is less than 3/8"
* Signifi cant sections of the support wire (approx. 1/3 or more of
the anode rods length) are visible.
If the anode rod shows signs of either or both it should be replaced.
NOTE: Whether re-installing or replacing the anode rod, check for any
leaks immediately, correct if found.
In replacing the anode:
1. Turn off gas supply to the water heater.
2. Shut off the water supply and open a nearby hot water faucet to
depressurize the water tank.
3. Drain approximately 5 gallons of water from the tank (Refer to
"Draining and Flushing" for proper procedures). Close drain
valve.
4. Reomve old anode rod.
5. Use Tefl on® tape or approved pipe sealant on threads and install
new anode rod.
6. Turn on water supply and open nearby hot water faucet to purge
air from water system. Check for any leaks and immediately
correct any if found.
16
. Once
Page 17
Restart the water heater as directed under "Operating Your Water
Heater." See the repair parts illustration for anode rod location.
Figure 9
SERVICE AND REPAIR
The water heater requires no special care other than the normal
maintenance as noted above. If you are having a problem with your
water heater, before calling for service please refer to the following
TROUBLESHOOTING sections. If service becomes necessary,
contact your dealer, installer or an authorized service agent. Do not
attempt to repair the water heater yourself. Any work performed by
unauthorized personnel may void the warranty.
TROUBLESHOOTING
Water heaters may exhibit problems that are unrelated to a malfunction
of the water heater itself. The following information and tables may
serve to answer your question about a problem that you are having
without having to call a service agent.
For your safety, water heater service should be performed only
by a qualifi ed service technician. Read the GENERAL SAFETY
INFORMATION section fi rst.
WATER HEATING CYCLE
(GAS AND ELECTRIC POWER ARE ON,“OFF/ON” SWITCH IS
ON)
1) CALLS FOR HEAT
A) THERMOSTAT SENSES NEED FOR HEATING WATER
B) CONTACTS CLOSE IN THERMOSTAT, POWER (115 VAC)
FLOWS TO BLOWER MOTOR
2) BLOWER MOTOR ROTATES BLOWER WHEEL
A) BLOWER WHEEL SPEED INCREASES
B) WHEEL SPEED INCREASES, AIR PRESSURE SWITCH
CONTACTS CLOSE
3) 120 VAC FLOWS TO HOT SURFACE IGNITER
NOTE: THE CONTROL MODULE ON THIS UNIT WILL TRY A
MAXIMUM OF THREE TIMES TO LIGHT THE UNIT. CYCLE CAN
BE RESTARTED AT ANY TIME BY TURNING OFF SWITCH AND
THEN TURNING BACK ON. IF UNIT HAS GONE THROUGH THREE
CYCLES AND DID NOT LIGHT, THEN REPAIRMAN SHOULD BE
CALLED TO CHECK OPERATION OF HEATER.
4) MAIN BURNER IGNITES
A) GAS FLOWS TO MAIN BURNER PORTS AND IS IGNITED
5) GAS VALVE SENSES BURNER FLAME
6) BURNER HEATS WATER
A) BURNER HEATS WATER TO THERMOSTAT SETTING
B) CONTACTS IN THERMOSTAT OPEN,
C) CYCLE IS COMPLETED
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Page 18
TROUBLESHOOTING
For your safety, water heater service should be performed only by a qualifi ed service technician.
Read the GENERAL SAFETY INFORMATION section fi rst
.
PROBLEM
NOT ENOUGH OR NO HOT WATER
CONDENSATIONA) Water on the fl oor under heater.See "Condensation"
WATER LEAKS
LEAKING T&P VALVE
HOT WATER ODORS OR COLOR
(Refer to ANODE ROD)
POSSILBE MALFUNCTION
1) Blower will not run.
A) "ON/OFF" control switch turned off.Turn switch to the on position.
B) Blower unplugged.Plug blower back into 115 vac. outlet.
C) No power at outlet.Repair service to outlet.
D) "ON/OFF" switch defective.Replace switch.
E) Control harness defective.Replace control harness.
F) Blower motor defective.Replace blower and motor.
2) Blower running, burner not onReplace switch.
A) Fan not running fast enough to close
air switch contacts.
B) Air pressure switch defective.Replace switch.
C) Gas valve defective.Replace gas control valve/thermostat.
D) Control harness defective.Replace harness.
E) Igniter defective.Replace ignitor.
F) Unit has completed three trials to light
and fail.
3) Thermostat problems
A) Thermostat set too low.Set temperature control higher.
B) Thermostat or ECO defective.Replace thermostat.
C) High limit control circuit open.Replace high limit control.
4) Others
A) Heater undersized.Reduce hot water usage.
B) Low gas pressure.Contact a qualifi ed person for service.
C) Incoming water is unusually cold.Allow more time for heater to re-heat.
D) Leaking hot water pipes or fi xtures.Have plumber check and repair leaks.
Improperly sealed, hot or cold supply
connections, relief valve, drain valve or
thermostat threads.
Leakage from other appliances or water
lines.
Condensation of fl ue products.Refer to "CONDENSATION"
Thermal expansion in closed water sys-
tem
Improperly seated valvesCheck relief valve for proper operation
High sulfate or mineral content in water
supply or iron or sulfate reducing bacteria
in water supply
SERVICE TO BE PERFORMED
Check for low voltage, less than 102 vac.,
have service checked and repaired.
Reset cycle by turning switch off and then
back on. If unit does not light in three trials, contact a qualifi ed person for service.
Turn off heater & water, repair unit.
Inspect other appliances near water
heater.
Install thermal expansion tank (DO NOT
PLUG T&P V ALVE)
(DO NOT PLUG T&P VALVE)
Drain and fl ush heater thoroughly, chlori-
nate, refi l and fl ush again then chlorinate
water supply.
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Page 19
WARNING: DO NOT BY-PASS ANY CONTROLS TO MAKE HEATER OPERATE.
OPERATE ONLY AS WIRED FROM FACTORY.
TROUBLE SHOOTING
Please check guidelines below. For your safety, water heater service should be performed only by a qualifi ed service technician.
Read the GENERAL SAFETY INFORMATION section fi rst.
#LED STATUSPROBLEMSOLUTION
1 Ensure the wall outlet (power supply) is properly
The gas control valve/thermostat
1
2
3
has sensed inadequate or no earth
ground.
The gas control valve/thermostat
has sensed reversed polarity in the
120 VAC power supply.
Pressure switch circuit remaining
closed for more than 5 seconds
after heating cycle begins.
Blower may not start in this
condition.
grounded.
2 Ensure all ground connections/wires on the water
heater are securely connected.
1 Ensure the wall outlet/power supply is properly wired.
2 Ensure all internal 120 VAC wiring connections and
wiring harness have no reversed wires. 120 VAC "hot"
wire must connect to the on/off switch.
1 Ensure air pressure switch circuit wiring is correct and
the air pressure switch is not jumpered.
2 Replace the air pressure switch.
1 Ensure the air pressure switch sensing tube is properly
connected at both ends and is not kinked or damaged.
Pressure switch circuit remains
open longer than 5 seconds after
4
5
6
the blower is energized.
Blower may run continuously in
this condition.
The gas control valve/thermostat
has detected an open igniter circuit.
Ignition/fl ame failure.
The gas control valve/thermostat
has reached the maximum number
of retries (3) for ignition and is
currently locked out for one hour.
Cycle the power to the water heater
off and on to reset.
2 Ensure the correct size of vent and intake air pipe (direct
vent products) was used per the installation instructions
in the manual that came with the water heater.
3 Ensure maximum number of elbows or maximum
equivalent feet of vent or intake air pipe has not been
exceeded per the installation instructions in the manual
that came with the water heater.
4 Ensure there are no obstructions in the vent or intake air pipe.
1 Check wiring to the hot surface igniter assembly -
replace igniter assembly if wiring is damaged or worn.
2 Check resistance of the igniter at igniter assembly
plug - should be between 11 and 18 ohms at room
temperature (77° F at plug end) - replace igniter if open
or shorted.
3 Check igniter assembly plug and the socket on the gas
control valve/thermostat for good connection.
4 Replace igniter assembly if the plug is worn or damaged.
5 Replace the gas control valve/thermostat if the igniter
assembly socket on the bottom of the control is worn or
damaged.
1 Ensure fl ame sensor is making good contact with the
burner fl ame and ensure fl ame is steady. Also ensure
supply and manifold gas pressures are within the
requirements in the installation manual.
2 Gas supply is turned off - pressure is too low.
3 Ensure the fl ame sensor is clean - use fi ne steel wool
to clean the fl ame sensor.
4 Check igniter assembly plug and the socket on the
bottom of the gas control valve/thermostat for good
connection. Replace igniter assembly if the plug is worn
or damaged. Replace the gas control valve/thermostat if
socket is worn or damaged.
5 Replace igniter assembly.
19
Page 20
#LED STATUSPROBLEMSOLUTION
10
11
12
13
14
7
8
9
Self diagnostic check has detected
a problem with the gas valve driver
circuit, internal microprocessor, or
other internal circuits.
The gas control valve/thermostat
has sensed main burner fl ame out
of proper sequence.
Water temperature in the tank has
exceeded 195° F and has activated
the ECO (energy cut off) high
temperature limit.
Self diagnostic check has detected
that one or both of the temperature
adjust buttons are stuck.
Self diagnostic check has detected
the water temperature sensor
(located in the control valve's
immersion probe) is either open or
shorted.
Self diagnostic check has detected
the FV (fl ammable vapor) sensor is
either open or shorted.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 If any of these error codes persist or cannot be cleared
- replace the gas control valve/thermostat.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if this error
code persists.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if the error
code persists.
1 Press and release both temperature adjust buttons
several times - cycle water heater power off and on.
2 Replace the gas control valve/thermostat if the error
code persists.
1 Turn the power off for 10-20 seconds then on again to
clear these error codes.
2 Replace the gas control valve/thermostat if the error
code persists.
1 Turn off power to the water heater. Ensure all FV
sensor wiring, the ignitor assembly plug, and the ignitor
assembly socket on the bottom of the Intellivent control
are making good contact. Repair or replace any
worn/damaged components that are not making good
connection.
15
16
Self diagnostic check has detected
the presence of fl ammable vapors
from the FV (fl ammable vapor)
sensor.
The gas control valve/thermostat
has detected the air pressure switch
circuit is opening repeatedly during
one heating cycle.
LDO (Lint, Dust, and Oil) lockout
condition.
2 Replace the FV sensor.
1 Do not touch any electrical switch, do not use any
phone in your building, and do not try to light any
appliance.
2 Smell around the water heater to ensure there are
no gas leaks at the gas control valve/thermostat, in
the supply gas line(s), or any other type of fl ammable
vapor(s) in the area.
3 Carefully inspect the area surrounding the water heater
for any substances such as gasoline, paint, paint
thinners, varnish, or cleaners that could emit fl ammable
vapors. Remove anything that can potentially emit
fl ammable vapors from the area and store it properly in
a different location.
4 Call the technical information support phone number
shown on the water heater labeling for further
assistance.
1 On models equipped with a dilution air intake screen on
the blower assembly - check/clean this screen.
2 On models equipped with a combustion air intake
screen on the base ring (bottom) of the water heater check/clean the screen.
3 Ensure intake air screen(s) on models so equipped are