State Water Heaters FVIR Installation Instructions And Use & Care Manual

Page 1

Installation Instructions and Use & Care Guide

RESIDENTIAL GAS WATER HEATERS

FVIR

(FLAMMABLE VAPOR IGNITION RESISTANT)

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

GAS WATER HEATER

FOR POTABLE WATER HEATING ONLY.

NOT FOR USE IN MOBILE HOMES.

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

• Safety Instructions

• Installation

• Operation

INSTALLER:

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

OWNER:

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

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

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

For more information, contact the your gas supplier.

If a gas leak is detected, follow the “WHAT TO DO IF YOU SMELL GAS” instructions.

• Care and Maintenance

• Troubleshooting

• Parts List

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

— Do not store or use gasoline or other

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

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

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

IF YOU ARE UNSUCCESSFUL, CONTACT RESIDENTIAL TECHNICAL ASSISTANCE AT 1-800-365-0024 OR WWW.STATEWATERHEATERS.COM.

PRINTED IN THE U.S.A 0910 PART NO. 319556-000

— Installation and service must be

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

LOW LEAD

COMPLIANT

Page 2

TABLE OF CONTENTS

Water Heater Safety .......................................................................................................................................................................... 1 -2

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

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

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

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

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

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

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

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

Location Requirements ......................................................................................................................................................... 6-7

Site Locations .......................................................................................................................................................................... 7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Water System Piping ..................................................................................................................................................................... 15-17

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

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

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

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

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

Operating Your Water Heater ....................................................................................................................................................... 19-21

Lighting Instructions ............................................................................................................................................................... 19

Checking the Draft ................................................................................................................................................................. 20

Burner Flames ....................................................................................................................................................................... 20

Emergency Shutdown ............................................................................................................................................................ 20

Water Temperature Regulation ......................................................................................................................................... 20-21

Water Temperature Adjustment ............................................................................................................................................. 21

Operating Modes and Settings .............................................................................................................................................. 21

Electrical Connections/Wiring Diagram ................................................................................................................................. 22

Operational Conditions ..................................................................................................................................................... 23-24

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

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

Temperature and Pressure Relief Valve ................................................................................................................................ 25

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

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

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

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

Replacing the Pilot/Igniter - Flame Sense Assembly ............................................................................................................. 26

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

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

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

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

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

Removing and Replacing the Gas Control Valve/Thermostat .......................................................................................... 28-29

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

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

Status Light Troubleshooting Flowchart .................................................................................................................................... 31-32

Sequence of Operation Chart ........................................................................................................................................................... 33

Repair Parts Illustration ................................................................................................................................................................ 34-35

Notes .... .......................................................................................................................................................................................... 36-38

Warranty .......................................................................................................................................................................................... 39-40

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SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your water heater to warn you and

others of a potential hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

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

DANGER indicates an imminently hazardous situation which, if not avoided, will

DANGER

WARNING

CAUTION

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

Do not use this appliance if any part has been under water. Immediately call a qualified person. Water heaters subjected to flood conditions or any time the gas controls, main burner or pilot have been submerged in water require replacement of the entire water heater. The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances

known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

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

result in death or serious injury.

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

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

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

IMPORTANT DEFINITIONS

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

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

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

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

FLAMMABLES

Read and follow water heater warnings and instructions.

Flammable Vapors

SAFETY PRECAUTIONS

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

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

WARNING

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Fire or Explosion Harzard

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

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

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

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

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TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe

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

* INSTALL IN ACCORDANCE WITH LOCAL CODES.

* DRIP LEG AS REQUIRED BY LOCAL CODES.

TO VENT

TERMINATION ON

ROOF

INSTALL THERMAL EXPANSION

TANK IF WATER HEATER IS

INSTALLED IN A CLOSED

WATER SYSTEM

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

(S) GAS CONTROL VALVE/

THERMOSTAT

HOT

LOW

VACUUM RELIEF

VALV E

*INSTALL PER

LOCAL CODES

GAS CONTROL/TEMPERATURE KNOB

(U) MANIFOLD/BURNER ASSEMBLY

IGNITER WIRE

PILOT ASSEMBLY

STATUS

OFF

•

VAC

STATUS LIGHT

HOT

MAIN BURNER

S Gas Control Valve/Thermostat T Drain Valve U Pilot and Main Burner V Flue W Metal Drain Pan X Igniter Wire Y Base-Ring Filter Z FV Sensor AA Transformer BB Flue Damper

* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.

MANIFOLD TUBE

MANIFOLD DOOR

DISCHARGE PIPE

(DO NOT CAP OR PLUG.)

6” MAXIMUM

AIR GAP

FLOOR DRAIN

NOTE: POWER CORD NOT SHOWN FOR CLARITY

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INSTALLING YOUR GAS WATER HEATER

Important Information About This Water Heater

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

Consumer Information

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

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

54)-current edition. This is available from the following:

CSA America, Inc. 8501 East Pleasant Valley Road Cleveland, OH 44131

National Fire Protection Agency 1 Batterymarch Park Quincy, MA 02269

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

Consumer Responsibilities

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

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

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

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

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

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

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

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

Unpacking the Water Heater

WARNING

Excessive Weight Hazard

Use two or more people to move and install the water heater.

Failure to do so can result in injury (including back injury).

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

• Remove exterior packaging and place installation components aside.

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

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

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

Location Requirements

WARNING

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home.

Doing so can result in carbon monoxide poisoning and death.

The Flammable Vapor (FV) Sensor is designed to reduce the risk of flammable vapor-related fires. Flammable liquids (such as gasoline, solvents, propane, etc,) emit flammable vapors which can be ignited by a gas water heater’s spark igniter or main burner. The resulting flashback and fire can cause death or serious burns to anyone in the area.

This heater is equipped with an FV sensor for detecting the presence of flammable vapors. When the sensor detects those vapors, the unit will shut down and not operate. Should this happen, please refer to the troubleshooting guide. Even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited, gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance. In the event the FV Sensor does not prevent the ignition of flammable vapors, the FVIR System is designed to reduce the risk of flammable vapor-related fires.

Page 7

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

FV Sensor

FIGURE 1.

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

WARNING

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other flammable

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

Read and follow water heater warnings and instructions

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

Flammable Vapors

WARNING

Fire or Explosion Hazard

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

• Improper use may result in fire or explosion.

• Maintain required clearances to combustibles.

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

Site Location

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

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

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

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

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

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

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

54)-current edition.

Page 8

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

DISCHARGE PIPE (DO NOT CAP OR PLUG)

METAL DRAIN PAN

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

PIPED TO AN ADEQUATE DRAIN

6” MAXIMUM AIR GAP

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

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

EXHAUST FAN

REVERSE FLOW OF GASES

FIGURE 3.

Clearances and Accessibility

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

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

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

• Figure 4 may be used as a reference guide to locate the specific clearance locations. A minimum of 24 inches of front clearance should be provided for inspection and service.

VENT

BACK

SIDES

TOP

CEILING

FIGURE 2.

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

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

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

TOP VIEW

FRONT 24” MINIMUM FOR SERVICE

FIGURE 4.

SIDES

State of California

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

Page 9

GAS SUPPLY

WARNING

Explosion Hazard

• Use a new CSA approved gas supply line.

• Install a shut-off valve.

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

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

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

Gas Requirements

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

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

as an indication of leaking gas.

Gas Piping

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

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

NOTE: Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases (See Figure 5.)

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

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

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

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

Correct any leak found.

MANUAL GAS SHUT-OFF VALVE

GROUND JOINT UNION

CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT

3” MINIMUM

DRIP LEG

SUITABLE DRAIN

FIGURE 5.

DISCHARGE PIPE

(DO NOT CAP

OR PLUG)

6” MAXIMUM AIR GAP

Gas Pressure

WARNING

Explosion Hazard

• Gas leaks can not always be detected by smell.

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

• For more information, contact your gas supplier.

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

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

adjustment.

Gas Pressure Testing

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

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

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

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

Page 10

LP Gas Only

WARNING

Explosion Hazard

Have a qualified person make sure L.P. gas pressure does not exceed 13” water column.

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

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

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

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

Page 11

COMBUSTION AIR & VENTILATION

WARNING

Carbon Monoxide Warning

Water heater must be vented to outdoors.

Vent must be installed by a qualified technician using the installation instructions.

Examples of a qualified technican include: gas technicians, authorized gas company personel, and authorized service persons.

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

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

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

• beauty shops

• photo processing labs

• buildings with indoor pools

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

• water heaters installed near chemical storage areas

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

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

Unconfined Space

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

TABLE 3

Minimum

BTUH Input

30,000 188 9 x 21

45,000 281 14 x 20

60,000 375 15 x 25

75,000 469 15 x 31

90,000 563 20 x 28

105,000 657 20 x 33

120,000 750 25 x 30

135,000 844 28 x 30

IMPORTANT:

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

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

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

Square Feet with 8’ Ceiling

Typical Room

with 8’ Ceiling

Confined Space

For the correct and proper operation of this water heater, ample air must be supplied for the combustion, ventilation, and dilution of flue gases. Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 6.

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

1. All air from inside the building.

2. All air from outdoors.

Page 12

PERMANENT

OPENINGS TO

HE OUTSIDE OR

ADDITIONAL

ROOMS WITHIN

THE BUILDING

12” MAXIMUM

CLOSET

OTHER

CONFINED

SPACE

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

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

The size of each of the two openings is determined by the method in which the air is to be provided. Refer to Table 4 to calculate the minimum free area for each opening. Figures 8, 9, 10 and 11 are typical examples of each method.

Louvers and Grilles

12” MAXIMUM

FIGURE 6.

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

All Air from Inside the Building

When additional air is to be provided to the confined area from additional room(s) within the building, the total volume of the room(s) must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area. If you are unsure that the structure meets this requirement, contact your local gas utility company or other qualified agency for a safety inspection. Each of the two openings shall have a minimum free area of 1 square inch per 1,000 BTUH of the total input rating of all gas utilization equipment in the confined area, but not less than 100 square inches (Figure 7).

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

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

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

TABLE 4

CONFINED

SPACE

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

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

PERMANENT

OPENINGS

1 SQUARE INCH/1000

BTUH

(MINIMUM

100 SQ. IN.)

FIGURE 7.

All Air from Outdoors

Opening Source

*D irec t to out doo rs 1 sq. in, per 4000 BTUH Fi gur e 8

Ver tic al Duc ts 1 sq. in, per 4000 BTUH Fi gur e 9

Ho r izo nta l D uct s 1 sq. in, per 2000 BTUH Fi gur e 10

Si ngl e O pen ing 1 sq. in, per 3000 BTUH Fig ure 11

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

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

These openings connect directly with the outdoors through

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

Minimum Free Area

Per Opening (sq. in.) Reference Drawing

outside wall.

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

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

Page 13

GABLE VENT

TO OUTDOORS

INSTALL ABOVE

INSULATION

CONFINED

SPACE

ALTERNATE

AIR INLET

1 SQ. INCH PER

4000 BTUH

ALL AIR FROM OUTDOORS: INLET AIR FROM VENTILATED

CRAWL SPACE/OUTLET AIR TO VENTILATED ATTIC

OUTLET

AIR TO

ATTIC 1 SQ.

INCH PER

4000 BTUH

INLET AIR FROM

THE CRAWL SPACE

OPEN

FOUNDATION

VENT

FIGURE 8.

GABLE VENT TO OUTDOORS

INSTALL ABOVE INSULATION

OUTLET AIR

CONFINED SPACE

ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC

TO ATTIC 1 SQ. INCH PER 4000 BTUH

INLET AIR DUCT 1 SQ. INCH PER 4000 BTUH

12” MAXIMUM

FIGURE 9.

1 SQ. INCH PER 2000 BTUH

ALTERNATIVE OPENING LOCATION

CONFINED

SPACE

ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING

1 SQ. INCH

PER 3000 BTUH

FIGURE 11.

Vent Pipe System

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

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

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

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

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

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

CONFINED SPACE

ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS

OUTLET

INLET

1 SQ. INCH PER 2000 BTUH

FIGURE 10.

OUTDOOR

AIR DUCTS

Draft Hood Installation

Draft hood

Flue Damper

Draft hood Leg Tips*

* Twist or bend the leg tips to secure the draft hood to the flue damper

FIGURE 12.

Page 14

Align the legs of the draft hood with the slots provided. Insert the draft hood leg tips into slots on the flue damper’s flange as shown in Figure 12. Secure the draft hood by twisting or bending the leg tips. See Figure 12. Do not alter the draft hood in any way. If you are replacing an existing water heater, be sure to use the new draft hood supplied with the water heater.

Vent Pipe Size

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

Vent Connectors

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

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

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

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

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

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

When installing a vent connector, please note the following (See Figures 13-15):

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

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

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

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

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

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

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

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

Chimney Connection

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

codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edition.

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

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

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

• The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney (Figure 13).

LISTED LINED CHIMNEY

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

DO NOT EXTEND VENT BEYOND EDGE OF CHIMNEY

VENT CONNECTOR

SUPPORT STRAP

MAINTAIN CLEARANCE*

3 FT. MINIMUM

SEAL

SLOPE

UP 1/4 IN.

PER FT.

MINIMUM

CHIMNEY TERMINATION VENT SYSTEM

FIGURE 13.

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

Vertical Exhaust Gas Vent

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

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

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

Gas vents must be supported to prevent damage, joint separation, and maintain clearances to combustible materials (Figures 14 and 15).

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

An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent (Figure 13).

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

Figures 13-15 are examples of vent pipe system installations and may or may not be typical for your specific application. Consult the “National Fuel Gas Code”,

Page 15

NFPA 54, ANSI Z223.1-current edition and the guidelines set forth by prevailing local codes.

LISTED VENT CAP

WATER SYSTEM PIPING

Piping Installation

2 FT. MINIMUM ABOVE ANY OBJECT

3 FT. MINIMUM

SUPPORT STRAP

*MAINTAIN CLEARANCE

VENT

CONNECTOR

SLOPE UP

1/4 IN. PER FT.

MINIMUM

VERTICAL GAS VENT SYSTEM WITH

TYPE B DOUBLE WALL VENT PIPE.

FIGURE 14.

MAINTAIN MANUFACTURER’S SPECIFIED MINIMUM CLEARANCE

SUPPORT STRAP

*MAINTAIN CLEARANCE

VENT

CONNECTOR

SLOPE UP

1/4 IN. PER FT.

MINIMUM

Maintain vent pipe clearance requirements to local, state

SEAL

VENTING THROUGH A CHIMNEY WITH

TYPE B DOUBLE WALL VENT PIPE.

FIGURE 15.

WITHIN 10 FT. HORIZONTALLY

TYPE B DOUBLE WALL VENT PIPE

**MAINTAIN SPECIFIED CLEARANCE

LISTED VENT CAP

**MAINTAIN SPECIFIED CLEARANCE

VENT CONNECTOR

UNUSED CHIMNEY FLUE OR MASONRY ENCLOSURE

and/or the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)current edition.

NFPA 211, Standard for Chimneys, Fireplaces, Vents,

** and Solid Fuel-Burning Appliances states that these

chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly. Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections.

Piping, fittings, and valves should be installed according to the installation drawing (Figure 16). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation.

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

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

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

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

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

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

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

3. The manufacturer of this water heater recommends installing a mixing valve or an anti-scald device in the domestic hot water line as shown in Figure 17. These valves reduce the point-of-use temperature of the water by mixing cold and hot water and are readily available for use.

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

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

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

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

Page 16

1” MINIMUM

METAL DRAIN PAN

HOT WATER OUTLET

SUITABLE DRAIN

IN A CLOSED SYSTEM USE A THERMAL EXPANSION TANK

COLD WATER SUPPLY TO FIXTURES

PRESSURE REDUCING VALVE WITH BYPASS

COLD WATER INLET

COLD WATER INLET VALVE (SHUT-OFF VALVE)

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

DISCHARGE PIPE (DO NOT CAP OR PLUG)

MASSACHUSETTS: INSTALL DRAIN LINE 3/4” ID MINIMUM

A VACUUM RELIEF IN COLD

WATER LINE PER SECTION

19 MGL 142.

6” MAXIMUM AIR GAP

Please note the following:

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

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

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

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

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

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

UNTEMPERED HOT WATER

HOT

WATER

OUTLET

FIGURE 16.

TEMPERED WATER

TO FIXTURES

COLD

WATER

INLET

MIXING VALVE

(SET TO 120°F)

FOLLOW THE MIXING

VALVE MANUFACTURER’S

INSTRUCTIONS

FIGURE 17.

Closed System/Thermal Expansion

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

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

Page 17

Temperature and Pressure Relief Valve

Explosion Harzard

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

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

• Can result in overheating and excessive tank pressure.

• Can cause serious injury or death.

TEMPERATURE AND PRESSURE (T&P)

DISCHARGE PIPE (DO NOT CAP OR PLUG)

DRAIN LINE 3/4” ID

1” MINIMUM

METAL DRAIN PAN

DRAIN

FIGURE 18.

For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF VALVE” (see Figure 17). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22. The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater. The valve’s relief pressure must not exceed the working

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

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

The Temperature & Pressure Relief Valve:

• Must not be in contact with any electrical part.

• Must be connected to an adequate discharge line.

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

MINIMUM

6” MAXIMUM AIR GAP

The Discharge Line:

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

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

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

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

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

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

1. Locate the temperature and pressure relief valve on the water heater (also known as a T&P relief valve). See Figure 18.

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

3. Spread the slit open and fit the insulation over the T&P relief valve. See Figure 19. Apply gentle pressure to the insulation to ensure that it is fully seated on the T&P Relief Valve. Once seated, secure the insulation with duct tape. IMPORTANT: The insulation or tape should not block or cover the T&P relief valve drain opening. Also, the insulation or tape should not block or hinder access to the manual relief lever (Figure 19).

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

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

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

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

8. Add additional sections of pipe insulation as needed.

T&P RELIEF VALVE INSULATION

MANUAL RELIEF LEVER

T&P RELIEF VALVE

FIGURE 19.

Page 18

IMPORTANT INFORMATION ABOUT THIS WATER HEATER

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

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

Installation Checklist

Water Heater Location

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

□ Installation area free of corrosive elements and

flammable materials.

□ Centrally located with the water piping system (For new

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

□ Located indoors and in a vertical position. Protected

from freezing temperatures.

□ Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted floor.

□ Provisions made to protect the area from water damage.

Metal drain pan installed and piped to an adequate drain.

□ Sufficient room to service the water heater. See

Clearances and Accessibility section of this manual.

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

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

Combustion Air Supply and Ventilation

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

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

the room/area?

□ Are the openings of sufficient size? Remember, if

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

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

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

as the water heater? If so, has a return air duct system been attached that exits the room? If so, check for leaks on the air duct system. If no air duct system is present, correct immediately by contacting a local Heating, Ventilation, Air-Conditioning & Refrigeration (HVAC-R) authorized service provider.

□ Fresh air supply free of corrosive elements and

flammable vapors.

□ Fresh air openings sized correctly with consideration

given to the blocking effect of louvers and grilles.

□ Ductwork is the same cross-sectional area as the

openings.

Vent Pipe System

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

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

supported properly to maintain six inch clearance.

□ Vent connector made of approved material and sized

correctly.

□ Vent pipe system installed according to all local and

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

54)-current edition.

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

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

□ Recheck for sufficient combustion air supply.

Water System Piping

□ Temperature and pressure relief valve properly installed

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

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

manufacturer’s instructions (See Water Temperature Regulation section).

Gas Supply and Piping

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

rating plate.

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

leg.

□ Use pipe joint compound or teflon tape marked as being

resistant to the action of petroleum [Propane (L.P.)] gases.

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

to check all connections and fittings for possible gas leaks. Correct any leak found.

Page 19

OPERATING YOUR WATER HEATER

Lighting Instructions

Read and understand these directions thoroughly before attempting to start or re-start the water heater. Make sure the viewport is not missing or damaged. (See Figure 27) Make sure the tank is completely filled with water before turning the power switch on. Check the data plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate. If you have any questions or doubts, consult your gas supplier or gas utility company.

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING:

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

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

This appliance is equipped with an ingnition

device which automatically lights the pilot. not open and try to light

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

WHAT TO DO IF YOU SMELL GAS

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

the inner door of the appliance

the pilot by hand.

smell all around the appliance

Immediately call your gas supplier from a neighbor's

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

If you do not follow these instructions exactly, a

WARNING

Explosion Hazard

Replace view port if glass is missing or damaged.

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

FLAMMABLE

Use only your hand to turn the gas control

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

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

Do not use this appliance if any part has been under

water. Immediately contact a qualified installer or

service agency to replace a flooded water heater. Do not attempt to repair the unit! It must be replaced! DO NOT USE THIS APPLIANCE IF THERE HAS

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

knob.

move by

service

result

LIGHTING INSTRUCTIONS

On / Off Switch

Status Light

STATUS

120°F

OFF

Position

HOT

•

HOT

•

LOW

VAC

Gas Control/Temperature Knob

STOP! It is imperative that you read

all the safety warnings above on

this label.

2. Remove the outer door.

3. Move the ON / OFF switch on the Gas Control Valve/Thermostat to the OFF position.

4. To clear any gas that may have accumulated, wait ten (10) minutes. If you then smell gas, STOP! Follow “B” in the safety warning above. If you do not smell gas go to the next step.

5. Turn on all electric power to the appliance. (Connect to a grounded 110/120 volt power outlet.)

6. Move the ON / OFF switch on the Gas Control Valve/ Thermostat to the ON position.

7. Turn the gas control/temperature knob to the “LOW” temperature setting. As shown above

8. This appliance is equipped with a device that automatically lights the pilot. DO NOT TRY TO LIGHT THE PILOT BY HAND.

LOW

VERY

•

HOT

•

VA C

Pilot

Igniter Electrode

When the pilot is lit, the status light should blink a heartbeat (bright, dim, bright, dim, etc). If the status light does not start blinking, repeat steps 3 - 7.

The pilot can be located by looking through the

glass view port. If the pilot is lit, you will see the pilot flame through the glass view port.

IMPORTANT:If the appliance (pilot) fails to light

after several tries, follow the instructions “To Turn Off Gas to Appliance” and call a qualified service technician or gas supplier. Record any status light flash codes.

10. Set the gas control/temperature knob to the desired setting.

11. Replace the outer door.

12.

Set thermostat to desired setting.

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

TO TURN OFF GAS TO APPLIANCE

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

2. Move the ON / OFF switch on the Gas Control Valve/Thermostat to the OFF position.

3. Turn off all electric power to the appliance. (Disconnect from grounded 110/120 volt power outlet.)

Page 20

Checking the Draft

WARNING

Burn Hazard

Do not touch vent.

Doing so can result in burns.

Water Temperature Regulation

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

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

Feel water before bathing or showering.

After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft (Figure 20). Make sure all other appliances in the area are operating and all doors are closed when performing the draft test. Pass a match flame around the relief opening of the draft hood. A steady flame drawn into the opening indicates proper draft.

Vent Pipe

Relief

Opening

FIGURE 20.

Draft Hood

Match

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

Burner Flames

Inspect the burner flames through the viewport and compare them to the drawings in Figure 21. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored flame. Contact a qualified technician if the flame is not satisfactory.

FIGURE 21.

Emergency Shut Down

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

Temperature limiting valves are available.

Read instruction manual for safe temperature setting.

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

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. See Figure 17. Follow manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, see Figure 29. Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater.

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

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

The thermostat of this water heater has been factory set at the VAC (Vacation) position. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The HOT mark is indicative of approximately 120°F (49°C) and is the preferred starting point. See Figure 22 on the next page. Some states have a requirement for a lower setting.

Turn the water temperature dial clockwise ( ) to increase the temperature, or counterclockwise ( ) to decrease the temperature.

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

Page 21

160°F (Approx.)

Status Light

STATUS

OFF

HOT

•

LOW

120°F

Position

HOT

•

VAC

Gas Control/Temperature Knob

110°F (Approx.)

HOT

LOW

•

VERY

•

VA C

70°F (Approx.)

HOT

FIGURE 22.

NOTE: During low demand periods when hot water is not being used, a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs. If hot water use is expected to be more than normal, a higher thermostat setting may be required to meet the increased

Water

Temperature

°F

Time for 1st

Degree Burn

(Less Severe Burns)

Time for Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

110 (normal shower temp.)

116 (pain threshold)

116 35 minutes 45 minutes

122 1 minute 5 minutes

131 5 seconds 25 seconds

140 2 seconds 5 seconds

149 1 second 2 seconds

154 instantaneous 1 second

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

demand. When leaving your home for extended periods (vacations, etc.) turn the temperature dial to its lowest setting. This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather.

Water Temperature Adjustment

The water temperature setting can be adjusted from 70°F to 160°F. Turn the Gas Control/Temperature Knob to the desired

Operating Modes and Settings

• Standard Mode - The controller adjusts the water heater to maintain the temperature set by the user.

setting/temperature.

• Vacation Setting - The Vacation Setting (VAC) sets

NOTE: The temperatures indicated are approximates. The actual

temperature of the heated water may vary.

the controller at approximately 70°F. This setting is recommended when the water heater is not in use for a long period of time. This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy.

Status Light Code

Table 5

LED FLASH SEQUENCE CONTROL STATUS

Short flash once every four second IDLE (No call for heat, no fault conditions)

“Heartbeat”, alternates bright/dim Call for Heat (No fault conditions)

One Flash, three second pause Low Flame Signal (control continues to operate)

Two Flash, three second pause End Switch Failed Closed

Three Flash, three second pause End Switch Failed Open or TCO Limit Lockout

Four Flash, three second pause ECO Limit Lockout (Overheat Failure)

Five Flash, three second pause Flame Out of Sequence

Six-One Flash, three second pause Soft Lockout* - Retry Limit - Failed TFI (Trial for Ignition)

Six-Two Flash, three second pause Soft Lockout* - Recycle Limit - Flame Lost - END Switch Fails

Six-Three Flash, three second pause Soft Lockout* - Recycle Limit - Flame Lost

Six-Four Flash, three second pause Soft Lockout* - Flame out of Sequence Sensed

Seven Flash, three second pause Flammable Vapor Sensor (FVS) Lockout

Eight-One Flash, three second pause Flammable Vapor Sensor (FVS) Fault Detected

Eight-Two Flash, three second pause Temperature Sensor Fault Detected

Eight-Three Flash, three second pause Electronic Fault Detected

Eight-Four Flash, three second pause Gas Control Valve/Thermostat Fault Detected

* Soft Lockout - 20 minute wait before returning to normal mode.

Page 22

ELECTRICAL CONNECTIONS/WIRING DIAGRAM

Electrical Connections

Before plugging in the water heater, always make sure:

• The Voltage and frequency correspond to that specified on the water heater.

• The electrical outlet has the proper overload fuse or breaker protection.

• Water heater to be located within 6 feet of 120VAC outlet.

• Unit is to connect to a 120VAC electrical supply outlet (extension cord is not allowed).

• The water heater and the outlet are properly grounded.

• Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Electric Code, ANSI/NFPS 70 current edition.

Completely fill the tank with water and check all connections for leaks. Open the nearest hot water faucet and let it run for three (3) minutes to purge the water lines of air and sediment and to ensure complete filling of the tank. The Electrical power may then be turned on. Verify proper operation after servicing.

WARNING

Electric Shock Hazard

WARNING

Electric Shock Hazard

Plug into a 3 prong outlet.

Do not remove ground prong.

Do not use an adapter.

Do not use an extension cord.

Failure to follow these instructions can result in death, fire, or electrical shock.

Disconnect power before servicing.

Replacing all parts and panels before operating.

Failure to do socan result in death or electrical shock

BN - 24VAC

V - 24VAC

BK - 120VAC

W - 120VAC

TRANSFORMER

YL 24 VAC

V 24 VAC

DAMPER

TEMPERATURE CUT-OFF SWITCH

GAS CONTROL VALVE/

IGNITER/FLAME SENSOR

You must provide all wiring of the proper size outside of the water heater. You must obey local utility requirements when you install this wiring. codes, with the

Note: If any of the original wire as supplied with the appliance must be replaced, it

National Electrical Code ANSI/NFPA No 70 (current edition) and/or THE CSA C22.1 ELECTRICAL CODE.(LATEST EDITION)

THERMOSTAT

FV SENSOR

BN 24 VAC

BK 24 VAC (H)

WH 24 VAC (N)

ON/OFF SWITCH

This appliance must be electrically grounded in accordance with local codes or, in the absence of

YL - 24VAC

BK - 120VAC

YL - 24VAC

TRANSFORMER

WH - 120VAC

must be replaced with 105°C wire or its equivalent.

BK - 24VAC (HOT)

WH - 24VAC (NEUTRAL)

BK - 24VAC (HOT)

codes and electric

6 5 4

3 2 1

BL RD

GAS CONTROL VALVE\THERMOSTAT

FLAME SENSOR\IGNITER

FLUE DAMPER

1 2 3

4 5 6

TEMPERATURE CUT-OFF SWITCH

FV SENSOR

4 3 2 1

END SWITCH

local

FIGURE 23.

Page 23

Operational Conditions

Condensation

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

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

time.

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

ticularly high efficiency models where flue temperatures are lower.

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

the refill water in the tank is very cold.

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

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

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

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

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

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

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

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

Water Heater Sounds

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

1. Normal expansion and contraction of metal parts during

periods of heat-up and cool-down.

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

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

Smoke/Odor

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

“AIR” In Hot Water Faucets

Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.

Safety Shut-off

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

1. The water temperature exceeds 189°F (87°C) for 160°F models.

3. Excessive combustion chamber temperatures.

4. The presence of flammable vapors.

This unit is equipped with a flammable vapor sensor, designed to shut off the gas supply in the event the heater has been exposed to flammable vapors (spilled gasoline or paint fumes for example). IMPORTANT: If the flammable vapor sensor activates a qualified service person must be contacted to reset the water heater. This unit is also equipped with a thermal switch designed to shut off the gas control valve/thermostat in the event the water heater has poor combustion caused by a blocked vent or insufficient combustion air. If the switch opens, check the flame-trap for signs of high temperature (blue or black discoloration), and inspect your installation for any problems with venting or combustion air (See Troubleshooting Flowchart on page 29). Reset the thermal switch by depressing the small button in the center of the switch. IMPORTANT: Correct any issues prior to resetting the switch. Contact the Product Service and Support Department for service information at: 1-800-365-0024.

A temperature limit switch or ECO (Energy Cut Off) sensor located in the gas control valve\thermostat, is used to shut off the water heater if the water temperature exceeds 189°F (87°C).

The Diagnostic Status Light will flash a code indicating an “Overheat Failure” (4 Flashes). See “Operating the Temperature Control System.” If the gas control valve/ thermostat has an “ECO Lockout” the gas control valve/ thermostat must be replaced by a qualified person. Contact your local dealer for service information.

Page 24

Anode Rod/Water Odor

Each water heater contains at least one anode rod, which will slowly deplete while protecting the glass-lined tank from corrosion and prolonging the life of the water heater. Once the anode is depleted, the tank will start to corrode, eventually developing a leak. Certain water conditions will cause a reaction between this rod and the water. The most common complaint associated with the anode rod is a “rotten egg smell” produced from the presence of hydrogen sulfide gas dissolved in the water. IMPORTANT: Do not remove this rod permanently as it will void any warranties. The parts list includes a special anode that can be ordered if water odor or discoloration occurs. NOTE: This rod may reduce but not eliminate water odor problems. The water supply system may require special aeration or chlorination equipment from a water conditioning company to successfully eliminate all water odor problems.

The use of a water softener may decrease the life of the water heater tank.

The anode rod should be removed from the water heater tank every 3 years for inspection. The following are typical (but not all) signs of a depleted anode rod:

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

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

If the anode rod shows signs of either or both it should be replaced. NOTE: Whether reinstalling or replacing the anode rod, check for any leaks and immediately correct if found.

In replacing the anode:

1. Turn off gas supply to the 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

EXPOSED SUPPORT WIRE

tank (Refer to the “Draining and Flushing” section for proper procedures). Close drain valve.

4. Remove old anode rod.

5. Use Teflon

tape or

PITTED ANODE ROD

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

EXPOSED SUPPORT WIRE

FIGURE 24.

immediately correct any if found.

7. Restart the water heater as directed under the “Operating Your Water Heater.” See the “Repair Parts Illustration” section for anode rod location.

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

Draining and Flushing

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

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

1. Move the switch on the gas control valve/thermostat to the “OFF” position to turn off the water heater.

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, refill the tank, and restart the heater as directed in this manual.

If the water heater is going to be shut down for an extended period, the drain valve should be left open.

IMPORTANT: Condensation may occur when refilling the tank and should not be confused with a tank leak.

Routine Preventive Maintenance

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

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

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

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

• Leaking or damaged water and gas piping.

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

• Presence of combustible materials near the water heater.

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

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

Page 25

Temperature and Pressure Relief Valve

Explosion Harzard

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

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

• Can result in overheating and excessive tank pressure.

• Can cause serious injury or death.

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

MAINTENANCE OF YOUR WATER HEATER

properly. To prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position. See Figure 25. If the valve fails to completely reset and continues to release water, immediately shut off the manual gas control valve and the cold water inlet valve and call a qualified technician.

TEMPERATURE AND PRESSURE RELIEF VALVE

DISCHARGE LINE TO DRAIN

FIGURE 25.

MANUAL RELIEF VALVE

Replacement Parts

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

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

1. model, serial, and product number

2. type of gas

3. item number

4. parts description

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

Removing the Manifold/Burner Assembly

1. Turn off the gas to the water heater at the manual shut-off valve (Figure 5).

2. Move the ON/OFF switch on the gas control valve/ thermostat to the “OFF” position to turn off the water heater. (Figure 26).

STATUS

OFF

HOT

•

LOW

VAC

Pilot

Igniter Wire

Wiring Harness

FIGURE 26.

Tube

Manifold Tube

3. Remove the outer door.

4. Remove the two screws (1/4” nut driver) securing the manifold door assembly to the combustion chamber (Figure 27).

Gas Control Valve/ Thermostat

Wiring

Pilot Tube

Viewport

FV Sensor

Harness

Manifold Tube

Thermal Switch

Manifold Door

Manifold Screw (2)

Manifold Component Block

FIGURE 27.

5. Disconnect the pilot tube (7/16” wrench), the igniter wire, and manifold tube (3/4” wrench) at the gas control valve/thermostat. Also use needle nose pliers to disconnect the yellow TCO wire leads from the thermal switch on the manifold door. NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube.

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

7. Carefully remove the manifold assembly from the burner compartment.

NOTE: Be sure not to damage internal parts.

Page 26

Removing the Burner from the Manifold/ Burner Assembly

OLD PILOT/IGNITER FLAME SENSOR ASSEMBLY

Natural Gas (Low Nox) & L.P. Gas Burner

1. Take off the burner by removing the two (2) screws located underneath the burner.

2. Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 28).

SCREWS

BURNER

(BOTTOM VIEW)

FIGURE 28.

Replacing the Pilot/Igniter Flame Sensor Assembly

1. Remove the manifold assembly as directed previously.

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

3. Using a 7/16” wrench, loosen the nut securing the pilot tube to the pilot assembly.

NOTE: To prevent any bending of the pilot bracket, use pliers to hold the pilot assembly bracket while loosening the pilot nut.

Pilot Tube

Retainer

Igniter Wire

Clip

(Figure 37).

Pilot/Igniter-Flame Sensor Assembly

SCREWS

PILOT TUBE

FIRST BEND(S)

FIGURE 30.

OTHER FITTINGS NOT SHOWN FOR CLARITY

7. Push the new pilot tube and igniter wire through the hole in the manifold door (See Figure 31). Reconnect the pilot tube and tighten the nut securing it to the pilot assembly. IMPORTANT: Keep the pilot orifice in the pilot when making the connection. DO NOT operate the water heater without the pilot orifice installed. Reattach the pilot assembly to the manifold.

8. Be sure the igniter wire is positioned through the bottom opening of the manifold component block. See “Replacing Manifold Assembly” section.

PILOT TUBE

IGNITER WIRE

MANIFOLD COMPONENT BLOCK

FIGURE 31.

External Inspection & Cleaning of the Base-Ring Filter

Manifold Component Block

Manifold Door

FIGURE 29.

4. Pull the pilot tube from the pilot assembly (Figure

30).IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components.

5. Use a screwdriver to remove the screws securing the Pilot/Igniter - Flame Sensor Assembly. Keep the screws for reattachement.

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

1. At least annually check the base-ring filter (Figure 32) for any dust or debris that may have accumulated on the filter screen. NOTE: If the water heater is located in an area that is subjected to lint and dirt, it may be necessary to check the base-ring filter more frequently.

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

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

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

Page 27

Cleaning the Combustion Chamber and

Flame-arrestor

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

2. Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 32). Use compressed air to clear any dust or debris that may have accumulated in the flame-arrestor.

FLAME ARRESTOR

DOOR GASKET

BASE-RING FILTER

FIGURE 32.

COMBUSTION CHAMBER

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

Replacing the Manifold/Burner Assembly

WARNING

Explosion Hazard

• Tighten both manifold door screws securely.

• Remove any fiberglass between gasket and combustion chamber.

• Replace viewport if glass is missing or damaged.

• Replace two piece wire connector if missing or removed.

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

3. Insert the manifold/burner assembly into the burner compartment, making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber (Figures 33 & 34).

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

5. Replace the two screws, which secure the manifold/ burner assembly door to the combustion chamber and tighten securely. Once the manifold/burner assembly door is tightened, visually inspect the door gasket between the manifold/burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber.

6. During the following procedure, do not cross-thread or apply any thread sealant to any of the fittings listed below. First, reconnect the manifold tubing to the gas control valve/thermostat. NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

NOTE: If a ferrule nut needs to be installed for the pilot

tube, locate the one provided with your parts kit. Install it in the gas control valve/thermostat at the pilot location, hand tight only.

Next, insert the pilot tube into the ferrule nut until it bot-

toms out. NOTE: Hold the tube in this position. Tighten the ferrule nut with a wrench until the crimp connection seals to the pilot tube. Continue to tighten until the nut is tight in the gas control valve/thermostat. When you are finished, connect the two wire leads that go to the thermal switch.

7. Reconnect the igniter wire.

8. Turn gas supply on and refer to the Lighting Instructions.

9. With the burner lit, check the gas control valve/thermostat supply line, manifold component block, manifold tube, and pilot tube connections for leaks. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found. IMPORTANT: All leaks must be fixed immediately.

10. Replace the outer door.

FLAME ARRESTOR

DOOR GASKET

COMBUSTION CHAMB

• Replace door gasket if damaged.

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

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

BASE-RING FILTER

FIGURE 33.

Page 28

CLOSE-UP INSIDE VIEW OF THE COMBUSTION CHAMBER.

BURNER

MANIFOLD TUBE

BRACKET

FIGURE 34.

TAB

SLOT

Igniter System

The STP (Spark-to-Pilot) igniter system consists of the pilot, electrode, and wire. The pilot is ignited by an electric spark generated when the gas control valve/thermostat sends an electrical signal to the electrode. Use only factory authorized STP igniter parts for replacement.

Igniter Wire Connection Point

FIGURE 35.

Pilot

Electrode

Pilot/Igniter-Flame Sensor Bracket

Testing the Igniter System

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

Removing and Replacing the Gas Control Valve/Thermostat

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

replacement parts.

Removing the Gas Valve:

1. Turn off the gas supply to the water heater at the

manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position then proceed to turn it off (Figure 5).

2. Move the ON/OFF switch on the gas control valve/ thermostat to the “OFF” position to turn off the water heater and unplug from the wall outlet. (Figure 27).

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

5. Disconnect the wire harness, flammable vapor sensor wires, and igniter wire from the gas control valve/ thermostat. Disconnect pilot tube (7/16” wrench) and manifold tube (3/4” wrench) at the gas control valve/ thermostat (Figure 26). NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube

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

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

Damage to the gas control valve/thermostat may result.

Replacing the Gas Valve:

1. To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a 4” section of pipe into the inlet and use it to turn the gas control valve/thermostat (clockwise.) DO NOT OVER TIGHTEN or damage may result. NOTE: Use an approved

TEFLON

tape or pipe compound only on the threaded section of the gas control valve/thermostat that screws into the tank.

2. Reconnect the gas piping to the gas control valve/thermostat. NOTE: Use an approved Teflon tape or pipe compound on the gas piping connections.

3. Do not use the (pilot) ferrule nut supplied with the new gas control valve/thermostat, unless the existing nut is not usable. Reconnect the manifold tube, pilot tube, igniter wire, wiring harness, and thermal switch wires. NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

4. Fill the tank completely with water. NOTE: To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained.

5. Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found.

6. Check the operation of the burner by following the lighting instructions on the front of the water heater. With the burner lit, check the gas control valve/thermostat supply line, manifold tube and pilot tube connections for leaks.

7. Verify proper operation and then replace the outer door.

8. If additional information is required, contact Residential Technical Assistance by referencing the number on the water heater.

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

Page 29

FVIR System Operational Checklist

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Flame-arrestor free of debris and undamaged.

4. Two piece wire connector properly installed.

TROUBLESHOOTING CHART

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER WILL NOT IGNITE 1. Pilot will not light

2. Thermostat set too low

3. No gas

4. Dirt in the gas lines

5. Pilot line clogged

6. Main burner line clogged

7. Non-functioning gas control valve/thermostat

8. Heater installed in a confined area

9. Flue Damper not functioning

PILOT WILL NOT LIGHT OR REMAIN LIT

BURNER FLAME YELLOWLAZY

HIGH OPERATION COSTS 1. Thermostat set too high

1. Non-functioning Pilot\Igniter-Flame Sensor

2. The thermal switch tripped

3. Igniter wire connection loose

4. Air in gas line

5. Low gas pressure

6. No gas

7. Dirt in gas lines

8. Cold drafts

9. Thermostat ECO switch open

10. Pilot line or orifice clogged

11. Air for combustion obstructed

12. FV Senor Lockout

13. Flue Damper not functioning

1. Insufficient secondary air

2. Low gas pressure

3. Flue clogged

4. Flue damper partially open

5. Main burner line clogged

6. Heater installed in a confined area

7. Obstruction in main burner orifice

2. Sediment or lime in tank

3. Water heater too small for job

4. Wrong piping connections

5. Leaking faucets

6. Gas leaks

7. Wasted hot water

8. Long runs of exposed piping

9. Hot water piping in exposed wall

10. Flue Damper seal not functioning

5. No leaks at pilot and manifold connection.

6. Manifold door screws securely tightened.

7. Depress the button on the thermal switch

1. See PILOT WILL NOT LIGHT OR REMAIN LIT

2. Turn temp. dial to desired temperature

3. Check with gas utility company

4. Notify utility-install trap in gas line

5. Clean, locate source and correct

6. Clean, locate source and correct

7. Replace gas control valve/thermostat

8. Provide fresh air ventilation

9. Cycle power to the water heater off and on. If problem persists replace the flue damper

1. See Status Light Code Troubleshooting Table section

2. See Pilot Light Troubleshooting Flowchart section

3. Seat connector firmly in socket

4. Bleed the air from the gas line

5. Check with gas utility company

6. Check with gas utility company

7. Notify utility-install dirt trap in gas line

8. Locate source and correct

9. Replace thermostat

10. Clean, locate source and correct

11. See maintenance section for inspection and cleaning of flame trap.

12. Contact a qualified person to reset the sensor

13. Cycle power to the water heater off and on. If problem persists replace the flue damper

1. Provide ventilation to water heater

2. Check with gas utility company

3. Clean, locate source and correct

4. Cycle gas control valve/thermostat OFF then ON. If problem persists replace damper

5. Clean, locate source and correct

6. Proper fresh air ventilation

7. Clean or replace orifice

1. Set temperature dial to lower setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

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

5. Repair faucets

6. Check with utility-repair at once

7. Ad v is e c us t o me r

8. Insulate piping

9. Insulate piping

10. Replace the flue damper

Page 30

INSUFFICIENT HOT WATER 1. Thermostat set too low

2. Sediment or lime in tank

3. Water heater too small

4. Wrong piping connections

5. Leaking faucets

6. Wasted hot water

7. Long runs of exposed piping

8. Hot water piping in outside wall

9. Low gas pressure

SLOW HOT WATER

1. Insufficient secondary air

RECOVERY

2. Flue clogged

3. Low gas pressure

4. Improper calibration

5. Water heater too small

6. Wasted hot water

DRIP FROM RELIEF VALVE 1. Excessive water pressure

2. Heater stacking

3. Closed water system

THERMOSTAT FAILS TO SHUT-OFF

1. Thermostat not functioning properly

2. Improper calibration

COMBUSTION ODORS 1. Insufficient secondary air

1. Turn temperature dial to desired setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

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

5 Repair faucets

6. Advise customer

7. Insulate piping

8. Insulate piping

9. Check with gas utility company

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

2. Clean flue, locate source and correct

3. Check with gas utility company

4. Replace thermostat

5. Install adequate heater

6. Advise customer

1. Use a pressure reducing valve and relief valve

2. Lower the thermostat setting

3. See “Closed System/Thermal Expansion”

1. Replace thermostat

2. Replace thermostat

1. Provide ventilation to water heater. Check flue

way, flue baffle, and burner

SMOKING AND CARBON FORMATION (SOOTING)

2. Flue clogged

3. Heater installed in a confined area

1. Insufficient secondary air

2. Low gas pressure

3. Flue clogged

4. Thermostat not functioning properly

5. Heater installed in a confined area

6. Burner flame yellow-lazy

2. Clean, locate source and correct

3. Provide fresh air ventilation

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

2. Check with gas utility company

3. Clean, locate source and correct

4. Replace thermostat

5. Provide fresh air ventilation

6. See “Burner Flame Yellow-Lazy”

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

BURNER FLAME FLOATS AND LIFTS OFF PORTS

1. Orifice too large

2. High gas pressure

3. Flue clogged

4. Cold drafts

1. Replace with correct orifice

2. Check with gas utility company

3. Clean flue and burner-locate source and correct

4. Locate source and correct

BURNER FLAME TOO HIGH 1. Orifice too large 1. Replace with correct orifice

FLAME BURNS AT ORIFICE 1. Thermostat not functioning properly

2. Low gas pressure

PILOT FLAME TOO SMALL

1. Pilot line or orifice clogged

2. Low gas pressure

1. Replace thermostat

2. Check with gas utility company

1. Clean, locate source and correct

2. Check with gas utility company

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

Page 31

Status Light Code

STATUS LIGHT TROUBLESHOOTING FLOWCHART

LED FLASH

CONTROL STATUS CORRECTIVE ACTION

SEQUENCE

Short flash once every four second IDLE (No call for heat, no fault conditions)

“Heartbeat”, alternates bright/dim Call for Heat (No fault conditions)

One Flash, three second pause Low Flame Signal (control continues to

operate)

Two Flash, three second pause End Switch Failed Closed Look at the top of water heater to see if the damper is open, see figure 12. If the damper is open insure

Three Flash, three second pause End Switch Failed Open or TCO Limit Lockout Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the

Four Flash, three second pause ECO Limit Lockout 1. Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds then turn

Five Flash, three second pause Flame Out of Sequence Turn the power switch on the gas control valve to the “OFF” position. Wait 10 minutes then follow the

Six-One Flash, three second pause Soft Lockout* - Retry Limit -

* Soft Lockout - 20 minute wait before returning to normal mode.

Failed TFI (Trial for Ignition)

Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet.

1. Check the incoming gas line pressure to ensure adequate supply to the water heater. If incoming gas supply pressure is adequate proceed to step 2.

2. Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact. If no connection problems are found proceed to step 3. Firmly seat any loose connections found. If any connections are found to be damaged consult the replacement parts list for the appropriate replacement. After any connection problems are fixed restart the water heater by following the lighting instructions on page 19. If the problem persists proceed to step 3.

3. Check condition of the base ring filter and flame arrestor. If they are clogged follow the instructions for cleaning on pages 26-27. If parts are not clogged proceed to step 4. After cleaning follow instructions for lighting on page 19. If problem persists proceed to step 4.

4. Follow the instructions on page 25 to remove the burner assembly. Once the burner assembly has been removed inspect the manifold tube and burner, see figure 29, for any obstructions. If any clogs or obstructions are present clear them. Inspect the electrode/flame sense rod, see figure 43, for corrosion buildup, degradation, or damage. If there is evidence of any damage to the electrode/ flame sense rod replace the igniter/pilot assembly. Follow the directions on page 27 to re-install the burner assembly into the combustion chamber. Follow the instructions for lighting on page 19. If the problem persists contact a certified service representative.

there is no obstruction that would prevent the damper from closing. If there are any obstructions turn the power switch on the gas valve to the “OFF” position, remove the obstruction, if the damper closes turn the power switch on the gas valve to the “ON” position. If there are no obstructions present turn the power switch on the gas valve to the “OFF” position. Observe the damper to see if the damper closes. If the damper does not close unplug the power cord from the power outlet and proceed to step 1. If the damper closes turn the power switch on the gas valve to the “ON” position.

1. Check all wiring connections to insure all harness and wire connections are seated firmly and provide proper electrical contact. If no connection problems are found replace the damper. Firmly seat any loose connections found. If any connections are found to be damaged consult the replacement parts list on pages 34-35 for the appropriate replacement. After any connection problems are fixed restart the water heater by following the lighting instructions on page 19. If the problem persists replace the damper.

power outlet.

1. Attempt to depress the TCO door switch button, see figure 27. If the TCO door switch button depresses follow the instructions for cleaning the filter and flame arrestor on page 24. After cleaning is completed follow the lighting instructions on page 19. If the TCO door switch button does not depress proceed to step 2.

2. Follow the lighting instructions on page 19. Observe the damper during initial startup. If there is a call for heat and the damper opens allow the unit to continue to perform and monitor any change in status. If there is a call for heat and the damper does not open proceed to step 3.

3. Check all wiring connections to insure all harness and wire connections are seated firmly and provide proper electrical contact. If no connection problems are found replace the damper. Firmly seat any loose connections found. If any connections are found to be damaged consult the replacement parts list on page 34-35 for the appropriate replacement. After any connection problems are fixed restart the water heater by following the lighting instructions on page 19. If the problem persists replace the damper.

the power switch on the gas control valve to the “ON” position. If the problem persists replace the gas control valve.

lighting instructions on page 19. If the problem persists replace the gas control valve.

Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet.

1. Check the incoming gas line pressure to ensure adequate supply to the water heater. If incoming gas supply pressure is adequate proceed to step 2.

4. Follow the instructions on page 25 to remove the burner assembly. Once the burner assembly has been removed inspect the manifold tube and burner, see figure 29 , for any obstructions. If any clogs or obstructions are present clear them. Inspect the electrode/flame sense rod, see figure 43 , for corrosion buildup, degradation, or damage. If there is evidence of any damage to the electrode/flame sense rod replace the igniter/pilot assembly. Follow the directions on page 27 to re-install the burner assembly into the combustion chamber. Follow the instructions for lighting on page 24. If the problem persists contact a qualified service representative.

Page 32

STATUS LIGHT TROUBLESHOOTING FLOWCHART

LED FLASH

CONTROL STATUS CORRECTIVE ACTION

SEQUENCE

Six-Two Flash, three second pause Soft Lockout* - Recycle Limit - Flame Lost -

END Switch Fails

Six-Three Flash, three second pause Soft Lockout* - Recycle Limit - Flame Lost Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the

Six-Four Flash, three second pause Soft Lockout* - Flame out of Sequence Sensed Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the

Seven Flash, three second pause Flammable Vapor Sensor (FVS) Lockout 1. Do not touch any electrical switch, do not use any phone in the building and do not try to light any

Eight-One Flash, three second pause Flammable Vapor Sensor (FVS) Fault Detected Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds then turn the

Eight-Two Flash, three second pause Temperature Sensor Fault Detected Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds then turn the

Eight-Three Flash, three second pause Electronic Fault Detected Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds then turn the

Eight-Four Flash, three second pause Gas Control Valve/Thermostat Fault Detected Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds then turn the

* Soft Lockout - 20 minute wait before returning to normal mode.

Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet.

power outlet.

1. Check the incoming gas line pressure to ensure adequate supply to the water heater. If incoming gas supply pressure is adequate proceed to step 2.

4. Follow the instructions on page 25 to remove the burner assembly. Once the burner assembly has been removed inspect the manifold tube and burner, see figure 29 , for any obstructions. If any clogs or obstructions are present clear them. Inspect the electrode/flame sense rod, see figure 43 , for corrosion buildup, degradation, or damage. If there is evidence of any damage to the electrode/flame sense rod replace the igniter/pilot assembly. Follow the directions on page 27 to re-install the burner assembly into the combustion chamber. Follow the instructions for lighting on page 19. If the problem persists contact a qualified service representative.

power outlet. Wait 10 minutes then follow the lighting instructions on page 19. If the problem persists replace the gas control valve.

appliance.

2. Smell around the water heater to ensure there are no gas leaks at the gas control valve or in the supply gas line or for any other type of flammable vapors 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 flammable vapors. Remove anything that can potentially emit flammable vapors from the area and store it properly in a different location.

4. Contact a qualified service representative for inspection and/or replacement of the FV sensor.

power switch on the gas control valve to the “ON” position. If the problem persists replace the gas valve.

Page 33

Apply Power to Appliance.

Is there a

Call for Heat.

Is Damper

Closed?

Damper Energizes.

Is Damper

Open?

Pilot Valve Energizes

SEQUENCE OF OPERATION CHART

Will not attempt to light. 2 flash error code. See

Corrective Action Table on pages 31-32.

Gas Valve attempts to open damper for 30 seconds, displays 3 flash error code, and then waits 2 mintues before

attempting to open damper again. See Corrective Action Table pages 31-32.

Does Pilot

Valve Open?

Spark Electrode

is Energized

Pilot Flame

Sensed Within

1.5 min. ?

Main Valve

Energized

Does Main

Valve Open?

Is Main

Flame Sensed?

Is Demand for

Heat Satisfied?

Will not light. 8-4 flash

error code. See Corrective Action Table on pages 31-32.

Will not light. 8-4 flash

error code. See Corrective Action Table on pages 31-32.

Will not light. 8-4 flash

error code. See Corrective Action Table on pages 31-32.

Will not light. 8-4 flash

error code. See Corrective Action Table on pages 31-32.

Water heater will continue to

operate normally until demand is satisfied.

Pilot & Main

Valve De-Energize.

Is Flame

Sensed?

Damper Energizes

and Closes.

Wait for flame lost, 5 flash

error code. See Corrective Action Table, pages 31-32.

Damper closes, displays 6-4 Flash Error Code, and gas control valve goes into 20 minute lockout. See Corrective Action Table, pages 31-32.

Page 34

REPAIR PARTS ILLUSTRATION

When ordering repair parts always give the following information:

1. Model, serial, and product number

2. Type of gas

3. Item number

4. Parts description

Repair Parts List

Item

No.

1 DRAFT HOOD

2 FLUE DAMPER

3 FLUE BAFFLE

4 HEAT TRAP (COLD) - SOME MODELS

5 HEAT TRAP (HOT) - SOME MODELS

6 COLD WATER DIP TUBE

7 ANODE ROD

8 TEMPERATURE & PRESSURE RELIEF VALVE

(LOCATED ON SIDE)

9 DRAIN VALVE

10 GAS CONTROL VALVE/THERMOSTAT

11 OUTER DOOR

12A* STP (SPARK TO PILOT) PILOT ASSEMBLY KIT

12B* STP (SPARK TO PILOT) PILOT ASSEMBLY KIT ( L.P.)

13A* BURNER (Natural Gas/Low Nox)

13B* BURNER (L.P.)

14A* BURNER ASSEMBLY

14B* BURNER ASSEMBLY ( L.P. Burner)

15* MANIFOLD COMPONENT BLOCK

16* MANIFOLD DOOR GASKET

17* VIEWPORT ASSEMBLY

18** TRANSFORMER ASSEMBLY KIT

Parts Description

*Pictured on next page.

** Not shown.

LEGEND

Special anode rod (see Anode Rod/Water Odor section)

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

Unique: FVIR System parts

Page 35

Listed Parts Kits and Illustrations

Item 12A: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (Natural

Gas)

Item 12B: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (L.P. Gas)

Item 13A: Burner (Natural Gas/L.P. Gas)

Item 13B: Burner (L.P. Gas)

Item 14A: Manifold door assembly which contains the manifold tube, gasket, door, pilot\igniter-flame sensor assembly,

manifold component block with retainer clip, thermal switch, and pilot tube. (Natural Gas/Low Nox)

Item 14B: Manifold door assembly which contains the manifold tube, gasket, door, pilot\igniter-flame sensor assembly,

manifold component block with retainer clip, thermal switch, and pilot tube. (L.P. Gas)

Item 15: Contains manifold component block and retainer clip

Item 16: Contains manifold door gasket

Item 17: Contains viewport

Item #12A

Item #12B

Item #14A

Item #13A

Item #14B

Item #13B

L.P. BURNER

Page 36

NOTES

Page 37

NOTES

Page 38

NOTES

Page 39

LIMITED RESIDENTIAL GAS WARRANTY

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

State Water Heaters (the warrantor) will furnish the ORIGINAL OWNER, 1) a replacement State water heater of equivalent size and current model if the glass-lined tank in this water heater leaks and, 2) a replacement part for any component part which fails.

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

SERIES TANK PARTS

Select 6-Year Models 6-Year 6-Year

GS6

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

1. The tank warranty shall be reduced to 1 year for 6 year models and to 3 years for 10 year models.

2. The parts warranty shall be reduced to 1 year for all models.

CONDITIONS AND EXCEPTIONS

This warranty shall apply only when the water heater is installed and operated in accordance with 1) all local ﬁ re codes and plumbing codes, ordinances and regulations,

2) the printed instructions provided with it, 3) good industry practices, and 4) proper safety practices such as but not limited to a properly sized drain pan if installed in an area where leakage from the tank or its connections would result in damage to the area adjacent to the heater. In addition, a new temperature and pressure relief valve, certiﬁ ed by the Canadian Gas Association must have been properly installed and piped to the nearest drain.

This warranty shall apply only when the heater is:

• owned by the original purchaser;

• installed for indoor operation only;

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

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

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

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

• used with factory approved anode(s) installed;

• in its original installation location;

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

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

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

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

• operated with properly installed drip leg in the gas supply line;

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

• ﬁ red at the factory rated input;

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

• installed with no attempted, nor actual modiﬁ cation or alteration of the water heater’s design in any way, including but not limited to, the attachment of noncompany approved appliances or equipment.

Any accident to the water heater or any part thereof (including freezing, ﬁ re, ﬂ oods, or lightning), any misuse, abuse or alteration of it, any operation of it in a modiﬁ ed form, any operation of the water heater on desalinated (deionized) water, or any damage caused by attempts to repair tank leaks or parts, will void this warranty. This warranty does not cover water heaters replaced for cosmetic reasons or for reasons of noise, taste, odor, discolored and/or rusty water. This warranty does not apply to water heaters used to heat pools, whirlpools or hot tubs or used for space heating where its sizing does not conform with speciﬁ cations of the heating component manufacturer.

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

SERVICE AND LABOR RESPONSIBILITY

UNDER THIS LIMITED WARRANTY, THE WARRANTOR WILL PROVIDE ONLY A REPLACEMENT WATER HEATER OR PART THEREOF. THE OWNER IS RESPONSIBLE FOR ALL OTHER COSTS. Such costs may include but are not limited to:

a. Labor charges for service, removal, or reinstallation of the water heater or part thereof. b. Shipping and delivery charges for forwarding the new

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

c. All cost necessary or incidental for handling and

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

LIMITATION ON IMPLIED WARRANTIES

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

Page 40

CLAIM PROCEDURE

Any claim under this warranty should be initiated with the dealer who sold the heater, or with any other dealer handling the warrantor’s products. If this is not practical, the owner should contact: State Industries, Inc., 500 Tennessee Waltz Parkway, Ashland City, Tennessee 37015. Phone: 1.800.365.0024 or visit our website: www.statewaterheaters.com.

Replacement Parts may be ordered through authorized servicers or distributors. Refer to your local Yellow Pages for where to call or contact State Industries, Inc., 500 Tennessee Waltz Parkway, Ashland City, TN 37015, phone:

1.800.821.2017.

The warrantor will only honor replacement with identical or

similar water heater or parts thereof which are manufactured or distributed by the warrantor.

Dealer replacements are made subject to in-warranty validation by warrantor.

PROOF-OF-PURCHASE AND PROOF-OF-INSTALLATION DATE ARE REQUIRED TO SUPPORT WARRANTY CLAIM FROM ORIGINAL OWNER. THIS FORM DOES NOT CONSTITUTE PROOF-OF-PURCHASE OR PROOF-OF INSTALLATION.

DISCLAIMERS

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

TO ANY PERSONS OR PROPERTY, WHETHER DIRECT OR INDIRECT, AND WHETHER ARISING IN CONTRACT OR IN TORT.

Should governmental regulations or industry standards prohibit the Manufacturer from furnishing a comparable model replacement under this warranty, the Owner will be furnished with the closest comparable water heater meeting the then current governmental regulations and industry standards. A supplementary fee may be assessed to cover the additional cost associated with the changes made to meet applicable regulations and standards.

IMPORTANT INFORMATION

Model Number ________________________________

Serial Number _________________________________

INSTALLATION INFORMATION

Date Installed _________________________________

Company’s Name ______________________________

Street or P.O. Box ______________________________

City, State, and Zip Code _________________________

Phone Number ________________________________

Plumber’s Name _______________________________

State Water Heaters FVIR Installation Instructions And Use & Care Manual

Specifications and Main Features

Frequently Asked Questions

User Manual