State Water Heaters Ultra Low Nox Series Installation Instructions And Use & Care Manual

Direct Vent

O

VAC

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

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.

Residential Gas

Water Heater

Installation

Instructions and

Use & Care Guide

Ultra Low NOx MODELS

All technical and warranty questions should be directed to the local
dealer from whom the water heater was purchased. If you are
unsuccessful, contact the company listed on the rating plate on the
water heater.

When calling for assistance, please have the following
information ready:

1. Model number

2. 7 digit product number

3. Serial number

4. Date of installation

5. Place of purchase

Table of Contents ...................................................... 2

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.

LOW LEAD

NTENT

C

325002-001

August 2013

1

WATER HEATER SAFETY

Your safety and the safety of others are very important.

We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.

This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or
“WARNING.” These words mean:

Indicates an imminently hazardous situation which, if
not avoided, will result in death or injury.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.

Important Instructions

• 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.

• 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.

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 listed in the act.

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

Table Of Contents

Water Heater Safety ..............................................................................1-3

Installing Your Gas Water Heater ........................................................4-16

Unpacking the Water Heater ........................................................... 4

Location Requirements ................................................................5-6

Gas Supply ..................................................................................7-8

Combustion Air Supply and Ventilation ...................................... 8-12

Water System Piping ...............................................................13-14

Temperature & Pressure Relief Valve ........................................... 15

Special Applications ...................................................................... 16

Installation Checklist ..................................................................... 17

Operating Your Water Heater ............................................................18-22

Lighting Instructions .................................................................18-19

Operating the Temperature Control System ................................. 22

Operational Conditions ................................................................. 23

Maintenance of Your Water Heater ...................................................24-28

Troubleshooting Charts ..................................................................... 28-30

Repair Parts Illustration ..................................................................... 31-32

PAGE

2

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

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

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

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.

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

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

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

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

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

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

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

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

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

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

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

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

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

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

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.

3

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, direct vented water heater which takes its com­bustion air from the outside of the structure and exhausts all
products of combustion to the outside of the structure.

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 Association
1 Batterymarch Park
Quincy, MA 02269

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

Unpacking the Water Heater

WARNING

Excessive Weight Hazard

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

Failure to do so can result in back or
other 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.

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.

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
person 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 data plate identifying your water heater can be found next
to the gas control valve/thermostat. When referring to your
water heater, always have the information listed on the data
plate readily available.

Retain your original receipt as proof of purchase.

4

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.

Flammable Vapors

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. Note: The water heater may
be installed in a closet with a door off a bedroom or
bathroom providing the units are installed and vented
per the manufacturer’s instructions..

• Consider the vent piping and vent cap termination
location. This is a direct vent water heater and
may be vented through-the-wall. See the “Vent Cap
Termination” section of this manual for the proper vent
cap locations.

• 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.

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.

Read and follow water heater warnings and
instructions.

Location Requirements

WARNING

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home.

Doing so can result in death or
carbon monoxide poisoning.

This water heater design has been tested by CSA
International and complies with ANSI Z21.10.1, Section

2.35 Flammable Vapors Resistance. Therefore this water
heater does not need to be installed 18 inches above the
floor unless specifically required by state or local codes.
The water heater must be located or protected to avoid
physical damage by vehicles or flooding.

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.

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.

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

5

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 the 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 person
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 adequate indoor drain.
The discharge pipe 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.
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. Under
no circumstances will the manufacturer or seller of this
water heater be held liable for any water damage which
is caused by your failure to follow these instructions.

Figure 1
Drain Pan Installation

DISCHARGE PIPE
(DO NOT CAP OR PLUG)

an alcove or closet installation, the entire floor must be
covered by the panel.

• Figure 2 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches of front clearance should be provided for
inspection and service.

Figure 2

Vent 0”

Back 0”

To p

View

Sides 0”

Front
24” minimum
for service

Sides
0”

State of California
NOTE: The water heater must be braced, anchored, or

strapped to avoid moving during an earthquake. Correct
installation procedure instructions may be obtained from
California’s Office of the State Architect, 1102 Q street,
Suite 5100, Sacramento, CA 95811. Instructions can be
downloaded to your computer at www.dsa.dgs.ca.gov/
Pubs.

VAC

METAL
DRAIN
PAN

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

PIPED TO AN
ADEQUATE DRAIN

6” MAXIMUM
AIR GAP

• 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
data plate.

Clearances and Accessibility

NOTE: Minimum clearances from combustible surfaces are

stated on the data 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

6

Gas Supply

WARNING

Figure 3
Gas Piping

Manual Gas

Shut-off Valve

Check with local

utility for

minimum height

Ground

Joint

Union

3” Minimum

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 data 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 data
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 on page 8 provides a sizing reference for commonly

used gas pipe materials. Consult the “National Fuel Gas Code”
for the recommended gas pipe size of other materials.

Refer to Figure 3
NOTE: When installing gas piping, apply approved pipe joint
compound.

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

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

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

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

Sediment Trap

Gas Pressure

IMPORTANT: The gas supply pressure must not exceed the

maximum supply pressure as stated on the water heater’s data
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 shut­off 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

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.

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 person after installation of the
gas piping system. While purging the gas piping system of air,
make sure 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.

7

Combustion Air Supply and
Ventilation

WARNING

Carbon Monoxide Hazard

Water heater must be vented to outdoors.

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

Examples of a qualified person include:
gas technicians,
authorized gas company personnel,
and authorized service persons.

Failure to follow these instructions 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.

IMPORTANT: Do not common vent this water heater with
any power vented appliance.

Vent Pipe System

This is a direct vent water heater which draws its
combustion air from outside of the structure and exhausts
all products of combustion to the outside of the structure.

Through-the-wall installations require locating the water
heater next to an outside wall. All necessary components
are supplied for the standard through-the-wall installation.
Optional vertical and horizontal extension kits are available
for installations that exceed the standard horizontal and
vertical distances (see table at right). Only one vertical and
one horizontal kit can be used on the same installation.

Through the Wall Flex Pipe Venting

1. Make sure a proper location has been selected for the
water heater installation. Consider the following:

• Water piping

• Gas Piping

• Access for service

• Proper clearance for combustibles

• Drainage for the temperature and pressure
relief valve and drain pan.

• Vent cap termination

2. Determine the “A” dimension for your specific water
heater by referencing figure 4A. Cut a 6 inch opening
through the wall in the location as shown. Determine
the location of electrical wiring, pipes, or wall studs
before cutting.

NOTE: Installations requiring an “A” dimension (vertical
height) greater than what is shown will require the use of a
Optional vertical extension kit (See “Vertical Install Kit” on
Page 11).

8

1.

2.

3. Uncompressing the corrugated Flex piping by pulling
the piping to the length as required. Make sure there
are two springs evenly spaced at the bend in the pipe.

4. Determine the “A” and “B” dimensions for the
size of the water heater being installed (Figure 4A).
Dim. “A” is measured from the center of cutout
to the bottom of heater. Maximum height for all
water heaters is 90”. Minimum height for 40
Gallon water heaters 68” and minimum height
for 50 Gallon water heaters is 76” (Figure 4A).
Dim. “B” is measured from the center of water heater
to the outside of the exterior wall. Minimum horizontal
is 22” for all water heaters at the maximum height of
90” (Figure 4A).

5. Cut a 6” opening through the wall in the location as
shown. Note: location is determine first by locating all
electrical wiring, pipes, and wall studs before cutting.

6. Metal hangers may be used to keep the pipe level or
with a slope upward from the water heater through the
wall to Vent Cap.

7. At the water heater: Pull the inner 3” corrugated pipe
to the water heater’s flue reducer and attached using
the Small Clamp included in kit. Apply hi-temp silicone
sealant around the connection making sure joint is tight
and leak proof (Figure 4A).

8. Pull the outer corrugated Flex V

ent pipe down covering
the connection and secure using the Large Clamp
included in kit to the collar at the Upper Air Box
(Figure 4A). Apply hi-temp silicone sealant around the
connection making sure joint is tight and leak proof.

9. At the exterior wall: Pull the Flex Vent piping through
the Inner Wall Plate through the clearance hole from
the exterior wall to the Outer Wall Plate. Secure Inner
Wall Plate to the inside wall with 1/2” screws.

10. Pull the outer corrugated Flex Vent pipe out to the
Outer Wall Plate, secure with Large Clamp. Pull the
inner 3” corrugated pipe out from the Flex Vent pipe
through the Outer Wall Plate and attached to the end of
the 3” tube at the Vent Cap and secure using the Small
Clamp included in kit. Apply hi-temp silicone sealant
around the connection making sure the joint is tight and
leak proof (Figure 4A).

11. Secure Vent Cap Assembly to the Outer Wall Plate to
the exterior wall with four 1-1/2” screws provided in kit
(Figure 4A). Note: varying wall structures may require a
different type of screw anchor.

12. Apply hi-temp silicone sealant around the connection
making sure the joint is tight and leak proof (Figure 4A).

Figure 4A
Installation Flex Vent Pipe

Secure Flex Vent Pipe to
Reducer with Small Clamp.
Apply silicone sealant to all
connections making sure all
joints are tight and leak proof

Large Clamp

Small Clamp

.

Secure Flex Vent Pipe to Vent
Cap with Small Clamp. Apply
silicone sealant to all connections
making sure all joints are tight
and leak proof

.

“B”

Inner Wall
Plate

Upper Air Box

Reducer

Vent Cap
Assembly

Small
Clamp

Outer Wall Plate

Large Clamp

“A”

NOTE:

1. Dim.

“A” measured from center of cutout to bottom of heater.

Maximum height for all water heaters 90”,
Minimum for 40 Gallon water heaters 68”,
Minimum for 50 Gallon water heaters 76”.

2. Dim.

“B” measured from center of heater to outside of wall.

Minimum horizontal of 22“ for all water heaters at Maximum height of 90”.

Optional through the Wall Venting

1. Make sure a proper location has been selected for the
water heater installation. Consider the following:

• Water piping

• Gas Piping

• Access for service

• Proper clearance for combustibles

• Drainage for the temperature and pressure
relief valve and drain pan.

• Vent cap termination

2. Determine the “A” dimension for your specific water
heater by referencing figure 4B. Cut a 6 inch opening
through the wall in the location as shown. Determine
the location of electrical wiring, pipes, or wall studs
before cutting.

NOTE: Installations requiring an “A” dimension (vertical
height) greater than what is shown as standard in the table
will require the use of a vertical extension kit (See “Vertical
Install Kit” on Page 11).

9

Figure 4B
Optional Installation

“A”

“B”

4. Extend the 3” telescoping pipe to its maximum length.
Place the smaller section onto the 3” elbow at least 1
and 1/2 inches (See Figure 6). Drill two holes 180°
apart and secure with the two #8 sheet metal screws
provided. Apply silicone sealant to the joint.

5. Attach the larger section of the 5” telescoping pipe to
the flange on the outer wall plate (See Figure 6). Drill
holes 90° apart with a 1/8” drill bit and fasten with
four #8 sheet metal screws (provided). Apply silicone
sealant to the seam.

6. Extend the 5” telescoping tube to its maximum length.
From outside of the building, insert a 5” tube/outer wall
plate assembly through the opening in the exterior wall
and onto the 5” elbow (See Figure 6). Seat the base of
the outer wall plate onto the exterior wall. Apply silicone
sealant between the plate and the exterior wall.

Figure 6:
Vertical Installation

NOTE:

1. Dim. “A” measured from center of cutout to bottom of heater.

2. Dim. “B” measured from center of heater to outside of wall.

Table 2

KIT

STANDARD 62.75” 18.00” - 24.50” 71.00” 18.00” - 24.50”

HORIZONTAL 62.75” 27.00” - 38.00” 71.00” 27.00” - 38.00”

VERTICAL 62.75” - 89-75” 18.00” - 24.50” 71.00” - 98.00” 18.00” - 24.50”

BOTH 62.75” - 89-75” 27.00” - 38.00” 71.00” - 98.00” 27.00” - 38.00”

40 GALLON 50 GALLON

ABAB

CAPACITY

3. If you are not using the vertical extension kit, place the
3” elbow on the flue pipe reducer on the air box and
point it in the desired direction (See Figure 8). Press
it firmly downward until seated. Drill 4 holes 90° apart
with a 1/8” drill bit and fasten the four #8 sheet metal
screws provided. Apply silicone sealant to the joint.
Install the 5” elbow over the 3” elbow and seat it into
the collar on the air box. Drill 4 holes 90° apart with a
1/8” drill bit and fasten the four #8 sheet metal screws
provided. Apply silicone sealant to the joint. Place the
inner wall cover plate over the 5” elbow. This plate will
be positioned later.

Figure 5
Vertical Installation

3” Elbow

1

Screws
&
Sealant

2

5” Pipe

3” Elbow

Inside Cover
Plate

Screws
& Sealant

Inner Wall
Plate

5” Elbow

Inner Wall
Plate

Screws
& Sealant

3” Pipe

5” Telescoping Pipe

Screws
& Sealant

3” Telescoping
Pipe

Wall

3” Telescoping
Pipe

Outer Wall Plate

7. Place the 3” tube located in the vent cap into the end
of the 3” telescoping tube (See Figure 7). Drill two
holes 180° apart with a 1/8” drill bit and secure with
two #8 sheet metal screws. Apply sealant to the joint.
Seat the cap against outer wall plate with the word
“HOT” in an upright position.

8. Secure the vent cap/outer wall plate assembly to the
exterior wall with the four 1 and 1/2” screws provided
(See Figure 7). Varying wall structures may require a
different type of screw anchor. To prevent rain from
entering the water heater vent pipe, the 5” tube should
be sloped downward towards the wall 1/4” per foot.

10

Figure 7
Vertical Installation

Slope down 1/4”
per foot

Screws

Inner Wall
Plate

Sealant

Outer
Wall
Plate

Screws

Screws
& Sealant

HOT

Vent Cap

9. Position and fasten the inner wall plate to the inside
wall using an appropriate fastener for the specific wall
construction. Apply silicone sealant between the inner
wall plate and the inside wall.

10. Make certain the 5” telescoping pipe has been fully
engaged onto the 5 inch elbow. Drill two 1/8” holes
180° apart at the junction of the two joints. Secure
with four #8 sheet metal screws and apply silicone
sealant to the seams. Make sure all the 5” pipe joints
are sealed including the joint to the collar on the water
heater’s air supply box (See Figure 8).

Optional Vertical Extension Kit

Installations requiring dimension “A” to be greater than

62.75” (40 Gallon) or 71.00” (50 Gallon) will require the

use of the optional vertical extension kit. The maximum
height of the “A” dimension cannot exceed 98 inches. If the
“A” dimension for your application is less than 98 inches,
you will have to cut the 3 and 5 inch pipes in the vertical
extension kit to the correct length. For example, if your
applicable “A” distance is 80 inches, then 98 inches - 80
inches = 18 inches. Therefore, you will need to cut 18
inches from both the 3 and 5 inch vertical extension pipes.
DO NOT CUT THE CRIMPED END OF THE 5 INCH PIPE.

After cutting both the pipes to the proper size, place the 3”
vertical extension pipe over the flue pipe reducer on the
upper air box and press it firmly downward until seated.
Using a level, make sure the extension tube is pointing
straight up. Drill 4 holes 90° apart with a 1/8” drill bit and
fasten with four #8 sheet metal screws (provided). Apply
silicone sealant to the seam.

Place the uncrimped end of the 5 inch extension pipe
over the 3 inch extension pipe and seat it onto the collar
on the air box. Making sure the 3 inch extension pipe is
centered in the 5 inch pipe, drill four holes 90° apart with
the 1/8” drill bit and fasten with four #8 sheet metal screws
(provided). Apply silicone sealant to the seam. Place the
flared end of the 3 inch elbow over the 3 inch extension
pipe and press it firmly downward until seated. Drill four
holes 90° apart with the 1/8” drill and fasten with four #8
sheet metal screws (provided). Apply silicone sealant to
the seam.

Install the 5 inch elbow over the 3 inch elbow and seat
it down onto the crimped end of the 5 inch extension
pipe. Temporarily place the 5 inch telescoping pipe onto
the 5 inch elbow and adjust it to give a 1/4 inch per foot
downward slope to the outside wall. Secure the 5 inch
elbow to the extension pipe by drilling four holes 90°
apart with the 1/8” drill and inserting four #8 sheet metal
screws. Apply silicone sealant to the joint. Place the inner
wall cover plate over the 5 inch elbow. This plate will be
positioned later. Proceed to step 4.

Through The Roof Venting*

1. Center the heater directly under the roof opening. This
vent system must be installed vertically only.

2. All the pipes needed to assemble the vent are
included in the kit. Do not add to the length of the
vent system. The total height is limited to 15 feet
on a 50-gallon heater (See Figure 8). The 40-gallon
heater is 8 and1/4” shorter. The total 15-foot height
must stick through the roof a minimum of 2 feet. If
the height needed is less than 15 feet, determine the
height needed and subtract that from 15 feet. That
amount needs to be cut off one of the 3” pipes and 5”
pipes. Cut the non-flared end of the 3” pipe and the
uncrimped end of the 5” pipe.

3. Assemble the kit from the top down starting with the
termination. Attach a 3” pipe using 4 #8 sheet metal
screws 90° apart and seal the joint with sealant. Then
attach the 5” section in the same manor. Drill 1/8”
pilot holes for the screws. Continue until the full length
is assembled. Put the telescoping 5” section on last.

4. Place the heater in position, feed the vent assembly
down through the roof with the flashing in place, and
allow it to rest with the 3” pipe attached to the 3” vent
terminal on the heater. Use screws and sealant to
secure that joint. Extend the 5” telescoping section to
connect to the 5” termination on the heater. Secure
that joint with screws. Seal that joint and the sliding
joint with silicone to make an airtight assembly.

5. Secure the flashing and vent assembly to the roof.

(*Through the Roof Venting Kit available from manufacturer)

Figure 8
Through the Roof Venting

Roof Jack Assembly

2 Ft. Min.
From Any Object

Roof Flashing

Secure All
Connection
s with
Screws and
Apply
Silicone
Sealant

within A 10 Foot
Horizontal Radius

VAC

8 Ft. Min.

15 Ft. Max

11

Vent Cap Termination

WARNING

Carbon Monoxide Hazard

Follow all instructions to locate and install
vent cap terminal.

Instructions can be found in this manual, in
state and local codes (or the authority
having jurisdiction), or in the absence of
such, the National Fuel Gas Code, ANSI
Z223.1, NFPA 54, Current Edition.

Failure to properly locate and install the
vent terminal can result in death, carbon
monoxide poisoning.

The termination of the vent cap must be in accordance
with the local code or the authority having jurisdiction, or
in the absence of such, the National Fuel Gas Code, ANSI
Z223.1, NFPA 54, Current Edition.

Figure 10
Vent Cap Termination Locations

Do not terminate the vent cap in areas containing acid
forming chemicals. Inlet air must not contain any corrosive
elements. Any water heater failure due to corrosive
elements in the atmosphere is excluded from warranty
coverage.

See Figures 7 and 8 for correct Vent Cap Termination
Locations.

Figure 9
Alcove Installation Minimums

18” Min.

24”

Max.

18” Min.

U.S. Installation

A. 12 in (30 cm) min. clearance above grade, veranda, porch, deck,

balcony, or maximum anticipated snow level.

B. 9 in (23 cm) min. clearance on top and side of window or door

that may be opened. Do not install below a window or door that

may be opened.
C. Clearance to permanently closed window.**
D. 12 in (30 cm) min vertical clearance to ventilated soffit.
E. 12 in (30 cm) min. clearance to unventilated soffit.
F. Clearance to outside corner **
**Clearance in accordance with local installation codes and the requirements of the gas supplier

The Vent terminal is HOT when the water heater is in
operation. Do not touch the vent terminal or place any
object where contact with the vent terminal may occur. A

G. 12 in (30 cm) min. clearance to inside corner formed by two

exterior walls.

H. 4 ft (122 cm) min. clearance to each side of center line extending

above meter/regulator assembly.
I. 4 ft (122 cm) min. clearance to service regulator vent outlet.
J. 12 in (30 cm) min. clearance to nonmechanical air supply inlet to

building or the combustion air inlet to any other appliance.
K. 3 ft (91 cm) above if within 10 ft (3 m) horizontally of mechanical

air supply inlet.

Figure 11
Protective Louvered Wall or Fence

protective louvered wall or fence is recommended when
the hot vent cap is low enough to be touched accidentally
(see Figure 5). A Vent guard kit (Kit # 6907245) may
be ordered by contacting the manufacturer of this water
heater at 1-800-999-9515.

• The exhaust outlet must not terminate under a patio,
deck, or any covered area.

• Do not terminate the exhaust outlet near walkways or
into alleys or other publicly accessible areas.

• Do not locate the vent terminal too close to shrubs or
bushes.

• Caulk all cracks, seams, and joints within 6 feet
horizontally above and below the vent.

• Do not terminate the vent within 12 inches of any other
direct vented appliance vent

12

HOT

Hot Vent Cap

Protective
Louvered
Wall or Fence

3 feet Min.

Water System Piping

Piping Installation

Piping, fittings, and valves should be installed according to
the installation drawing (Figure 12). 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
fitting marked “C”. Connect the hot water supply (3/4”
NPT) to the fitting marked “H”.

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 13. 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”
section.

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” section.

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.

Figure 12
Water Piping Installation

In a closed system use a
thermal expansion tank

Cold Water

Hot Water
Outlet

Union

1”minimum

Metal
Drain Pan
1 3/4” depth maximum

Figure 13
Typical Mixing
Valve Installation

Follow the mixing
valve manufacturer’s
instructions.

Tempered water
to fixtures

Cold Water

Inlet Valve

Temperature and
Pressure Relief Valve

Discharge Pipe

Do Not Cap or Plug

Drain line 3/4”
ID minimum

Floor Drain

Hot
Water
Outlet

Supply to Fixtures

Main water supply

Pressure reducing

valve with bypass

6” Maximum
Air Gap

Massachussetts:
Install a vacuum relief
in cold water line per
section 19 MGL 142.

Cold

Water

Inlet

Mixing valve
(Set to 120°F)

13

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.

• Use only full flow ball or gate valves. 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.

Closed System/Thermal Expansion

WARNING

Explosion Hazard

If the temperature and pressure relief valve
is dripping or leaking, have a qualified
person replace it.

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

Do not plug valve.

Do not remove valve.

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

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.

14

Temperature and Pressure
Relief Valve

WARNING

Explosion Hazard

If the temperature and pressure relief valve
is dripping or leaking, have a qualified
person replace it.

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

Do not plug valve.

Do not remove valve.

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

Figure 14
Temperature and Pressure
Relief Valve Installation

Optional location
some models only

Temperature and
Pressure Relief Valve

Discharge Pipe

(Do not cap or plug.)

Drain Line

3/4” ID minimum

6" Maximum
Air Gap

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 data plate of the water heater.

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 15.

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 15. 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 15).

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.

Floor

Metal Drain Pan

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 14). 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 and
Automatic Shut-off Devices 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 data plate.

Drain

Figure 15
T&P Relief Valve Insulation

Manual Relief Lever

T&P Relief Valve

T&P Relief Valve
Drain Line

T&P Relief Valve Insulation

15

Special Applications

Combination Space Heating/Potable
Water System

Some water heater models are equipped with inlet/
outlet tappings for use with space heating applications.
Note: This water heater is suitable for combination water
(potable) heating and space heating and not suitable for
space heating applications only. If this water heater is to be
used to supply both space heating and potable (drinking
water), the instructions listed below must be followed.

• Be sure to follow the manual(s) shipped with the air
handler system.

• This water heater is not to be used as a replacement
for an existing boiler installation.

• Do not use with piping that has been treated with
chromates, boiler seal or other chemicals and do not
add any chemicals to the water heater piping.

• If the space heating system requires water tempera­tures in excess of 120°F, a mixing valve or an anti­scald device should be installed per its manufacturer’s
instructions in the domestic (potable) hot water supply
to limit the risk of scald injury.

• Pumps, valves, piping and fittings must be compatible
with potable water.

• A properly installed flow control valve is required to pre­vent thermosiphoning. Thermosiphoning is the result
of a continuous flow of water through the air handler
circuit during the off cycle. Weeping (blow off) of the
temperature and pressure relief valve (T & P) or higher
than normal water temperatures are the first signs of
thermosiphoning.

• The domestic hot water line from the water heater
should be vertical past any mixing valve or supply line
to the air handler to remove air bubbles from the sys­tem. Otherwise, these bubbles will be trapped in the air
handler heat exchanger coil, reducing the efficiency.

• Do not connect the water heater to any system or
components previously used with non-potable water
heating appliances when used to supply potable water.

Some jurisdictions may require a backflow preventer
in the incoming cold water line. This may cause the
temperature and pressure relief valve on the water heater
to discharge or weep due to expansion of the heated water.
A diaphragm-type expansion tank suitable for potable
water will normally eliminate this weeping condition. Please
read and follow the manufacturer’s instructions for the
installation of such tanks.

Also see “Water System Piping” section for additional
instructions on the proper installation and operation of this
water heater.

Figure 16
Typical Mixing Valve Installation
Combination Space Heating/Potable
Water Heating System

Domestic

Hot Water

Out

Mixing
Valve

Hot

Water

Out

Unions

Metal Drain Pan

Must be vertical to
remove air bubbles

Cold Water Inle

Discharge Pipe

Do Not Cap or Plug

Shut-off

Valve

Floor Drain

Flow Control

t

Pump

To
Air

Handler

6" Maximum
Air Gap

Massachusetts code does
not allow this type installation.

Out

Handler

Valve

In

Coil

Air

Solar Installation

If this water heater is used as a solar storage heater
or as a backup for the solar system, the water supply
temperatures to the water heater tank may be in excess of
115°F. A mixing valve or other temperature limiting valve
must be installed in the water supply line to limit the supply
temperature to 115°F. The unit must be set to Standard
Mode (See Operating theTemperature Control System
section).

NOTE: Solar water heating systems can often supply water
with temperatures exceeding 180°F and may result in water
heater malfunction.

16

Important Information About This Water Heater

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

Installation Checklist

Water Heater Location

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

□ Installation area free of corrosive elements and

flammable materials.

□ Centrally located with the water piping system.

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

□ Located indoors and in a vertical position. Protected

from freezing temperatures.

□ Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted
floor.

□ Provisions made to protect the area from water

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

□ Sufficient room to service the water heater. See

“Clearances and Accessibility” section of this
manual.

□ Water heater not located near an air moving device.

Combustion Air Supply and Ventilation

□ Fresh air supply free of corrosive elements and

flammable vapors.

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.

□ Proper location on an outside wall selected for

Through the Wall Venting.

□ “A” Dimensions determined per water heater to

determine whether a Vertical Extension kit is
needed.

□ Optional Vertical Extension Kit Installed (if

necessary).

□ Heater centered directly under the roof opening

for Through the Roof Venting.

□ Through the roof venting has a 15 foot maximum

height for the 50 Gallon direct vent water heater
and a maximum of 14’ 3-1/4” for the 40 Gallon
direct vent water heater.

□ 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.

Water System Piping

□ Temperature and pressure relief valve properly

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

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

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

Gas Supply and Piping

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

heater data plate.

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

sediment trap.

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

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

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

17

OPERATING YOUR WATER HEATER

Lighting Instructions

Read and understand these directions thoroughly before
attempting to light or re-light the pilot. Make sure that the
view port (sight glass) is not missing or damaged. See
Figure 23. Make sure the tank is completely fi lled with
water before lighting the pilot. 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.

WARNING

Explosion Hazard

Replace view port if glass is missing
or damaged.

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

Lighting the Pilot:

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

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

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

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

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

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

If the Status Light Does Not Blink:

1. Wait 10 minutes before another lighting attempt.

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

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

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

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

6. Replace the outer door.

If the Pilot Does Not Light:

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

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

Each time you click the igniter button, you should be
able to see the spark by looking through the view port.
See Figure 23. (You may have to darken the room
lights to see the spark.) You do not have to push the
Control Knob in to check the Igniter button. Simply look
through the sight glass while clicking the Igniter button
and look for a spark. If you can’t see a spark when the
Igniter button is clicked, check the wiring connections
from the Igniter button and make sure that they are
tight.

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

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

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

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

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

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

18

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING:

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

A. This appliance has a pilot which is lighted by a

piezoelectric igniter. When lighting the pilot, follow these
instructions exactly.

B. BEFORE LIGHTING smell all around the appliance area

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

WHAT TO DO IF YOU SMELL GAS:

 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.

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

LIGHTING INSTRUCTIONS

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

2. Turn the gas control/temperature knob counterclockwise

to the "OFF" setting.

Gas control/
temperature knob

Igniter
Button

Status light

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

4. Turn the gas control/temperature knob clockwise

to “ PILOT” .

120° F (48.9° C)

Mark

Index mark

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

temperature knob. Never use tools. If the knob will not
push in or move by hand, don’t try to repair it, call a
qualified service technician. Force or attempted repair
may result in a fire or explosion.

D. Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to
inspect the applian ce. Water heaters subjected to flood
conditions or anytime the gas controls, main burner or
pilot h ave been submer ged in water r equire replac ement
of the entire water heater.

E. DO NOT USE THIS APPL IANCE IF THERE HAS BEEN AN

IGNITION OF VAPORS. Immed iately call a q ualif ied service
technician to inspect the appliance. Water heaters
subject ed to a flamm able vapors ign ition will s how a
discol oration on the air intake g rid (bottom of combustion
chamber) and require replacement of the entire water heater.

Press the gas control/temperature knob all the way in

5.

and hold it in. The knob should travel in about 1/4 inch
(6.35 mm) if it is set to "PILOT" correctly.

While holding the gas control/temperature knob in,
click the igniter button continuously (about once a
second) for up to 90 seconds or until Status Light
begins to blink.

When the status light starts blinking, release the gas

6.

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

If the status light does not start blinking within 90
seconds, repeat steps 2 through 5 up to THREE (3)
times, waiting 10 minutes between lighting attempts.

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

If the status light turns a solid color, release the gas
control/temperature knob and repeat steps 2 through 5
(waiting 10 minutes before attempting to relight the pilot).

If the status light does not start blinking after three lighting
attempts, turn the gas control/temperature knob to "OFF"
and call a qualified service technician or your gas supplier.

Thermopile

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

Pilot

TO TURN OFF GAS TO APPLIANCE

19

Burner Flames

Inspect the burner flames through the viewport. Flames
should be very small with a blue haze and small amounts
of yellow or orange at the edges. After several minutes
of operation, the burner screen may glow red. If large
flames are observed at any time, shut-off unit and call a
qualified person.

Figure 17
Flame Characteristics

Correct flame

soft blue

Water Temperature Stacking

Stacking occurs when a series of short draws of hot water
(3 gallons or less) are taken from the water heater tank.
This causes increased cycling of the burner and can result
in increased water temperatures at the hot water outlet.

This water heater’s temperature control has been designed
to accurately regulate the water temperature. However,
under certain operating conditions, the water temperature
may temporarily exceed the dial setting. Consequently, in
addition to setting the temperature no higher than 120°F,
we recommend the installation of a mixing valve or an anti­scald device in the hot water supply line or at the point of
use to further reduce the risk of scald injury. These devices
can be obtained from a plumbing service agency or your
retail supplier.

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 person.

20

Water Temperature Regulation

WARNING

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

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

Feel water before bathing or showering.

Temperature limiting valves are available.

The thermostat is adjusted to the pilot position when it
is shipped from the factory. Water temperature can be
regulated by moving the temperature dial to the preferred
setting. The preferred starting point is 120°F at the “HOT”
setting. Align the knob with the desired water temperature
as shown in Figure 18. There is a hot water scald potential
if the thermostat is set too high.
NOTE: Temperatures shown on the gas control valve/
thermostat are approximates. The actual temperature of the
heated water may vary.

IMPORTANT: Adjusting the thermostat past the 120°F bar
on the temperature dial will increase the risk of scald injury.
Hot water can produce first degree burns within:

Table 3:

Water

Temperature °F

110
116

116
122
131
140
149
154

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

Figure 18
Gas Control Valve/Thermostat
Settings

Gas Control/Temperature Knob

VAC

Igniter

NOTE: During low demand periods when hot water is not
being used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs.
If hot water use is expected to be more than normal, a
higher thermostat setting may be required to meet the
increased demand. When leaving your home for extended
periods (vacations, etc.) turn the temperature dial to the
vacation (VAC) setting. This will maintain the water at low
temperatures with minimum energy losses and prevent the
tank from freezing during cold weather.

Time for 1st

Degree Burn

(Less Severe Burns)

(normal shower temp.)

(pain threshold)

35 minutes

1 minute
5 seconds
2 seconds

1 second

instantaneous

120°F

Status
Light

Mark

Time for

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

45 minutes

5 minutes

25 seconds

5 seconds
2 seconds

1 second

21

Operating the Temperature Control System

Figure 19: Status Codes

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

VAC

Water Temperature Adjustment

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

NOTE: The temperatures indicated are approximates. The
actual temperature of the heated water may vary.

Status Light Code

Normal Flashes:

• 0 Flashes Indicates Control Off/Pilot Out.

• 1 Flash Indicates Normal Operation.

• Continuous Light indicates the gas control
valve/thermostat is shutting down.

Diagnostic Flashes: If the water heater is not working look

for the following diagnostic flashes after lighting the pilot.

2 Flashes Indicates Thermopile Voltage Low

4 Flashes Indicates Overheat Failure

5 Flashes Indicates Sensor Failure

7 Flashes Indicates Electronic Control Failure

8 Flashes See “Status Light Code Troubleshooting Chart.”

Operating Modes and Settings

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

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

22

Operational Conditions

Condensation

Moisture from the products of combustion condenses on the
tank surface and the outside jacket of the water heater and
forms drops of water which may fall onto the burner or other
hot surfaces. This will produce a “sizzling” or “frying” noise.
NOTE: This condensation is normal and should not be
confused with a leaking tank. Condensation may increase or
decrease at different times of the year.

High efficient energy saver water heaters will produce
larger amounts of condensation on initial start-up or when
a large amount of hot water is being used. NOTE: Do not
confuse this with a “tank leak”. Once the water reaches a
temperature of 120°F and the tank warms up (usually 1-2
hours), the condensation will stop.

IMPORTANT: 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 “Location Requirements” on page

5. Under no circumstances is the manufacturer to be held

responsible for any water damage in connection with this
water heater.

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 “Draining and

Flushing”.

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 few minutes of operation.

Safety Shut-off

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

1. The pilot flame is extinguished for any reason.

2. The water temperature exceeds 189°F (87°C).

3. Excessive combustion chamber temperatures.

4. The ignition of flammable vapors.

A thermopile is used to determine if a pilot flame is present,
and will shut off the gas supply to the main burner and the
pilot if the flame is absent. 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 ECO has functioned the
gas control valve/thermostat should be replaced by a qualified
person. Contact your local dealer for service information.

Anode Rod/Water Odor

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

Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water.
IMPORTANT: Do not remove this rod permanently as it will
void any warranties. A special anode rod may be available
if water odor or discoloration occurs.
NOTE: This rod may reduce but not eliminate water odor
problems. The water supply system may require special
filtration equipment from a water conditioning company to
successfully eliminate all water odor problems.

Artificially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease
the life of the water heater tank.

The anode rod should be inspected after a maximum of
three years and annually thereafter until the condition of
the anode rod dictates its replacement. NOTE: Artificially
softened water requires the anode rod to be inspected
annually.

The following are typical (but not all) signs of a depleted
anode rod:

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

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

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

In replacing the anode:

1. Turn off gas supply to the water
heater.

2. Shut off the water supply and
open a nearby hot water faucet to
depressurize the water tank.

3. Drain approximately 5 gallons
of water from tank. (Refer to
“Draining and Flushing” for proper
procedures). Close drain valve.

4. Remove old anode rod.

5. Use Teflon® tape or approved pipe
sealant on threads and install new
anode rod.

6. Turn on water supply and open a nearby hot water
faucet to purge air from water system.

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

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

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

Figure 20:

23

MAINTENANCE OF YOUR WATER HEATER

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
shut-off valve.

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

3. Close the cold water inlet valve.

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

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

6. Close the drain valve, 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.

Temperature and Pressure
Relief Valve

WARNING

Explosion Hazard

If the temperature and pressure relief valve
is dripping or leaking, have a qualified
person replace it.

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

Do not plug valve.

Do not remove valve.

Routine Preventative
Maintenance

At least annually, a visual inspection should be made of
the venting and air supply system, piping systems, main
burner, and pilot burner. 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.

• Build up of soot and carbon on the main burner and
pilot burner. Check for a soft blue flame.

• 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 person.

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

Manually operate
the temperature
and pressure relief
valve at least once
a year to make
sure it is working
properly. To prevent
water damage,
the valve must be
properly connected
to a discharge line
which terminates
at an adequate
drain. Standing clear of the outlet (discharged water may
be hot), slowly lift and release the lever handle on the
temperature and pressure relief valve to allow the valve to
operate freely and return to its closed position. 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 person.

Figure 21

Temperature and Pressure
Relief Valve

Manual Relief
Valve

Discharge line to drain

24

Replacement Parts

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 pages 31-32 for a list of available repair parts.

Removing the Burner Door Assembly

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

2. Turn the gas control/temperature knob to the “OFF”
position (Figure 18).

3. Remove the outer door.

4. Remove the four screws (1/4” nut driver) securing the
burner door assembly to
the combustion chamber
(Figure 23).

5. Disconnect the pilot tube
(7/16” wrench), the igniter
wire from the igniter lead
wire, and manifold tube
(3/4” wrench) at the gas
control valve/thermostat.
Also disconnect the red (+)
and white (-) thermopile
wires from the gas control
valve/thermostat. See
Figures 22 & 23.

6. Grasp the manifold tube
and push down slightly,
carefully remove the burner door assembly from the
burner compartment.

NOTE: Be sure not to damage internal parts.

Figure 22
Gas Control Valve/
Thermostat

VAC

Igniter
Button

Igniter
Lead
Wire

Igniter
Wire

Pilot
Tube

Manifold
Tube

White

Wire
(Right
Side)

Red
Wire
(Left
Side)

Natural Gas Burner (Ultra Low Nox)

Check the burner to see if it is dirty or clogged. The burner
may be cleaned with soft paint brush (Figure 24). Do not
use a wire brush or any tool that may damage the burner
screen. Important: Do not use the burner if the burner screen
is damaged. NOTE: Damage may be rips or holes in the
burner screen. Discoloration is normal.

Figure24
NaturalGas(LowNox)
Burner Door Assembly

Burner

Use brush on this surface.

Pilot Assembly

Figure 23
Burner Door Assembly
Removal

Piezo Igniter Button

Manifold Tube

Viewport

Pilot Tube

Outer Door
Not Shown

Manifold Component Block

Gas Control Valve/Thermostat

VAC

Burner Door Screws (4)

Thermopile
Wire
Connections

Burner Door

25

Replacing the Pilot/Thermopile Assembly

1. Remove the burner door 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 burner door assembly

(Figure 25).

WARNING

Figure 25
Manifold Component
Block Assembly

Retainer Clip

Burner Door
Opening

Manifold Component Block

Thermopile Connectors

Igniter Wire

Pilot Tube

3. Locate and remove the phillips screw attaching the pilot to
the pilot bracket,

then pull the pilot/thermopile assembly

(including the igniter wire) out of the burner door assembly.

4. Using a 7/16” wrench, loosen the nut securing the pilot
tube to the pilot assembly (right-hand threads).

5. Pull the pilot tube from the pilot assembly (Figure 26).

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

Using the old pilot tube as a guide, bend the new pilot

6.
tube to match the old one. Make only the bends closest
to the pilot before going to the next step.

Figure 26
Pilot/Thermopile Assembly

Thermopile Connectors

Igniter
Connector

Pilot/Thermopile
Assembly

Thermopile

Pilot

Explosion Hazard

Tighten all burner door screws
securely.

Remove any fiberglass between gasket

and combustion chamber.

Replace viewport if glass is missing or
damaged.

Replace manifold component block if missing
or removed.

Replace door gasket if damaged.

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

Pilot Tube
(Ferrule Nut
Not Shown)

7. Reconnect the pilot tube and tighten the nut securing it
to the pilot assembly. To prevent any bending of the pilot
bracket, use pliers to hold the pilot assembly bracket
while tightening the pilot nut.

IMPORTANT: Keep the pilot orifice in the pilot when

making the connection. DO NOT operate the water heater
without the pilot orifice installed.

8. Push the new pilot assembly connectors through the
opening in the burner door (See Figure 25).

9. Attach the pilot assembly to the Burner Door Assembly.

10.

Position the new thermopile wires through the top opening
of the manifold component block (Figure 25). Be sure that
the igniter wire is positioned through the middle opening
of the manifold component block. Position the pilot tube
through the bottom opening of the manifold component
block.

11. See “Replacing the Burner Door Assembly”.

26

Replacing the Burner Door Assembly

WARNING

Explosion Hazard

Figure 27
Combustion Chamber

Combustion Chamber

Tighten all burner door screws
securely.

Remove any fiberglass between gasket

and combustion chamber.

Replace viewport if glass is missing or
damaged.

Replace manifold component block if missing
or removed.

Replace door gasket if damaged.

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

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

2. Inspect the viewport for damage and replace as required.

3. Insert the burner door assembly into the burner
compartment.

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

5. Replace the four screws which secure the burner door
assembly to the combustion chamber and tighten
securely. There should be no space between the
gasket part of the burner door and combustion
chamber. IMPORTANT: Do not operate the water heater
if the door gasket does not create a seal between the
burner door and the combustion chamber.

6. Reconnect the manifold tubing (3/4” wrench), pilot
tubing (7/16” wrench), temperature sensor wires, and
thermopile wires to the gas control valve/thermostat.
(See Figure 22 for the correct position of the thermopile
wires.) Do not cross-thread or apply any thread sealant
to the fittings.

7. Reconnect the igniter wire.

8. Turn the gas supply on and refer to the “Lighting
Instructions” on page 18.

9. 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.

Door Gasket

Figure 28
Close-up inside view of the combustion chamber

Combustion Chamber

Piezoelectric Igniter System

The piezoelectric igniter system consists of the igniter
button, electrode, and wire. The pilot is ignited by an
electric spark generated when the igniter button is pressed.
(See Figure 29). Use only factory authorized piezoelectric

igniter parts for replacement.

Figure 29
Gas Igniter Assembly

VAC

Wire to Electrode

Igniter Button

Electrode

Pilot/Thermopile Bracket
(Opposite Side)

Pilot

Thermopile

Testing the Igniter System

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

27

Removing and Replacing the Gas
Control Valve/Thermostat

IMPORTANT: The gas control valve/thermostat is a standard

valve with wire leads that connect to the thermopile.
Removing the Gas Control Valve/Thermostat:

1. Turn the gas control/temperature knob to the “OFF”
position (Figure 18).

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

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

4. Disconnect the igniter wire from the igniter lead wire.
Disconnect the temperature sensor wire. Disconnect
the red (+) and white (-) thermopile wires. Disconnect
the pilot tube (7/16” wrench) and manifold tube (3/4”

wrench) at the gas control valve/thermostat (Figure 22).

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

6. To remove the gas control valve/thermostat, thread a 4”
section of gas pipe into the inlet and use it to turn the
gas control valve/thermostat (counterclockwise.) Do not
use 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.

Gas Control Valve/Thermostat:

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

• Be sure to use approved Teflon® tape or pipe joint
compound on the gas piping connections and fitting on
the back of the gas control valve that screws into tank.

• Be sure to remove the pilot ferrule nut from the new gas
control valve/thermostat.

• Turn the gas supply on and check for leaks. Test the
water heater by brushing on an approved noncorrosive
leak detection solution. Bubbles forming indicate a leak.
Correct any leak found.

• Be sure tank is completely filled with water before
lighting and activating the water heater. Follow the
“Lighting Instructions” on page 18.

• If additional information is required, contact Residential
Technical Assistance.

Operational Checklist

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Manifold component block properly installed.

4. No leaks at pilot and manifold connection.

5. Manifold door screws securely tightened.

TROUBLESHOOTING CHART

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER WILL NOT IGNITE 1. Pilot not lit

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

BURNER FLAME
YELLOW-LAZY

PILOT WILL NOT LIGHT OR
REMAIN LIT

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 thermopile

8. Non-functioning thermostat

9. Heater installed in a confined area

1. Insufficient secondary air

2. Low gas pressure

3. Flue clogged

4. Main burner line clogged

5. Obstruction in main burner orifice

1. Non-functioning igniter

2. Thermopile connection loose

3. Air in gas line

4. Proper Lighting Sequence not followed.
Gas Control /Temperature Knob was not
held in for sufficient time

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. Non-functioning thermopile

1. Light pilot

2. Turn temp. dial to desired temperature

3. Check with gas utility company

4. Notify utility-install trap in gas line

5. Clean, locate source and correct

6. Clean, locate source and correct

7. Replace thermopile

8. Replace thermostat

9. Provide fresh air ventilation

1. Provide ventilation to water heater

2. Check with gas utility company

3. Clean, locate source and correct

4. Clean, locate source and correct

5. Clean or replace orifice

1. Replace igniter pilot assembly

2. Seat connector firmly in socket

3. Bleed the air from the gas line

4. Do not attempt to relight if the status light is
lit, and the pilot flame is not visible through
the view port. Wait until the status light is no
longer lit, then follow lighting instructions on
the water heater

5. Check with gas utility company

6. Check with gas utility company

7. Notify utility-install sediment trap in gas line

8. Locate source and correct

9. Replace thermostat

10. Clean, locate source and correct

11. Replace thermopile

28

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

HIGH OPERATION COSTS 1. Thermostat set too high

INSUFFICIENT HOT WATER 1. Thermostat set too low

SLOW HOT WATER
RECOVERY

DRIP FROM RELIEF VALVE 1. Excessive water pressure

THERMOSTAT FAILS TO
SHUT-OFF

COMBUSTION ODORS 1. Insufficient secondary air

SMOKING AND CARBON
FORMATION (SOOTING)

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

BURNER FLAME FLOATS
AND LIFTS OFF PORTS

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

FLAME BURNS AT ORIFICE 1. Thermostat not functioning properly

PILOT FLAME
TOO SMALL

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

2. Sediment or lime in tank

3. Water heater too small

4. Wrong piping connections

5. Leaking faucets

6. Wasted hot water

7. Long runs of exposed piping

8. Hot water piping in outside wall

9. Low gas pressure

1. Insufficient secondary air

2. Flue clogged

3. Low gas pressure

4. Improper calibration

5. Thermostat set too low

6. Water heater too small

7. Wrong piping connections

8. Wasted hot water

2. Heater stacking

3. Closed water system

1. Thermostat not functioning properly

2. Improper calibration

2. Flue clogged

1. Insufficient secondary air

2. Low gas pressure

3. Flue clogged

4. Thermostat not functioning properly

5. Burner flame yellow-lazy

1. Orifice too large

2. High gas pressure

3. Flue clogged

4. Cold drafts

2. Low gas pressure

1. Pilot line or orifice clogged

2. Low gas pressure

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. Advise customer

8. Insulate piping

9. Insulate piping

1. Turn temperature dial to desired setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

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

5 Repair faucets

6. Advise customer

7. Insulate piping

8. Insulate piping

9. Check with gas utility company

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. Turn temperature dial to desired setting

6. Install adequate heater

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

8. 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

2. Clean, locate source and correct

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. See “Burner Flame Yellow-Lazy”

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

1. Replace thermostat

2. Check with gas utility company

1. Clean, locate source and correct

2. Check with gas utility company

29

STATUS LIGHT CODE TROUBLESHOOTING CHART

LED STATUS PROBLEM CORRECTIVE ACTION

0 FLASHES (LED NOT LIT) Pilot light is not lit. Not enough

power (millivolts) to keep it lit.

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

2 FLASHES Insufficient power (millivolts) to the

gas control valve/thermostat.

4 FLASHES High water temperature has

activated the over heat sensor.

5 FLASHES Sensor failure Replace the gas control valve/thermostat. If you

7 FLASHES Gas Control Valve/Thermostat

failure.

8 FLASHES This condition only appears if the

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

Follow the lighting instructions on the front of the
water heater and record any diagnostic codes.
See Diagnostic Status Light Code section.

1. Check all wiring connections. If problem
persists proceed to step 2.

2. Replace the thermopile. If you feel
uncomfortable with this procedure contact a
qualified person.

Replace the gas control valve/thermostat. If you
feel uncomfortable with this procedure contact a
qualified person.

feel uncomfortable with this procedure contact a
qualified person.

Replace the gas control valve/thermostat. If you
feel uncomfortable with this procedure contact a
qualified person.

Make sure that the gas control valve/thermostat
knob is set to OFF. Wait one minute. Remove
the outer door. Look through the sight glass for
a pilot flame. If a pilot flame is observed with the
gas control valve/thermostat knob set to the OFF
position, the pilot valve is stuck open. Turn the main
gas supply OFF. Replace the gas control valve/
thermostat. If you feel uncomfortable with this
procedure contact a qualified person.

If the pilot flame is not observed when the gas
control valve/thermostat knob is set to the OFF
position, wait 10 minutes for the thermopile to cool,
then attempt to relight the pilot by following the
lighting instructions on the water heater’s label. If
this condition returns, replace the gas control valve/
thermostat. If you feel uncomfortable with this
procedure contact a qualified person.

30

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 VENT CAP ASSEMBLY

2 OUTER WALL PLATE

3 INNER WALL PLATE

4 FLEX VENT PIPE (WITH CLAMPS)

5 UPPER AIR BOX

6 4” TO 3” REDUCER

7 DRAIN VALVE

8 FLUE BAFFLE

9 DIP TUBE

10 LOWER AIR BOX

11 SNAP IN PLUG

12 TEMPERATURE & PRESSURE RELIEF VALVE

13 GAS CONTROL VALVE/THERMOSTAT

14* MANIFOLD DOOR GASKET

15 FLANGE

16 DRAIN VALVE

17 ANODE ROD

18* VIEWPORT

19 DOOR SCREW

20* BURNER DOOR ASSEMBLY (NAT. GAS)

21* MANIFOLD COMPONENT BLOCK

22 OUTER DOOR

23 OPTIONAL VENT GUARD (SEE PAGE 12, -KIT # 6907245)

Parts Description

1

2

3

4

6

8

12

17

18

19

21

22

13

14

15

16

19

20

11

11

5

7

10

9

*Pictured on next page.

LEGEND

Special anode rod (see page 23)

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

31

Listed Parts Kits and Illustrations

Item 14: Manifold door gasket

Item 18: Viewport

Item 20: Burner Door assembly, which contains the burner, gasket, door, pilot tube, manifold component block with

retainer clip, temperature sensor, and pilot assembly. (Natural Gas/Low Nox)

Item 20a: Pilot assembly kit, which contains the pilot, electrode, and thermopile (Natural Gas)

Item 20b: Flexible manifold tube

Item 21: Manifold component block and retainer clip

Item #20a

14

20b

20

21

18

32

NOTES

33

NOTES

34

NOTES

35

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