Whirlpool FG6140T403NOV, FG6130T303NOV, FG1F5050T4NOV, FG6150S403NOV, FG6130S303NOV Installation And Use Manual

TM

HEATERS

Gas Water Heater

with the Flame Lock TM

Safety System

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.

Installation

Instructions and

Use & Care Guide

To obtain technical, warranty, or service assistance during or
after the installation of this water heater, call toll free:

1-877-817-6750

When calling for assistance, please have the following

information ready:

I. Model number

2. 7 Digit product number

3. Serial number

4. Date of installation

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

6510233

September 2001

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:

You can be killed or seriously injured if you don't
immediately follow instructions.

You can be killed or seriously injured if you don't
follow instructions.

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 service technician. Water
heaters subjected to flood conditions or anytime 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, including formaldehyde, carbon

monoxide, and soot.

PAGE

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

Installing Your Gas Water Heater ................................................ 3-16

Unpacking the Water Heater ....................................................... 3

Location Requirements .............................................................. 4

Gas Supply ................................................................................. 6

Combustion Air Supply and Ventilation ....................................... 7

Water System Piping ................................................................ 12

Installation Checklist ................................................................ 16

Operating YourWater Heater .................................................... 17-19

Lighting Instructions ....................................................................... 17

Operational Conditions ............................................................ 19

Maintenance of YourWater Heater ..................................... 20-24

Trouble Shooting Chart ............................................................ 25-26

Repair Parts Illustration ............................................................ 27-28

I ;TALL! YOU GAS EATE

Consumer information

This water heater is design-certified by CSA
International as a Category I, non-direct vented water

heater which takes its combustion air either from the
installation area or from air ducted to the unit from the
outside.

This water heater must be installed according to all
local and state codes or in the absence of local and

state codes with the "National Fuel Gas Code", ANSI
Z223.1 (NFPA 54)- latest edition. This is available from
the following:

American Gas Association

1515 Wilson Boulevard

Arlington, VA22209

National Fire Protection Agency

1 Batterymarch Park

Quincy, MA02269
Check your phone listings for the local authorities

having jurisdiction over your installation.

Consumer Responsibilities

This manual has been prepared to acquaint you with
the installation, operation and maintenance of your gas

water heater and provide important safety information in

these areas.
Read all of the instructions thoroughly before

attempting the installation or operation of this water
heater. Keep this manual for future reference.

Service to the Flame Lock TM safety system should
only be performed by a qualified service technician.

The manufacturer of this water heater will not be liable

for any damages 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.

Unpacking the Water Heater

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.

Removing Packaging Materials

Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater

or on the inside of 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 packaging material in

the proper manner.

_lLVapors from flammable liquids will

explode and catch fire causing death or
severe burns.

Do not use or store flammable products

such as gasoline, solvents or adhesives

in the same room or area near the water
heater.

Keep flammable products:

1. far away from heater

2. in approved containers,

3. tightly closed and

4. out of children's reach.
Water heater has a main burner and pilot

flame. The pilot flame:

1. is on all the time and

2. will ignite flammable vapors.
Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the floor and

4. can be carried from other rooms to
the pilot flame by air currents.

Do not install this water where flammable
products will be stored.

Location Requirements

Carbon Dioxide Poisoning Hazard

Do not install in a mobile home.
Doing so can result in death or carbon

monoxide poisoning.

The Flame Lock TM safety system is designed to reduce
the risk of flammable vapor related fires. The patented

system protects your family by trapping the burning
vapors within the water heater combustion chamber
through the special flame-trap. The burning vapors

literally "burn themselves out" without escaping back
into the room. In the event of a flammable vapor

incident, the Flame Lock TM safety system shuts off the
gas supply to the water heater's burner and pilot
preventing re-ignition of any remaining flammable
vapors in the area. This will permanently disable the

water heater.
Although this water heater is equipped with the Flame

Lock TM safety system, areas where flammable liquids
(gasoline, solvents, liquid propane, butane, etc.) or
other substances which emit flammable vapors are

stored are not suitable for water heater installation.

Never store or use flammable substances in the same
room or area containing a gas 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.

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.

Locate the water heater as close to the chimney or

gas vent as practical. Consider the vent system

piping and combustion air supply requirements

when selecting the water heater location. The
venting system must be able to run from the water

heater to termination with minimal length and

elbows.

* Locate the water heater near the existing gas

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

Note: The water heater must be installed according to
all local and state codes or in absence of the local and
state codes with the "National Fuel Gas Code", ANSI

Z223.1 (NFPA54)-Iatest edition.

Important:Thewaterheatershouldbelocatedinan
areawhereleakageofthetankorconnectionswillnot
resultindamagetotheareaadjacenttothewater

heaterortolowerfloorsofthestructure.Duetothe
normalcorrosiveactionofthewater,thetankwill

eventuallyleakafteranextendedperiodoftime.A
suitablemetaldrainpanshouldbeinstalledunderthe

waterheaterasshownbelow,tohelpprotectthe

propertyfromdamagewhichmayoccurfrom
condensateformationorleaksinthe piping
connectionsortank.Thepanmustlimitthewater
leveltoa maximumdepthof13/4inchesandbetwo
incheswiderthantheheaterandpipedtoan
adequatedrain.Thepanmustnotrestrictcombustion

airflow.Locatethewaterheaternearasuitable
indoordrain.Outsidedrainsaresubjecttofreezing

temperatureswhichcanobstructthedrainline.The
pipingshouldbeatleast3/4"IDandpitchedfor
properdrainage.Undernocircumstanceswillthe
manufacturerbeheldliableforanywaterdamagein

connectionwiththiswaterheater.

1 3/4" Max

t

At least 2" inches greater
than the diameter of the "--_

water heater.

,, 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.

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

Pipe to

adequate

drain

Figure 1

Air Moving

Devices

Exhaust

Fan

/

L Reverse flow

of gases

Clearances and Accessibility

Notice: Minimum clearances from combustible

materials are stated on the data plate adjacent to the
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 3 inches (76.2mm) in any direction or if in a
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
Minimum Clearance
Locations

vi"-Back Sides

CTI_i°Pn___

service

II* Vent

si es- lFI!

T® l

View

State of California

Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake.

Contact local utilities for code requirements in your area
or call 1-877-817-6750 and request instructions.

Gas Supply

Explosion Hazard

Use a new AGA or CSA approved gas

supply line.

Install a shut-off valve.
Do not connect a natural gas water

heater to a L.P. Gas Supply.
Failure to follow these instructions can

result in death, explosion, or carbon
monoxide poisoning.

OBSERVE ALL GOVERNING CODES AND ORDINANCES.

Gas Requirements

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. 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 absence of local and state codes

with the "National Fuel Gas Code", ANSI Z223.1

(NFPA54)-Iatest edition.
Tables 1 and 2 on page 7 are provided as 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 drip leg (if not already incorporated as part
of the water heater) as shown. The drip leg must be
no less than 3 inches long for the accumulation of
dirt, foreign material and water droplets.

3. Install a ground joint union between the gas
valve/thermostat and the manual shut-off valve.

This is to allow easy removal of the gas valve/
thermostat.

.

Turn the gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles
forming indicate a leak) or other approved method.

Figure 3
Gas Piping

Manual Gas c:::3
Shut-off Valve

Ground

[

Check with
local utility

for min. height

1

Joint _---_

Union

3 in. min.

t/

Drip leg"

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 shut-off valve must be disconnected

from the gas supply piping system and the line
capped.

_, If the gas lines are to be tested at a pressure less

than 14" W.C., the water heater must be isolated
from the gas supply piping system by closing its

manual shut-off valve.

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 service

technician after installation of the gas piping system.

LP Gas

Explosion Hazard

Have a qualified person make sure L.R

gas pressure does not exceed 13" water

column.

Examples of a qualified person include

licensed heating personnel, authorized
gas company personnel, and authorized
service personnel.

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

Table 1

Natural Gas Pipe Capacity Table (Cu. Ft./hr)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity

of 0.60 (natural gas).
Nominal Iron Pipe Length of Pipe, Feet

Size, in. 10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/2 132 92 73 63 56 50 46 43 40 38 34 31 28 26
3/4 278 190 152 130 115 105 96 90 84 79 72 64 59 55

1 520 350 285 245 215 195 180 170 160 150 130 120 110 100
1-1/4 1050 730 590 500 440 400 370 350 320 305 275 250 225 210
I-I/2 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour
required for the gas input rating of the water heater. By formula:

Cu. Ft. Per Hr. Required=

The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT _)
may be determined by consulting the local natural gas utility.

Gas Input of Water Heater (BTU/HR)

Heating Value of Gas (BTU/FT 3)

Table 2
LP Gas Capacity Table

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water
column pressure). Based on a Pressure Drop of 0.5 Inch Water Column.

Nominal Iron Pipe Length of Pipe, Feet
Size, in. 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63

3/4 576 393 315 267 237 217 196 185 173 162 146 132

1 1071 732 590 504 448 409 378 346 322 307 275 252

I-1/4 2205 1496 1212 1039 913 834 771 724 677 630 567 511

Example: Input BTU requirement of the water heater I00,000 BTUH

Total pipe length, 80 feet = 3/4" IPS required.

Additional tables are available in the latestedition of the "National Fuel Gas Code", ANSI Z223.1

Combustion Air Supply and

Ventilation

Carbon Monoxide Warning

Follow all the local and state codes or in
absence of local and state codes the

"National Fuel Gas Code", ANSI Z223.1
(NFPA 54)- latest edition to properly

install vent system.
Failure to do so can result in death,

explosion, or carbon monoxide poisoning.

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

warranty coverage.

The following types of installation (but not limited to the

following) will require outdoor air for combustion due to

chemical exposure and may reduce but not eliminate
the presence of corrosive chemicals in the air:

,, Beauty shops
,, Photo processing labs
,, Buildings with indoor pools

,, Water heaters installed in laundry, hobby or

craft rooms.
Water heaters installed near chemical storage

areas.

Combustion air must be free of acid-forming chemicals
such as sulfur, fluorine, and chlorine. These elements

are found in aerosol sprays, detergents, bleaches,
cleaning solvents, air fresheners, paint and varnish
removers, refrigerants, and many other commercial and
household products. When burned, vapors from these
products form highly corrosive acid compounds. These
products should not be stored or used near the water

heater or air inlet.
Combustion and ventilation air requirements are

determined by the location of the water heater. The
water heater may be located in either an open
(unconfined) area or in a confined area or small

enclosure such as a closet or small room. Confined
spaces are areas with less than 50 cubic feet for each

1,000 BTUH of the total input for all gas-using

appliances.

Unconfined Space

A water heater in an unconfined space uses indoor air
for combustion and requires at least 50 cubic feet for

each 1,000 BTUH of the total input for all gas
appliances. The table below shows a few examples of
the minimum square footage (area) required for various
BTUH inputs.

Table 3

BTUH Typical Room

Input with 8' Ceiling

Figure 4
Opening Locations-
Confined Spaces

I

Permanent

openings to
the outside or

additional

rooms within

the building

I

12" inches maximum

...1.._

Closet

or

-- Other
Confined

Space

30,000
45,000

60,000
75,000

90,000

105,000
120,000

135,000

9x21
14x20
15x25
15x31

20 x 28
20 x 33
25x 30
28 x 30

Important:

,, The area must be open and be able to provide the

proper air requirements to the water heater. Areas
that are being used for storage or contain large

objects may not be suitable for water heater
installation.

,, Water heaters installed in open spaces in buildings

with unusually tight construction may still require
outdoor air to function properly. In this situation,
outside air openings should be sized the same as

for a confined space.

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

Confined Space

For the correct and proper operation of this water
heater, ample air must be supplied for the combustion,

ventilation and dilution of flue gases. Small enclosures
and confined areas must have two permanent openings
so that sufficient fresh air can be drawn from outside of

the enclosure. One opening shall be within 12 inches of
the top and one within 12 inches of the bottom of the

enclosure as shown in Figure 4.
The size of each opening (free area) is determined by

the total BTUH input of all gas utilization equipment
(i.e., water heaters, furnaces, clothes dryers, etc.) and

the method by which the air is provided. The BTUH
input can be found on the water heater data plate.

Additional air can be provided by two methods:

1. All Air from Inside the Building.

2. All Air from Outdoors.

12" inch
maximum

All Air from Inside the Building

When additional air is to be provided to the confined
area from additional room(s) within the building, the
total volume of the room(s) must be of sufficient size to
properly provide the necessary amount of fresh air to
the water heater and other gas utilization equipment in
the area. If you are unsure that the structure meets this
requirement, contact your local gas utility company or
other qualified agency for a safety inspection.

Each of the two openings shall have a minimum free
area of 1 square inch per 1,000 BTUH of the total input
rating of all gas utilization equipment in the confined
area, but not less than 100 square inches (Figure 5).

Confined

Space

Permanent
Openings

inch/1000
BTUH

(min, 100

+_.....1 square

sq. in)

Figure 5
All Air From Inside Building
Confined Space Installation

All Air from Outdoors

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

ducts. The fresh air can be taken from the outdoors or

from crawl or attic spaces that freely communicate with

the outdoors. Attic or crawl spaces cannot be closed
and must be properly ventilated to the outside.

Ductwork must be of the same cross-sectional area as
the free area of the opening to which they connect. The

minimum dimension of rectangular air ducts cannot be
less than 3 inches.

The size of each of the two openings is determined by
the method in which the air is to be provided. Refer to

Table 4 to calculate the minimum free area for each
opening. Figures 6, 7, and 8 are typical examples of

each method.

Louvers and Grilles

In calculating free area for ventilation and combustion
air supply openings, consideration must be given to the
blocking effect of protection louvers, grilles, and
screens. These devices can reduce airflow, which in
turn may require larger openings to achieve the
required minimum free area. Screens must not be
smaller than 1/4-inch mesh. If the free area through a
particular design of louver or grille is known, it should
be used in calculating the specified free area of the
opening. If the design and free area are not known, it

can be assumed that most wood louvers will allow
20 - 25% of free area while metal louvers and grilles will

allow 60 - 75% of free area.
Louvers and grilles must be locked open or

interconnected with the equipment so that they are
opened automatically during equipment operation.

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

Table 4

Gable vent
to outdoors

Install above

insulation

Confined " Outlet
Space -- air to attic

Alternate _ from the
Air Inlet.. / crawl

/€_ space

F

1 sq. inch per Open
4000 BTUH Foundation '_

Figure 6

All Air from Outdoors; Inlet Air from Ventilated

Crawl Space/Outlet Air to Ventilated Attic

[_S nstall above

Confined
Space

i _! Outletair

Vent

Gable vent
to outdoors

insulation

b to attic

4000 BTUH

\

\

Figure 7

All Air from Outdoors
Through Ventilated Attic

\ 12" inches max.

1 Sq. inch per

4000 BTUH

Inlet air

1 Sq. inch per

4000 BTUH

Inlet air duct
1 sq. inch per

-,-.,,,

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

Based on the total BTUH input rating for all gas utilizing equipment
within the confined space.

Minimum Free Area

Opening Per Opening Reference

Source (sq. in.) Drawing

Direct to 1 Square inch per 4000 Figure 6

outdoors BTUH

Vertical ducts 1 Square inch per 4000 Figure 7

Horizontal ducts 1 Square inch per 2000 Figure 8

Example: A water heater with an input rate of 50,000 BTUH using
horizontal ducts would require each opening to have a minimum

free area of 25 square inches.

Minmum Free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25

Sq. Inches.

BTUH

BTUH

These openings connect directly with the outdoors
through a ventilated attic, a ventilated crawl space,
or through an outside wall.

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

1 Sqe,rnCh_..

2000 BTU H "___

Confined
Space

Figure 8 1 sq. Inch
All Air from Outdoors per

Using Horizontal Ducts 2000 BTUH

Outlet t

Outdoor

Air Ducts

Inlet _'

Vent Pipe System

Vent Pipe Size

This water heater uses a non-direct, single-pipe vent
system to remove exhaust gases created by the
burning of fossil fuels. Air for combustion is taken from

the immediate water heater location or is ducted in from
the outside (see "Combustion Air Supply and

Ventilation").
This water heater must be properly vented for the

removal of exhaust gases to the outside atmosphere.
Correct installation of the vent pipe system is
mandatory for the proper and efficient operation of this

water heater and is an important factor in the life of the

unit.
The vent pipe must be installed according to all local

and state codes or in absence of local and state codes

with the "National Fuel Gas Code", ANSI Z223.1

(NFPA54)qatest edition. The vent pipe installation must
not be obstructed so as to prevent the removal of
exhaust gases to the outside atmosphere.

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

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

technician.

Drafthood Installation

Align the legs of the draft hood with the slots provided.

Insert the legs and secure the drafthood to the water
heater's top with the four screws provided as shown in
Figure 9. Do not alter the drafthood in any way. If you
are replacing an existing water heater be sure to use
the new drafthood supplied with the water heater.

Figure 9
Drafthood Installation

heet_tal Screws (four provided)

_-_ Drafthood

_- Jacket top

Install the drafthood with
the four screws provided.

The vent pipe must be installed according to all local
and state codes or in absence of local and state codes

with the "National Fuel Gas Code", ANSI Z223.1
(NFPA54)-Iatest edition. It is important that you follow
the guidelines in these instructions for sizing a vent pipe
system. If a transition to a larger vent size is required,

the vent transition connection must be made at the
drafthood outlet.

Vent Connectors

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

2. Single Wall Vent Pipe.

Maintain the manufacturer's specified minimum
clearance from combustible materials when using type

B doublewall vent pipe.
Vent connectors made of type B, double wall vent pipe

material may pass through walls or partitions
constructed of combustible material if the minimum

listed clearance is maintained.

Maintain a 6 inch minimum clearance from all
combustible materials when using single wall vent pipe.

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

When installing a vent connector, please note the
following:

• Install the vent connector avoiding unnecessary

bends, which create resistance to the flow of vent

gases.

_, Install without dips or sags with an upward slope of

at least 1/4-inch per foot.

,, Joints must be fastened by sheet metal screws or

other approved means. It must be supported to

maintain clearances and prevent separation of

joints and damage.

_, The length of the vent connector cannot exceed

75% of the vertical vent height.

• The vent connector must be accessible for

cleaning, inspection and replacement.

• Vent connectors cannot pass through any ceiling,

floor, fire wall, or fire partition.

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

10

Chimney Connection

Important: Before connecting a vent to a chimney,
make sure the chimney passageway is clear and free of
obstructions. The chimney must be cleaned if
previously used for venting solid fuel appliances or

fireplaces.

• The connector must be installed above the extreme
bottom of the chimney to prevent potential

stoppage of the flue gases.
The connector must be firmly attached and sealed

to prevent it from falling out.

,, To aid in removing the connector, a thimble or slip

joint may be used.

,, The connector must not extend beyond the inner

edge of the chimney as it may restrict the space
between it and the opposite wall of the chimney
(Figure 10).

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

Vertical Exhaust Gas Vent

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

It must be connected to the water heater's drafthood by
a certified vent connector or by directly originating at
the drafthood opening.

Vertical gas vents must terminate with a listed cap or
other roof assembly and be installed according to their

manufacturer's instructions.
Gas vents must be supported to prevent damage, joint

separation, and maintain clearances to combustible
materials (Figures 11 and 12).

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

gases.

An unused chimney flue or masonry enclosure may be

used as a passageway for the installation of a gas
vent(Figure 12).

Common (combined) venting is allowable with vertical
type B vent systems and lined masonry chimneys. The
vent pipe must be installed according to all local and

state codes or in absence of local and state codes with
the "National Fuel Gas Code", ANSI Z223.1 (NFPA 54)-

latest edition.
Figures 10-12 are examples of vent pipe system

installations and may or may not be typical for your
specific application. Consult the "National Fuel Gas

Code", NFPA54, ANSI Z223.1-1atest edition and the
guidelines set forth by prevailing local codes.

Figure 10
Chimney Termination

Vent System

I

Maintain 3 Ft. Min.._1
clearance

±

6 inches

minimum

Figure 11

Vertical Gas
Vent System

With Type B

Double Wall

Vent Pipe

Maintain

clearance

t

6 inches

minimum

Figure 12 _,
Venting Through
a Chimney 5 inches min,

with Type B Double
Wall Vent Pipe.

Maintain
clearance

±

t

6 inches
minimum

Certified Lined

F _himney

2 ft. min. above any object

Do not extend

beyond edge

of chimney

Connector

2 ft. min. above any object

Type B Double
Wall Vent Pipe

Maintain
specified

clearance

_l'_Listed Vent Cap

Vent

Connector

Unused chimney
flue or masonry

enclosure

within 10 ft,
Horizontally

Cap

within 10 ft,
horizontally

Maintain

specified
clearance

11

Water System Piping

Piping Installation

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

water piping must be protected by insulation.

Water supply pressure should not exceed 80% of the

working pressure of the water heater. The working

pressure is stated on the water heater's data plate. If
this occurs a pressure limiting valve with a bypass may

need to be installed in the cold water inlet line. This
should be placed on the supply to the entire house in

order to maintain equal hot and cold water pressures.
Important: Heat cannot be applied to the water fittings

on the heater as they may contain nonmetallic parts. If
solder connections are used, solder the pipe to the
adapter before attaching the adapter to the hot and cold

water fittings.

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

1. Install the water piping and fittings as shown in
Figure 13. Connect the cold water supply (3/4"
NPT) to the 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 tempering valve or an anti-scald device

in the domestic hot water line as shown in Figure

14. These valves reduce the point of use
temperature of the water by mixing cold and hot
water and are readily available for use. Contact a
licensed plumber or the local plumbing authority.

4. If installing the water heater in a closed water
system, install a relief valve or expansion tank in
the cold water line as specified under "Closed
System/Thermal Expansion" (Page 13).

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.

.

Install a temperature and pressure relief valve in
the opening marked "Temperature and Pressure(T
& P) Relief Valve" on the water heater. Add a
discharge line to the opening of the T & P relief
valve. Follow the instructions under Temperature
and Pressure Relief Valve" (Page 14).

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 13

Water Piping Installation

Hot Water

Drain Pan _"
1 3/4 inch depth max.

Figure 14
Typical Tempering

Valve Installation

Follow the tempering

valve manufacturer's
instructions.

Tempered water
to fixtures

In a closed system
use either:

1. Thermal Expansion Tank

_" 2. Pressure Relief Valve

Pressure reducing

valve with bypass

_, Cold Water

Cold Water

Inlet Valve

perature and

Pressure Relief Valve

Discharge line
above drain

Drain line
3/4 inch ID

j Drain Install vacuum relief

minimum Massachusetts: ]

in cold water line per
sect on 19 MGL142.

Water

l Cold

Inlet

Tempering valve
(Set to 120 ° f)

Inlet

12

Pleasenotethefollowing:

DONOTinstallthiswaterheaterwithironpiping.
Thesystemshouldbeinstalledonlywithnewpiping
thatissuitableforpotable(drinkable)watersuchas
copper,CPVC,orpolybutylene.DONOTusePVC
waterpiping.

DONOTuseanypumps,valves,orfittingsthatare
notcompatiblewithpotablewater.

DONOTusevalvesthatmaycauseexcessive
restrictiontowaterflow.Usefullflowballorgate
valvesonly.

DONOTuse50/50tin-leadsolder(oranylead
basedsolder)inpotablewaterlines.Use95/5tin-
antimonyorotherequivalentmaterial.

DONOTtamperwiththegasvalve/thermostat,
igniter,thermocouple,ortemperatureandpressure
reliefvalve.Tamperingvoidsallwarranties.Only
qualifiedtechniciansshouldservicethese
components.

DONOTusewithpipingthathasbeentreatedwith
chromates,boilerseal,orotherchemicals.

DONOTaddanychemicalstothesystempiping
whichwillcontaminatethepotablewatersupply.

Closed System/Thermal Expansion

Periodic discharge of the temperature and pressure
relief valve may be due to thermal expansion in a
closed water supply system. The water utility supply
meter may contain a check valve, backflow preventer or
water pressure reducing valve. This will create a closed
water system. During the heating cycle of the water
heater, the water expands causing pressure inside the
water heater to increase. This may cause the
temperature and pressure relief valve to discharge
small quantities of hot water. To prevent this from
happening, there are two recommendations:

1. Install a diaphragm-type expansion tank that is
suitable for potable water on the cold water supply

line. The expansion tank must have a minimum

capacity of 1.5 U.S. gallons for every 50 gallons of
stored water.

.

Install a 125 PSI pressure relief valve in the cold
water supply line. Make sure the discharge of this
valve is directed to an open drain and protected
from freezing. Contact the local water supplier or

plumbing inspector for information on how to
control this situation. Do not plug the temperature
and pressure relief valve.

13

Temperature and Pressure

Relief Valve

Explosion Hazard

If the temperature and pressure relief
valve is dripping or leaking, have a
licensed plumber repair it.

Do not plug valve.
Do not remove valve.

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

location

some models only

F Temperature and

Pressure Relief Valve

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 6 inches above a
floor drain or external to 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.

Discharge line 3/4

min.

Do not cap or plug.

6 inch

- maximum

Drain

l Figure 15

Drain Pan Relief Valve Installation

t

Temperature and Pressure

For protection against excessive pressures and
temperatures, a temperature and pressure relief valve
must be installed in the opening marked "T & P RELIEF
VALVE" (see Figure 15). This valve must be design
certified by a nationally recognized testing laboratory
that maintains periodic inspection of the production of
listed equipment or materials as meeting the
requirements for Relief Valves andAutomatic 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.

14

Special Applications

Combination Space Heating/Potable
Water System

Some water heater models are equipped with
inlet/outlet tappings for use with space heating
applications. If this water heater is to be used to supply
both space heating and domestic 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 tempering valve
or an anti-scald 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 tempering 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" (Page 12) for
additional instructions on the safe and correct

installation and operation of this water heater.

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 120°F. Atempering valve or other temperature
limiting valve must be installed in the water supply line
to limit the supply temperature to 120°F.

Note: Solar water heating systems can often supply
water with temperatures exceeding 180°F and may

result in water heater malfunction.

Domestic

Hot Water Must be vertical to

"_'/--remove air bubbles

Out

Temperingn 7 ^ Cold
Valve-,,,_J.[_ 1_1 Water

/

c::_,_::=:::::::__ Inlet

Flow Control

Pump Valve

HotII I tJl it-----

Water_t;l_]_ _ "_ I1

out h

Unions _ ___._t ATer

Handler

I III Shut-off

N

Figure 16
Typical Tempering Valve Installation

Combination Space Heating/Potable
Water Heating System

Massachusettscodedoesnot

a 0w th stypeof nsta aton

15

installation Checklist

Water Heater Location

• 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. Drain pan installed and piped to an
adequate drain.

• Installation area free of corrosive elements and
flammable materials.

• Sufficient room to service the water heater.
Water heater not located near an air moving device.

Combustion Air Supply and Ventilation

,, Sufficient fresh air supply for proper water heater

operation.
Fresh air not taken from areas that contain negative

pressure producing devices such as exhaust fans,
fireplaces, etc.

Fresh air supply free of corrosive elements and
flammable vapors.

• Fresh air openings sized correctly with
consideration given to the blocking effect of louvers
and grilles.

Ductwork is the same cross-sectional area as the
openings.

Vent Pipe System

• Drafthood properly installed.

• Vent connectors securely fastened with screws and
supported properly to maintain 6 inch clearance.

,, Vent connector made of approved material and

sized correctly.

,, Vent pipe system in accordance to all local and

state codes or in absence of local and state codes
with the "National Fuel Gas Code", NFPA54, ANSI

Z223.1-1atest edition.

!1

Flue baffle engaged in slots provided in the flue

tube.

o

Flue way, drafthood or vent pipe system not

obstructed in any way.

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 precautions

installed.

• Tempering valve installed per manufacturer's

instructions.

Gas Supply and Piping

• Gas supply is the same type as listed on the water

heater data plate.

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

drip leg.
Approved pipe joint compound used.

,, Adequate pipe size and of approved material.
,, Chloride-free soap and water solution or other

approved means used to check all connections and
fittings for possible gas leaks.

16

OPE G YOUR EATE

Lighting instructions

Read and understand these directions thoroughly
before attempting to light or re-light the pilot. Make sure
the tank is completely filled with water before lighting
the pilot. Check the data plate near the gas valve
control/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.

Replace viewport if glass is missing or damaged.

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

LIGHTINGINSTRUCTIONS

1. Remove the outer door.

2. Turn the temperature dial counterclockwise _ to its
lowest setting.

120 ° F

BAR

_o_N 1_

LP.G. (Bottled Propane) Models
Liquefied Petroleum Gas is over 50% heavier than air

and in the occurrence of a leak in the system the gas will
settle at floor level. Basements, crawl spaces, skirted
areas under mobile homes (even when ventilated),
closets and areas below ground level will serve as
pockets for the accumulation of gas. Before lighting an
LP. gas water heater, smell all around the appliance at
floor level. If you smell gas, follow the instructions as
given in the warning on the front page.

When your LP. tank runs out of fuel, turn off the gas at
all gas appliances including pilot lights. After the tank is
refilled, all appliances must be re-lit according to their

manufacturer's instructions.

Explosion Hazard

Depress the reset button all the way
in and IMMEDIATELY depress the igniter

button until you hear a loud click.
Observe the pilot through the view port.

Do not release the reset button. Repeat
immediately if pilot does not light on

the first try. If the pilot does not light
by the fourth attempt with the i_

_eat steps 3 - 6. Continue to hold the
button for about (1) minute after the

pilot is lit. Release the reset button and
it will pop back up. Pilot should remain
lit. If the pilot light goes out, repeat
steps 2- 6.

3. Turn gas control knob clockwise _'
to the "OFF" position.

4. To clear any gas that may have
accumulated wait ten (10) minutes.
If you then smell gas, STOPt Refer to the safety warning
on the cover. If you do not smell gas go to the next step.

5. Turn the gas control knob
counterclockwise V(_

to "PILOT".

1. Turn the temperature dial counterclockwise _'_ to its 2. Turn the gas control knob clockwise (_ to the "OFF"
lowest setting, position.

IMPORTANT: If the pilot will not stay lit after several tries,
turn gas control knob to "OFF" and call your service

technician or gas supplier.
IMPORTANT: If the reset button does not pop up when

released, stop and immediately shut off the gas at the line
valve or tank. Call your service technician or gas supplier.

7. Turn the gas control knob __

counterclockwise _ to"ON".

8. Set the temperature dial to
the desired setting.

9. Replace the outer door.

TOTURNOFFGASTO APPLIANCE

17

Checking the Draft

Burn Hazard

Do not touch vent.
Doing so can result in

burns.

After successfully lighting the water heater, allow the

unit to operate for 15 minutes and check the drafthood
relief opening for proper draft. Pass a match flame
around the relief opening of
the drafthood. A steady

flame drawn into the

Figure 17

Relief

opening indicates proper
draft. If the flame flutters or

is blown out, combustion
products are escaping from

Ma_ Opening

the relief opening. If this
occurs, do not operate the

water heater until proper

adjustments or repairs are made to the vent pipe
system.

Burner Flames

Figure 18

Inspect the burner

flames through the

viewport and compare
them to the drawings in

Figure 18. A properly
operating burner
should produce a soft

blue flame. Blue tips

with yellow inner cones

are satisfactory. The tips of the flame may have a slight
yellow tint. The flame should not be all yellow or have a
sharp blue-orange color. Contaminated air may cause
an orange colored flame. Contact a qualified service
technician if the flame is not satisfactory.

Flame Characteristics

Tips may have
a yellow tint

cones are

atisfactory

egow inner

Correct flame incorrect flame

soft blue lazy yellow

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. An anti-scald device is
recommended in the hot water supply line to reduce the

risk of scald injury.

Water Temperature Regulation

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

scalds.
Children, disabled and elderly are at

highest risk of being scalded.

See instructions manual before setting
temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available.

The thermostat is adjusted to its lowest temperature
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. Align the index bar on the thermostat with the
desired water temperature as shown in Figure 19.
There is a hot water scald potential if the
thermostat is set too high.

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:

120°F (49°C) more than 5 minutes
130°F (54°C) at 20 seconds
140°F (60°C) at 3 seconds
150°F (66°C) at 1-1/2 seconds
160°F (71 °C) at less than 1 second

Figure 19
Robertshaw Gas Valv_ Thermostat

Settings

Reset

Index

Bars

Control

Dial

Stop

Gas

Knob

130OF 120°F

130OF

Bar

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 service technician.

18

Note: During low demand periods when hot water is
not being used, a lower thermostat setting will reduce
energy losses and may satisfy your normal hot water

needs. If hot water use is expected to be more than
normal, a higher thermostat setting may be required to

meet the increased demand. When leaving your home
for extended periods (vacations, etc.) turn the
temperature dial to its lowest setting. This will maintain

the water at low temperatures with minimum energy
losses and prevent the tank from freezing during cold
weather.

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. 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. 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

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

4. 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.

.

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 180°F (83°C).

3. Excessive combustion chamber temperatures.

4. The ignition of flammable vapors.

A thermocouple is used to determine if a pilot flame is

present and will shut off the gas supply to the main
burner and the pilot burner if the flame is absent. In
addition, as part of the Flame Lock TM safety system,
this thermocouple is equipped with a thermal fuse

which is designed to disable the gas valve in the event
of excessive combustion chamber temperatures or a
flammable vapor ignition. If the fuse opens, the water
heater cannot be used unless the thermocouple is
replaced by a qualified service technician. Contact the

Product Service and Support Department for service

information at 1-877-817-6750.
A high temperature limit switch or ECO (Energy Cut Off)

in the tank is used to shut off the unit if the water
temperature exceeds 180°F (83°C). The ECO is a

single use switch and requires complete replacement of
the entire thermostat. If the ECO should function, the

water heater cannot be used until the thermostat is
replaced by a qualified service agency. Contact your

local dealer for service information.

Anode Rod/Water Odor

Each water heater contains at least one anode rod,
which will slowly deplete while protecting the glass-lined
tank from corrosion and prolonging the life of the water

heater. Certain water conditions will cause a reaction
between this rod and the water. Once the anode is

depleted, the tank will start to corrode, eventually
developing a leak. 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. Do not remove this rod
permanently as it will void any warranties, stated or

implied. The parts list includes a special anode that
can be ordered if water odor or discoloration occurs.

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 removed from the water
heater tank every 3 years for inspection. If the rod is

more than 50% depleted, the anode rod should be
replaced.

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.

.

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

7.

Restart the water heater as directed under
"Operating Your Water Heater." See the "Repair

Parts Illustration" for anode rod location on
page 27.

19

NTENANCE OF YOU WATER EATER

Draining and Flushing

It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may buildup

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. Close the cold water inlet valve.

3. Open a nearby hot water faucet.

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

Note: The drain hose should be rated for at least
200°F. Ifthe drain hose does not have this rating, open

the cold water inlet valve and a nearby hot faucet until
the water is no longer hot.

5. Open the water heater drain valve and allow all 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 under "Operating Your Water

Heater".

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.

3 Month Inspection

At least every 3 months, 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. See
section titled "Cleaning the Combustion Chamber
and Flame-trap."

,, 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.

Important: Verify proper operation after servicing this

water heater.

Temperature and Pressure

Relief Valve

Explosion Hazard

If the temperature and pressure relief

valve is dripping or leaking, have a

licensed plumber repair it.
Do not plug valve.

Do not remove valve.
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 valve and the cold water inlet valve and call
a qualified service technician.

Figure 20

Discharge line to drain

Self-Cleaning (Some Models)

Some water heaters may include a self-cleaning device
that inhibits the build-up of lime and other sediment on

the metal surfaces of the water heater. As cold water
passes through the dip tube, lime-causing particles and

minerals are suspended automatically. This controls
sediment and lime build-up within the tank and results
in higher efficiencies and lower operation costs.

2O

Replacement Parts

The following maintenance procedures are for the
Flame Lock TM safety system components and

should be performed by a qualified service

technician.
Replacement parts may be ordered through your

plumber or the local distributor. Parts will be shipped at
prevailing prices and billed accordingly. When ordering

replacement parts, always have the following
information ready:

1. Model, serial and product number.

2. Type of gas.

3. Item number.

4. Parts description.
See page 27 for a list of available repair parts.

Removing the Manifold Assembly

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

2. Turn the gas control knob on the combination gas
control valve/thermostat

clockwise to the "OFF"
position (Figure 19).

.

Remove the outer door.

4.

Remove the (2) screws
securing the manifold door

assembly to the skirt
(Figure 22).

.

Disconnect the
thermocouple (left-hand

thread), pilot tube, the
igniter wire from the igniter
button, and manifold tube

at the thermostat. (Figure

21.) Note: LR gas
systems use reverse (left-

hand) threads on the
manifold tube.

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

7. Carefully remove the manifold assembly from the
burner compartment. Be sure not to damage

internal parts.

Figure 21

Thermocouple Pilot

Igniter

Manifold

Tube

Tube

Figure 22

Burner Assembly

Removal

Piezo

igniter

Pilot Tube

Two Piece Wire

/ Connector

Thermocouple

Manifold

Tube

Manifold

Door

Manifold
Screw (2)

Gas Valve /
Thermostat

Removing the Burner from the
Manifold Assembly

Natural Gas Burner

1. Turn the burner counterclockwise to remove it from
the manifold assembly.

2. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(Figure 23A).

Figure 23A Two Piece Wire Manifold Door
Natural Gas Connector Assembly

Burner Assembly Burner

burner Thermocouple

To remove 1

Gasket

Thermocouple

Retainer Clip

Pilot Assembly

Igniter Wire

Viewport

Manifold

Thermocouple

Tube

21

Natural Gas Burner (Low Nox)

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

.

Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water
(Figure 23B).

Figure 23B Manifold Door
Natural Gas (Low Nox) Assembly

Burner Assembly S

Burner Connector ,_. Igniter Wire

Thermocouple \

Retainer Clip Pilot Assembly

Two Piece Wire

Pilot

Tube

Gasket Thermocouple

Pilot Bracket Viewport

LP. Gas Burner

1. Separate the pilot bracket from the LR burner by
removing screw.

2. Loosen set screw located on top of the L P.burner
near the manifold door. Carefully, pull the burner
away from the manifold door assembly.

3. Check the burner to see if it is dirty or clogged. The
burner may be cleaned with soap and hot water

(Figure 23C).

Figure 23C Manifold Door
LP. Gas Burner Manifold Door Assembly

Assembly Gasket _ig

Two Piece Wire

niter Wire

\

Pilot

Tube

Manifold

Replacing the Thermocouple

Important: Use only a factory authorized Flame

Lock TM safety system thermocouple for replacement.

1. Remove the manifold assembly as directed
previously.

2. Remove the retainer clip from the back of the two
piece wire connector. Remove the two piece wire

connector from the manifold door. Remove the
thermocouple (Figure 24).

3. Pull the thermocouple from the pilot assembly.
(Figures 23, and 27).

4. Push the new thermocouple through the holes in

the pilot bracket. Insert the thermocouple tube into
the holes provided in the pilot assembly until it
clicks into place.

5. Position the new thermocouple through the larger

opening of the two piece wire connector (Figure

24). Note: Thermocouple contains a thermal
fuse. Do not bend in the location shown below

(Figure 25). Be sure igniter wire is positioned

through the small opening of the two piece wire
connector.

.

See "Replacing Manifold Assembly" at the top of
next column.

Figure 24 Other fittings
Two Piece Wire not shown

Connector for clarity
Assembly igniter

Wire

Retainer Clip

/

Manifold

Thermocouple

S Door

Pilot Assembly

Thermocoupte Pilot Bracket
Retainer Clip

22

Thermocouple

,'iewport

Figure 25
Thermocouple
Assembly

Two Piece"

Wire Connector

Notice:

Thermocouple

must not be bent
in this location.

Cleaning the Combustion Chamber
and Flame-trap

1. Follow procedure outlined in "Removing the
Manifold Assembly".

2. Use a vacuum cleaner/shop vac to remove all loose
debris in the combustion chamber and flame-trap.
See Figure 26.

3. Reassemble following the procedure under
"Replacing the Manifold Assembly".

FI Bracket

Figure 26 _, , IIHII _" T_

Combustion Chamber u_J

Replacing the Manifold Assembly

Explosion Hazard

Tighten both manifold door screws
securely.

Remove any fiberglass between gasket
and combustion chamber.

Replace viewport if glass is missing or

damaged.

Replace two piece wire connector if
missing or removed.

Replace door gasket if damaged.

Failure to do so 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 manifold assembly into the burner
compartment making sure that tab of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figure 26). The tab is located

at the bottom of the burner for L.R models.

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

combustion chamber.

.

Replace the two (2) screws which secure the

manifold assembly door to the combustion
chamber. Tighten securely. There should be no
space between the gasket part of the manifold door
and combustion chamber. Do not operate the
water heater if the door gasket is not sealed.

.

Reconnect the manifold tubing, pilot tubing, and
thermocouple to the thermostat. Do not cross-
thread or apply any thread sealant to these fittings.

Note: L R gas systems use reverse (left-

hand) threads on the manifold tube.

,, The thermocouple nut should be started and

turned all the way in by hand. Note: These are
left-hand threads. An additional quarter turn
with a 7/16" open-end wrench will then be

sufficient to seat the Iockwasher.

7. Reconnect the igniter wire.

8. Turn gas supply on and refer to the "Lighting
Instructions" on page 17.

9. Check for leaks. Use a chloride-free soap and

water solution (bubbles forming indicate a leak) or
other approved method. All leaks must be fixed

immediately.

10. Replace the outer door.

23

Piezoelectric Igniter System

The piezoelectric igniter system is part of the Flame
Lock TM safety system and consists of the igniter button,
electrode and wire. The pilot is ignited by an electric
spark generated when the igniter button is pressed. The
spark gap of 0.125 inch is set when the electrode is
installed at the factory. (See Figure 27Aand 27B). Use
only factory authorized Flame Lock TM safety system
piezoelectric igniter parts for replacement.

Figure 27A
Natural Gas igniter Assembly

_4/-I°°"°" //P,,O,_ /

Igniter /._ Thermocouple

ec', ode Eiectro0e

iSnap-on Connector

Figure 27B
LP. IgniterAssembty

ThermocouplePilot _

-- Snap-on Connector

Testing the Igniter System

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

Pilot

Removing and Replacing the Gas

Control Valve/Thermostat

Important: The gas control valve/thermostat is a
standard valve with a left hand thread thermocouple
that is unique to the Flame Lock TM safety system. Use
only factory authorized replacement parts.

1. On the gas control valve/thermostat turn the
temperature dial counterclockwise to its lowest
setting. Turn the gas control knob clockwise to the

"OFF" position (Figure 19).

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" on page 20 and follow the
procedure.

4. Disconnect the igniter wire from the igniter button.

Remove the igniter button by depressing front and
rear holding tabs and lift. Remove igniter bracket.
Disconnect the thermocouple (left hand threads),
pilot tube, and manifold tube at the thermostat
(Figure 21). Note: L. P.gas systems use
reverse(left-hand) threads on the manifold tube.

5. Refer to "Gas Piping" (Figure 3) and disconnect the
ground joint union in the gas piping. Disconnect the

remaining pipe from the gas valve/thermostat.

Important: When removing the gas control
valve/thermostat do not use pipe wrench or vise to grip
body. Do not insert any type of blunt instrument into the
inlet or outlet connections. Using these type tools may
result in damage to the gas control valve/thermostat.

6. Turn the gas control valve/thermostat
counterclockwise. Remove the gas control

valve/thermostat.

To replace the gas control valve/thermostat reassemble
in reverse order. The gas control valve/thermostat is a
standard valve with a left hand thread thermocouple
that is unique to the Flame Lock TM safety system. Use
only factory authorized replacement parts.

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

,, Be sure to remove the pilot ferrule nut from the new

gas control valve/thermostat.
Turn gas supply on and check for leaks. Use a

chloride-free soap and water solution (bubbles
forming indicate a leak) or other approved method.

,, Be sure tank is completely filled with water before

lighting and activating the water heater. Follow the
"Lighting Instructions" on page 17.

If additional information is required, contact the
Service Department at: 1-877-817-6750.

24

Flame Lock TM Safety System Operational Checklist

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Flame-trap free of debris and undamaged.

4. Two piece wire connector properly installed.

5. No leaks at pilot and manifold connection.

6. Manifold door screws securely tightened.

TROUBLESHOOTING CHART

PROBLEM CORRECTIVE ACTION

BURNERWILLNOTIGNITE

SMELLYWATER
BURNERFLAMEYELLOW-LAZY Insufficientsecondaryair 1. Provideventilationtowater heater

PILOTWILLNOTLIGHTOR
REMAINLIT.

HIGHOPERATIONCOSTS

INSUFFICIENTHOTWATER

1. Pilotnottit

2. Thermostatsettoolow

3. Nogas

4. Dirtin thegaslines

5. Pilotlineclogged

6. Mainburnerlineclogged

7. Defectivethermocoupte

8. Defectivethermostat

9. Heaterinstalledin aconfinedarea

1. Sulfidesin thewater

1,

2.

Lowgas pressure 2. Checkwithgasutilitycompany

3.

Flueclogged 3. Clean,locatesourceandcorrect

4.

Mainburnerline clogged 4. Clean,locatesourceandcorrect

5.

Heaterinstalledina confinedarea 5. Properfreshairventilation

6.

Obstructioninmainburnerorifice 6. Cleanor replaceorifice

1.

Air in gasline

2,,

Nogas

3.

Dirtin gaslines

4.

PilotIineororificeclogged

5.

Thermocoupteconnectionloose

6.

Defectivethermocoupte

7.

Colddrafts

8.

ThermostatECOswitchopen

9.

Temperaturelimitswitchincombustionchamber

Activated

10.

Defectiveigniter

11.

Flammablevaporsincident,FlameLockTM function
utilized

12. Lowgas pressure

1. Thermostatsettoo high

2. Sedimentorlime intank

3. Waterheatertoosmallforjob

4. Wrongpipingconnections

5. Leakingfaucets

6. Gasleaks

7. Wastedhotwater

8. Longrunsofexposedpiping

9. Hotwaterpipinginexposedwail

1. Thermostatsettoolow

2. Sedimentorlimein tank

3. WaterheatertoosmaIt

4. Wrongpipingconnections

5. Leakingfaucets

6. Wastedhotwater

7. Longrunsofexposedpiping

8. Hotwaterpipingin outsidewall

9. Lowgas pressure

POSSIBLE CAUSE(S}

1. Lightpilot

2. Turn temp.dialto desiredtemperature

3. Checkwith gas utilitycompany

4. Notifyutility-installtrapingasline

5. Clean,locatesourceandcorrect

6. Clean,locatesourceandcorrect

7. Replacethermocoupte

8. Replacethermostat

9. Providefreshairventilation

1. Replacetheanodewitha specialanode

1. Bleedthe airfromthegasline

2. Checkwithgasutilitycompany

3. Notifyutility-installdirttrap in gasline

4. Clean,locatesourceandcorrect

5. Fingertighten;then1/4turnwithwrench

6. Replacethermocoupte

7. Locatesourceand correct

8. Replacethermostat

9. Call1-877-817-6750

10. Replaceigniterpilot assembly

11. Replacewaterheater,eliminateflammablevapors
source.Call1-877-817-6750

12. Checkwithgas utilitycompany

1. Settemperaturedialtolowersetting

2. Drain/Flush-Providewatertreatmentifneeded

3. Installadequateheater

4. Correctpiping-diptube mustbein coldinlet

5. Repairfaucets

6. Checkwithutility-repairatonce

7. Advisecustomer

8. Insulatepiping

9. Insulatepiping

1. Turntemperaturedialtodesiredsetting

2. Drain/flush-providewatertreatmentif needed

3. Installadequateheater

4. Correctpiping-diptubemustbeincold inlet
5 Repairfaucets

6. Advisecustomer

7. Insulatepiping

8. Insulatepiping

9. Checkwithgasutilitycompany

continued on next page

25

TROUBLESHOOTING CHART (continued)

PROBLEM POSSIBLE CAUSE(S} CORRECTIVE ACTION

SLOWHOTWATERRECOVERY 1. Insufficientsecondaryair 1.

2. Flueclogged

3. Lowgas pressure

4. Impropercalibration
5, Thermostatsettoolow

6. Waterheatertoosmall
7, Wrongpipingconnections

8. Wastedhotwater

DRIPFROMRELIEFVALVE

THERMOSTATFAILSTOSHUT
OFF

COMBUSTIONODORS

SMOKINGANDCARBON 1.

FORMATION(SOOTING)

CONDENSATION

BURNERFLAMEFLOATSAND
LIFTS OFFPORTS

BURNERFLAMETOOHIGH 1. Replacewithcorrectorifice
FLAMEBURNSATORIFICE 1. Replacethermostat

PILOTFLAME 1. Clean,locatesourceandcorrect

TOOSMALL 2. Checkwithgasutilitycompany

1. Excessivewaterpressure

2. Heaterstacking

3. Closedwatersystem

1. Defectivethermostat

2. Impropercalibration

1. Insufficientsecondaryair

2. Flueciogged

3. HeaterinstaItedinaconfinedarea

1. Insufficientsecondaryair

2. Lowgas pressure

3. Flueclogged

4. Defectivethermostat
5, Heaterinstalledin aconfinedarea

6. Burnerflameyellow-lazy

1. Temperaturesettingtoo low

1. Orificetoolarge

2. Highgaspressure

3. Flueclogged

4. Colddrafts

1. Orificetoo large

1. Defectivethermostat

2. Lowgas pressure

1. Pilottine ororifice clogged

2. Lowgas pressure

Provideventilationtowaterheater.Checkflueway
Fluebaffleandburner

2. Cleanflue,locatesourceandcorrect

3. Checkwithgasutilitycompany

4. Replacethermostat
5, Turntemperaturedialto desiredsetting

6. Installadequateheater
7, Correctpiping-diptubemustbe incoldinlet

8. Advisecustomer

1. Usea pressurereducingvalveand reliefvalve

2. Lowerthethermostatsetting

3. See"ClosedSystem/ThermalExpansion"

1. Replacethermostat

2. Replacethermostat

1. Provideventilationtowaterheater.Checkflue

way,fluebaffle,burner

2,

Clean,locatesourceandcorrect

3.

Providefreshairventilation
Provideventilationtowaterheater.Checkflueway,

flue baffle,burner

2. Checkwithgasutilitycompany

3. Clean,locatesourceandcorrect

4. Replacethermostat
5, Providefreshairventilation

6. See"BurnerFlameYellow-Lazy"

1. Increasethetemperaturesetting

1. Replacewithcorrectorifice

2. Checkwithgasutilitycompany

3. Cleanflueandburner-locatesource& correct

4. Locatesourceand correct

2. Checkwithgasutilitycompany

26

PARTS ILLUSTRAT!

location for top

T&P

Alternate anode ___

Anode location

for side T & P

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 Parts Description

No.

1 DRAFTHOOD

2 REDUCERRING- SOMEMODELS
3 FLUEBAFFLE
4 HEATTRAP(COLD)-SOMEMODELS

5 HEATTRAP(HOT)- SOMEMODELS
6 COLDWATERDIPTUBE

7 ANODEROD A,
8 TEMPERATURE& PRESSURERELIEFVALVE

(LOCATEDTOPORSIDE) •

9 DRAINVALVE

10 GASVALVE/THERMOSTAT _r
11,_ PILOTASSEMBLY/THERMOCOUPLEKIT

(NaturalGas)

12_ PILOTASSEMBLY/THERMOCOUPLEKIT

(L.P.Gas)

13 OUTERDOOR
14'_ MANIFOLDBURNERASSEMBLY(NaturalGas)

15_ MANIFOLDBURNERASSEMBLY(NaturalGas LowNox)
16'_ MANIFOLDBURNERASSEMBLY(L.P.Gas)

17_ TWOPIECEWIRECONNECTOR

WITHRETAINERCLIP
18'_ MANIFOLDDOORGASKET "k
19_ VlEWPORTASSEMBLY

LEGEND

A Special anode rod (see page 19)

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

Unique: Flame Lock TM safety system parts

Pictured on next page.

27

Listed Part Kits and Illustrations

item 11:

item 12:

item 14:

item 15:

item 16:

item 17:

item 18:
item 19:

Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter,
thermocouple, and retainer clip. (Natural Gas)

Pilot assembly/thermocouple kit, which contains the pilot assembly with piezoelectric igniter,
thermocouple, and retainer clip. (LR Gas)

Manifold burner assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (Natural Gas)

Manifold burner assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (Natural Gas Low Nox)

Manifold burner assembly which contains the manifold tube, gasket, door, pilot tube, thermocouple, two
piece wire connector with retainer clip, and pilot assembly. (LR Gas)

Contains two piece wire connector with retainer clip, and pilot assembly.
Contains manifold door gasket.
Contains viewport.

Item #11 Ite

Item #14

Item #17

Item #15

Item #18

Item #16

Item #1_9 1

®2001 Whirlpool "All rights reserved."

7MRegistered trademark/TM Trademark of Whirlpool, U.S.A.

28

Printed in the U.S.