Professional Documents
Culture Documents
Installation
Instructions and
Use & Care Guide
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
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
CONTENT
186221-004
June 2012
1
DANGER
WARNING
CAUTION
CAUTION
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 included 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
PAGE
WARNING
Consumer Information
Consumer Responsibilities
WARNING
FLAMMABLES
Flammable Vapors
WARNING
Fire or Explosion Hazard
Read instruction manual before installing,
using or servicing water heater.
Improper use may result in fire or explosion.
Location Requirements
WARNING
Site Location
DISCHARGE PIPE
(DO NOT CAP OR PLUG)
METAL
DRAIN
PAN
Figure 1A
Air-moving
Devices
Exhaust
Fan
Reverse flow
of gases
6 MAXIMUM
AIR GAP
Back
Vent
Top
to
ceiling
Sides
PIPED TO AN
ADEQUATE DRAIN
Front
24 minimum
for service
Sides
Top
View
State of California
NOTE: For California installation, this water heater must be
braced, anchored, or strapped to avoid falling or moving
during an earthquake. Correct installation procedure instructions may be obtained from Californias Office of the
State Architect, 1102 Q street, Suite 5100, Sacramento, CA
95811. Instructions can also be downloaded to your computer at www.dsa.dgs.ca.gov/Pubs.
Gas Supply
Figure 3
Gas Piping
Manual Gas
Shut-off Valve
WARNING
Ground
Joint
Union
Check with local
utility for
minimum height
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.
Table 1 on page 7 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.
6
Sediment Trap
Gas Pressure
IMPORTANT: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heaters data
plate. The minimum supply pressure is for the purpose of input
adjustment.
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.
beauty shops
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 BTU/HR of the total input for all gas appliances. The
table below shows a few examples of the minimum square
footage (area) required for various BTU/HR inputs.
Table 2
BTU/HR
Input
Minimum Square
Feet with
8' Ceiling
Typical Room
with 8' Ceiling
30,000
188
9 x 21
45,000
281
14 x 20
60,000
375
15 x 25
75,000
469
15 x 31
90,000
563
20 x 28
105,000
657
20 x 33
120,000
750
25 x 30
135,000
844
28 x 30
IMPORTANT:
Figure 4
Opening LocationsConfined Spaces
12 maximum
Permanent
openings to
the outside or
additional
rooms within
the building
12 maximum
Confined
Space
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 BTU/HR input of all gas utilization equipment (i.e.,
water heaters, furnaces, clothes dryers, etc.) and the
method by which the air is provided. The BTU/HR 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.
8
Closet
or
other
confined
space
1 square
inch/1000
BTU/HR
(minimum
100 sq. In.)
Figure 5
All Air from Inside Building
Confined Space Installation
Gable vent
to outdoors
Install above
insulation
Confined
Space
Alternate
Air Inlet
Opening Source
Install above
insulation
Confined
Space
Figure 7
All Air from Outdoors
Through Ventilated Attic
Figure 7
Horizontal ducts
Figure 8A
Single Opening
Figure 8B
12 maximum
1 sq. inch
per
2000 BTU/HR
Figure 6
Outlet air
to attic
1 Sq. inch per
4000 BTU/HR
Inlet air duct
1 sq. inch per
4000 BTU/HR
Reference
Drawing
Vertical ducts
Open
Foundation
Vent
Gable vent
to outdoors
Inlet air
from the
crawl
space
Figure 6
All Air from Outdoors; Inlet Air from Ventilated
Crawl Space/Outlet Air to Ventilated Attic
Table 3
Outlet
air to attic
1 Sq. inch per
4000 BTU/HR
Confined
Space
Outlet
Outdoor
Air Ducts
Inlet
Figure 8A
All Air from Outdoors
Using Horizontal Ducts
1 sq. Inch
per
2000 BTU/HR
Figure 9
Draft hood Installation
Sheet Metal Screws (four provided)
Alternative
Opening
Location
Draft hood
Legs
Legs
Confined
Space
1 sq. Inch
Per 3000 BTU/HR
Slot
Slot
Jacket top
3- 4 Draft Hood
Combination
Legs
Figure 8B
All Air from Outdoors
Using a Single Permanent Opening
Legs
Slot
Jacket top
4 Draft Hood
(50K Models)
Slot
Vent Connectors
1. Type B, Double wall, U.L. Listed Vent Pipe.
2. Single wall Vent Pipe.
Maintain the manufacturers specified minimum clearance from
combustible materials when using type B double wall vent
pipe.
Vent connectors made of type B, double wall vent pipe
material may pass through walls or partitions constructed
of combustible material if the minimum listed clearance is
maintained.
Maintain a six inch minimum clearance from all combustible
materials when using single wall vent pipe.
IMPORTANT: Single wall vent pipe cannot be used for water
heaters located in attics and may not pass through attic
spaces, crawl spaces or any confined or inaccessible location.
A single wall metal vent connector cannot pass through any
interior wall.
When installing a vent connector, please note the following:
Install the vent connector avoiding unnecessary bends,
which create resistance to the flow of vent gases.
Install without dips or sags with an upward slope of at least
1/4-inch per foot.
Joints must be fastened by sheet metal screws or other
approved means. It must be supported to maintain
clearances and prevent separation of joints and damage.
The length of the vent connector cannot exceed 75% of
the vertical vent height.
The vent connector must be accessible for cleaning,
inspection, and replacement.
Vent connectors cannot pass through any ceiling, floor,
firewall, or fire partition.
It is recommended (but not mandatory) that a minimum 12
inches of vertical vent pipe be installed on the draft hood
prior to any elbow in the vent system to improve conditions
for positive flow of venting gases.
IMPORTANT: Existing vent systems must be inspected for
obstructions, corrosion, and proper installation.
Chimney Connection
Listed Lined
Chimney
3 ft. minimum
*
Support
Strap
Slope up
1/4 in.
per ft.
minimum
3 ft. minimum
Support Strap
*
**
Vent
connector
slope up
1/4 in. per ft.
minimum
Figure 12
Venting Through
MAINTAIN MANUFACTURERS
a Chimney
SPECIFIED MINIMUM CLEARANCE
with Type B
Double Wall
Vent Pipe.
SUPPORT
STRAP
*MAINTAIN
CLEARANCE
VENT
CONNECTOR
SLOPE UP
1/4 IN. PER FT.
MINIMUM
SEAL
VENT CONNECTOR
UNUSED CHIMNEY
FLUE OR MASONRY
ENCLOSURE
Hot Water
Outlet
Union
Temperature and
Pressure Relief Valve
Discharge Pipe
Do Not Cap or Plug
Drain line 3/4
ID minimum
12
Pressure reducing
valve with bypass
1minimum
Metal
Drain Pan
1 3/4 depth maximum
Figure 14
Typical Mixing
Valve Installation
6 Maximum
Air Gap
Massachussetts:
Install a vacuum relief
in cold water line per
section 19 MGL 142.
Floor Drain
Cold
Water
Inlet
Tempered water
to fixtures
Mixing valve
(Set to 120F)
Use only full flow ball or gate valves. The use of valves
that may cause excessive restriction to water flow is
not recommended.
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.
13
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 15A
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
Floor
Drain
Metal Drain Pan
Special Applications
Combination Space Heating/Potable
Water System
Some water heater models are equipped with inlet/outlet
tappings 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 domestic potable (drinking) water,
the instructions listed below must be followed.
If the space heating system requires water temperatures in excess of 120F, a mixing valve or an antiscald device should be installed per its manufacturers
instructions in the domestic (potable) hot water supply
to limit the risk of scald injury.
Coil
Discharge P ipe
Do Not Cap o r Plug
Flow Control
Valve
Pump
In
Out
Air
Handler
Shut-off
Valve
6" Maximum
Air Gap
Metal Drain Pan
Floor Drain
Massachusetts code
does not allow this
type of installation.
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
120F. A mixing valve or other temperature limiting valve
must be installed in the water supply line to limit the supply
temperature to 120F. The unit must be set to Standard
Mode (See Operating the Temperature Control System
section).
NOTE: Solar water heating systems can often supply water
with temperatures exceeding 180F and may result in water
heater malfunction.
15
Installation Checklist
Water Heater Location
16
Explosion Hazard
17
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all safety warnings
before lighting the pilot.
5.
120 F (48.9 C)
Mark
control/temperature knob. Set the gas control/ temperature knob to the desired setting.
Igniter
Button
Status light
Index mark
Pilot
18
Burner Flames
WARNING
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. Make sure all other appliances
in the area are operating and all doors are closed when
performing the draft
test. Pass a match
Figure 17
Drafthood
flame around the
relief opening of the
Relief
Opening
drafthood. A steady
Match
flame drawn into the
opening indicates
proper draft. If
the flame flutters
or is blown out,
combustion products
are escaping from
the relief opening. If this occurs, do not operate the water
heater until proper adjustments or repairs are made to the
vent pipe system and/or air supply requirements.
19
WARNING
Water
Temperature F
Time for
Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110
116
116
122
131
140
149
154
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 seconds
Figure 19A
Gas Control Valve/Thermostat
Settings
Gas Control/Temperature Knob
120F
Status Mark
Light
VAC
Igniter
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 120F and the tank warms up (usually 1-2
hours), the condensation will stop.
VAC
Operational Conditions
Smoke/Odor
Normal Flashes:
0 Flashes
Safety Shut-off
2 Flashes
4 Flashes
5 Flashes
7 Flashes
8 Flashes
9 Flashes
NOTE: This anode 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:
22
WARNING
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.
Routine Preventive
Maintenance
At least annually, a visual inspection should be made of
the venting and air supply system, piping systems, main
burner, pilot burner, and Flame-trap. Check the water
heater for the following:
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.
Manually operate
Figure 21
the temperature
Temperature and Pressure
Relief Valve
and pressure relief
Manual Relief
valve at least once
Valve
a year to make
sure it is working
properly. To prevent
water damage,
the valve must be
properly connected
to a discharge line
Discharge line to drain
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.
23
Replacement Parts
IMPORTANT: The following maintenance procedures are
for the FVIR Safety System components and should be
performed by a qualified person.
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:
Pilot Assembly
Igniter
Button
Igniter
Lead
Wire
Igniter
Wire
White
Wire
(Right
Side)
Pilot
Tube
Manifold
Tube
Temperature Sensor
Wire Connection
Thermopile
Wire
Connections
Pilot Tube
Viewport
Outer Door
Not Shown
Burner Door Screws (2)
24
Figure24B
NaturalGas(LowNox)
Burner Door Assembly
50K Models
Red
Wire
(Left
Side)
Figure 23
Burner Assembly
Removal
Burner
Manifold Tube
Temperature
Sensor
Burner Door
Manifold Component Block
Pilot Assembly
Burner
Use brush on this surface.
Igniter
Wire
Pilot Tube
Thermopile
Connectors
Retainer
Clip
Manifold
Component
Block
Thermopile
Connectors
Retainer
Clip
Manifold
Component
Block
Igniter Connector
Pilot
Igniter
Wire
Thermopile
Thermopile
Connectors
Pilot/Thermopile
Assembly
Pilot Tube
(Ferrule Nut
Not Shown)
5. Use the old pilot tube as a guide and bend the new
pilot tube to match the old one. Make only the bends
closest to the pilot before going to the next step.
25
Figure 28
Pilot/Thermopile Assembly
(50K Models)
Igniter
Connector
Thermopile
Connectors
Pilot Tube
(Ferrule Nut
Not Shown)
Pilot/Thermopile
Assembly
Thermopile
Pilot
Although not likely to occur, if debris collects on the flametrap, use a vacuum, compressed air, or a soft bristle brush
to remove it.
NOTE: If unable to inspect or clean the flame trap from
underneath, follow the Cleaning the Combustion Chamber
and Flame-trap section instructions.
Figure 29
Flame-trap visual inspection
Flashlight
Mirror
26
WARNING
Figure 30A
Combustion Chamber
Flame-trap
Bracket
Explosion Hazard
Tighten both burner door screws
securely.
Remove any fiberglass between gasket
and combustion chamber.
Door Gasket
Figure 30B
Close-up inside view of the combustion chamber
Bracket
VAC
Electrode
Wire to Electrode
Igniter Button
Pilot/Thermopile Bracket
(Opposite Side)
27
TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Light pilot
Turn temp. dial to desired temperature
Check with gas utility company
Notify utility-install trap in gas line
Clean, locate source and correct
Clean, locate source and correct
Replace thermopile
Replace thermostat
Provide fresh air ventilation
SMELLY WATER
1.
1.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
Non-functioning igniter
Thermopile connection loose
Air in gas line
Proper Lighting Sequence not followed.
Gas Control / Temperature Knob was not
held in for sufficient time.
1.
2.
3.
4.
5.
6.
7.
8.
5.
6.
7.
8.
28
PROBLEM
PILOT WILL NOT LIGHT OR
REMAIN LIT (continued)
POSSIBLE CAUSE(S)
9.
10.
11.
12.
1.
2.
3.
4.
5.
6.
7.
8.
9.
CORRECTIVE ACTION
9.
10.
11.
12.
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5
6.
7.
8.
9.
1.
1.
2.
3.
4.
5.
6.
7.
8.
Flue clogged
Low gas pressure
Improper calibration
Thermostat set too low
Water heater too small
Wrong piping connections
Wasted hot water
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
1.
2.
3.
THERMOSTAT FAILS TO
SHUT-OFF
1.
2.
1.
2.
Replace thermostat
Replace thermostat
COMBUSTION ODORS
1.
1.
2.
3.
Flue clogged
Heater installed in a confined area
2.
3.
1.
1.
2.
3.
4.
5.
6.
2.
3.
4.
5.
6.
CONDENSATION
1.
1.
1.
2.
3.
4.
1.
2.
3.
4.
1.
PILOT FLAME
TOO SMALL
1.
2.
1.
2.
29
PROBLEM
CORRECTIVE ACTION
Normal operation.
2 FLASHES
4 FLASHES
5 FLASHES
7 FLASHES
8 FLASHES
1.
2.
3.
1.
2.
3.
9 FLASHES
10 FLASHES
30
NO
NO
NO
Follow the Testing the Igniter
System section in this manual.
YES
Is there proper drafting at the
drafthood? See Checking the
Draft section in this manual.
YES
NO
Correct size of
openings to allow
sufficient air.
YES
YES
NO
NO
NO
YES
NO
YES
YES
NO
31
1A
5B
5A
3
6A
Item
No.
Parts Description
1A
DRAFT HOOD
1B
FLUE BAFFLE
5A
5B
6A
6B
ANODE ROD
DRAIN VALVE
10
10
CONTROL MODULE
11
OUTER DOOR
12A*
12B*
13A*
13B*
14*
15*
16*
VIEWPORT ASSEMBLY
17*
18*
TEMPERATURE SENSOR
19*
THERMOPILE
10
9
11
6B
LEGEND
Special anode rod (see page 21)
Temperature and Pressure Relief Valve is required,
but may not be factory installed
Unique: Flame Guard Safety System parts
32
Item #12B
Item #12A
13A
14
17
13B
15
16
18
19
33
NOTES
34
NOTES
35
36