AO Smith G12-UFDT5040NV Signature 300 50-Gallon Tall User Manual

100366637_ 2000622613_REV. A

Residential Gas

Water Heater

Installaon Instrucons and

Use & Care Guide

Keep this manual in the pocket on heater for future reference whenever maintenance, adjustment or service is required.

Retain your original receipt as proof of purchase.

Residenal Atmospheric Ultra Low Nox Gas Water Heater

with the Flammable Vapor Ignion Resistant (FVIR) Safety System

DO NOT RETURN THIS UNIT TO THE STORE

Read this manual and the labels on the water heater before you install,

operate, or service it. If you have diculty following the direcons, or

aren’t sure you can safely and properly do any of this work yourself:

• Call our Technical Assistance Hotline at 1-877-817-6750 or visit hp:// www.AOS-

mithAtLowes.com. We can help you with installaon, operaons, troubleshoong,

or maintenance. Before you call, write down the model and serial number from the

water heater’s data plate.

Incorrect installaon, operaon, or service can damage the water heater, your house

and other property, and present risks including re, scalding, electric shock, and

explosion, causing serious injury or death.

Do not store or use gasoline or other

ammable 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 build-

ing.

• Immediately call your gas supplier

from a neighbor’s phone. Follow the

gas supplier’s instrucons.

• If you cannot reach your gas sup-

plier, call the re department.

Installaon and service must be per-

formed by a qualied installer, service

agency or the gas supplier.

WARNING: If the informaon in

these instrucons is not followed

exactly, a re or explosion may

result causing property damage,

personal injury or death.

LOW LEAD

NTENT

Table of Contents Page

IMPORTANT SAFETY INFORMATION ............................................. 3

GETTING STARTED ........................................................................ 7

INSTALLATION ............................................................................. 14

OPERATION ................................................................................. 23

TROUBLESHOOTING ................................................................... 25

MAINTENANCE ........................................................................... 31

REPAIR PARTS ............................................................................. 37

NOTES ......................................................................................... 38

February 2023

COMPLETED INSTALLATION (TYPICAL)

A Vent Pipe

B Draft Hood

C Anode (Not Shown)

D Hot Water Outlet

E Insulation

F Gas Supply Piping

 G ManualGasShut-o󰀨Valve

H Ground Joint Union

I Drip Leg (Sediment Trap)

* INSTALL IN ACCORDANCE

WITH LOCAL CODES.

* DRIP LEG AS REQUIRED

BY LOCAL CODES

* DAMPER ORIENTATION

MAY VARY

J Inner Door

K Outer Door

L Union

 M InletWaterShut-o󰀨Valve

N Cold Water Inlet

O Inlet Dip Tube

 P Temperature-PressureReliefValve

Q Rating Plate

 R FlueBa󰀪e

 S GasControlValve/Thermostat

 T DrainValve

U Pilot and Main Burner

V Flue

W Metal Drain Pan

X Igniter Wire

Y Base-Ring Filter

Z Flammable Vapor (FV) Sensor

AA LDO Module

BB Flue Damper

* ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

TO VENT

TERMINATION ON

ROOF

NOTE: POWER CORD NOT SHOWN.

(S) GAS CONTROL VALVE/

THERMOSTAT

GAS CONTROL/TEMPERATURE KNOB

STATUS

LIGHT

OFF

STATUS

INSTALL THERMAL EXPANSION

TANK IF WATER HEATER IS

INSTALLED IN A CLOSED

WATER SYSTEM

VACUUM RELIEF

VALVE

*INSTALL PER

LOCAL CODES

MANIFOLD

TUBE

IGNITER WIRE

MAIN BURNER

PILOT ASSEMBLY

(U) MANIFOLD/BURNER ASSEMBLY

MANIFOLD DOOR

•

VERY

HOT

LOW

VAC

DISCHARGE PIPE

(DO NOT CAP OR PLUG.)

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 3

SAFETY

IMPORTANT SAFETY INFORMATION

Important informaon to keep

Fill out this secon and keep this

manual in the pocket of the water

heater for reference.

Date Installed:

Model number:

Serial number:

Maintenance performed:* Date:

This is the safety alert symbol. It is used to alert you to

potenal physical injury hazards. Obey all safety mes-

sages that follow this symbol to avoid possible property

damage, serious injury or death. Do not remove any

permanent instrucons, labels, or the data plate from either the outside of

the water heater or on the inside of the access panels. Keep this manual

near the water heater.

DANGER

Read and follow all safety messages and instrucons in

this manual.

DANGER indicates hazardous situa-

on that, if not avoided, will result

in death or serious injury.

WARNING

WARNING indicates a hazardous

situaon that, if not avoided, could

result in death or serious injury.

CAUTION

CAUTION indicates a hazardous

situaon that, if not avoided, could

result in minor or moderate injury.

NOTICE

NOTICE indicates pracces not

related to physical injury.

WARNING! If the informaon in these instrucons is not followed exactly,

a re or explosion may result causing property damage, personal injury or

death. Do not store or use gasoline or other ammable vapors and liquids in

the vicinity of this or any other appliance.

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 me. Do not depend upon

this odorant as an indicaon of leaking gas. We recommend installing a fuel gas

and carbon monoxide detector.

This product is cered to comply with a maximum weighted average of 0.25%

lead content as required in some areas.

*Drain and ush tank and remove and

inspect anode rod aer rst six months

of operaon and at least annually

thereaer. Operate the Temperature

and Pressure Relief Valve (T&P) annu-

ally and inspect T&P valve every 2-4

years (see the label on the T&P valve for

maintenance schedule). See the Main-

tenance secon for more informaon

about maintaining this water heater.

4 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

SAFETY

IMPORTANT SAFETY INFORMATION

o reduce the risk of property

damage, serious injury or death,

read and follow the precauons below,

all labels on the water heater, and

the safety messages and instrucons

throughout this manual.

RISKS DURING

INSTALLATION AND

MAINTENANCE

Liing Risk

WARNING! The

water heater is heavy.

Follow these precau-

ons to reduce the

risk of property damage, injuries from

liing or impact injuries from dropping

the water heater.

• Use at least two people to li the

water heater.

• Be sure you both have a good grip

before liing.

• Use an appliance dolly or hand

truck to move the water heater.

Explosion Risk

WARNING! Read the water heater’s

data plate to determine the type of

gas required. Failure to follow these

instrucons can result in serious injury

or death from explosion, re or

carbon monoxide poisoning.

• 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.

• Use a new CSA approved gas

supply line.

• Install a shut-o valve on the gas

supply line.

Gas Pressure

WARNING! 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.

RISKS DURING

OPERATION

Scalding Risk

This water heater

can make water hot

enough to cause severe burns instantly,

resulng in severe injury or death.

• Feel water before bathing or

showering.

• To reduce the risk of scalding,

install Thermostac Mixing Valves

(temperature liming valves) at

each point-of-use. These valves

automacally mix hot and cold

water to limit the temperature

at the tap. Mixing valves are

available from Lowe’s®. Follow

manufacturer’s instrucons for

installaon and adjustment of the

valves.

• The gas control valve on this water

heater has been factory set to its

lowest seng to reduce the risk

of scalding. Higher temperatures

increase the risk of scalding, but

even at 120°F, hot water can scald.

If you choose a higher tempera-

ture seng, Thermostac Mixing

Valves located at each point-of-use

are parcularly important to help

avoid scalding.

Table 1

Temperature

Time to Produce

a Serious Burn

120°F (49°C) More than 5 minutes

125°F (52°C) 1½ to 2 minutes

130°F (54°C) About 30 seconds

135°F (57°C) About 10 seconds

140°F (60°C) Less than 5 seconds

145°F (63°C) Less than 3 seconds

150°F (66°C) About 1½ seconds

155°F (68°C) About 1 second

For informaon about changing the

factory temperature seng, refer to

the “Adjusng the Temperature” sec-

on in this manual .

Even if you set the water heater’s gas

control valve to a low seng, higher

water temperatures may occur in cer-

tain circumstances:

• In some cases, repeated small draws

of water can cause the hot and cold

water in the tank to “stack” in layers.

If this happens, the water can be as

much as thirty degrees hoer than

the gas control valve seng. This

temperature variaon is the result

of your usage paern and is not a

malfuncon.

• Water temperature will be hoer if

someone adjusted the gas control

valve to a higher seng.

• Problems with the gas control valve

or other malfuncons may result in

higher than expected water tem-

peratures.

• If the water heater is in a hot envi-

ronment, the water in the tank can

become as hot as the surrounding

air, regardless of the temperature

seng.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 5

SAFETY

IMPORTANT SAFETY INFORMATION

• If the water supplied to the water

heater is pre-heated (for example,

by a solar system) the temperature

in the tank may be higher than the

water heater’s temperature seng.

• Should overheang occur or the

burner fail to shut o, turn o the

manual gas supply valve to the water

heater and call a qualied person.

To reduce the risk of unusually hot wa-

ter reaching the xtures in the house,

install Thermostac Mixing Valves at

each point-of-use.

If anyone in your home is at parcular

risk of scalding (for example, the elder-

ly, children, or people with disabilies)

or if there is a local code or state law

requiring a certain water temperature

at the hot water tap, these precauons

are parcularly important.

According to a naonal standard (ASSE

1070) and many local plumbing codes,

the water heater’s gas control valve

should not be used as the sole means

to regulate water temperature and

avoid scalds.

Properly adjusted Thermostac Mixing

Valves installed at each point-of-use al-

low you to set the tank temperature to

a higher seng without increasing risk

of scalds. A higher temperature seng

allows the tank to provide much more

hot water and can help provide proper

water temperatures for appliances such

as dishwashers and washing machines.

Higher tank temperatures (140°F)

also kill bacteria that cause a condi-

on known as “smelly water” and can

reduce the levels of bacteria that cause

water-borne diseases.

Water Contaminaon Risk

Do not use chemicals that could con-

taminate the potable water supply. Do

not use piping that has been treated

with chromates, boiler seal, or other

chemicals.

Fire Risk

This water heater is

equipped with a

Flammable Vapor (FV)

sensor which is designed

to detect the presence of ammable

vapors. When the sensor detects those

vapors, the unit will shut down and not

operate. Even though this water heater

is ammable vapors ignion resistent

and is designed to reduce the chances

of ammable vapors being ignited,

ammable substances such as gasoline

should never be used or stored in the

same area containing a gas water

heater or other open ame or spark-

producing appliance.

Turn the gas control valve OFF and do

not operate this appliance if you sus-

pect ammable vapors have accumu-

lated inside or outside the appliance.

Immediately call a qualied person to

inspect the appliance. Water heaters

subjected to a ammable vapors inci-

dent will show a discoloraon on the

ame arrestor and require replacement

of the enre water heater. Improper

installaon or an inadequate air supply

can also cause the FVIR system to dis-

able the water heater.

To reduce the risk of a re that could

destroy your home and seriously injure

or kill people:

• Do not store things that can burn

easily such as paper or clothes next

to the water heater.

• Do not store or use gasoline or other

ammable substances in the vicinity

of this or any other appliance.

• Keep the water heater from becom-

ing wet. Immediately shut the water

heater o and have it inspected by a

qualied person if you nd that the

wiring, thermostat(s) or surround-

ing insulaon have been exposed

to water in any way (e.g., leaks from

plumbing, leaks from the water

heater itself can damage property

and could cause a re risk). If the

water heater is subjected to ood

condions or the thermostat(s) have

been submerged in water, the enre

water heater must be replaced.

• Replace the water heater’s viewport

if glass is missing or damaged. Repair

the combuson chamber door seals

if damaged.

Explosion Risk

High temperatures and

pressures in the water

heater tank can cause an explosion re-

sulng in property damage, serious in-

jury or death. A new Temperature and

Pressure (T&P) Relief Valve is included

with your water heater to reduce risk

of explosion by discharging hot water.

Addional temperature and pressure

protecve equipment may be required

by local codes.

A naonally recognized tesng labo-

ratory maintains periodic inspecon

of the valve producon process and

ceres that it meets the requirements

for Relief Valves for Hot Water Supply

Systems, ANSI Z21.22. The T&P Relief

Valve’s relief pressure must not exceed

the working pressure rang of the wa-

ter heater as stated on the rang plate.

Maintain the T&P Relief Valve properly.

Follow the maintenance instrucons

provided by the manufacturer of the

T&P Relief Valve (label aached to T&P

6 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

SAFETY

IMPORTANT SAFETY INFORMATION

Relief Valve). An explosion could occur

if the T&P Relief Valve or discharge

pipe is blocked. Do not cap or plug the

T&P Relief Valve or discharge pipe.

Fire and Explosion Risk if Hot Water is

Not Used for Two Weeks or More.

CAUTION! Hydrogen gas builds up

in a hot water system when it is not

used for a long period (two weeks or

more). Hydrogen gas is extremely

ammable. If the hot water system

has not been used for two weeks or

more, open a hot water faucet for

several minutes at the kitchen sink

before using any electrical appliances

connected to the hot water system. If

hydrogen is present there will

probably be an unusual sound such as

“air” escaping through the pipe as hot

water begins to ow. Do not smoke or

have an open ame or other ignion

source near the faucet while it is

open.

Carbon Monoxide Risk

WARNING! This water heater

operates by burning gas. Carbon

monoxide is a colorless, odorless, gas

that is a by-product

of burning of fuels

such as coal, wood,

charcoal, oil,

kerosene, propane,

and natural gas.

Breathing excessive and abnormal

amounts of carbon monoxide can

cause carbon monoxide poisoning,

resulng in serious injury or death.

This water heater must be supplied

with adequate combuson air and

must be properly vented to the

outdoors. Have a qualied person

(licensed plumber, authorized gas

company personnel, or authorized

service technician) install the venng

system using these installaon

instrucons. When the installaon is

complete, check the vent’s dra using

the instrucons on pages 23-24.

• Install a fuel gas and carbon mon-

oxide detector in the living areas

of your home.

• Do not install this water heater in

a mobile home or manufactured

housing.

• Failure to follow these instruc-

ons can result in serious injury

or death from carbon monoxide

poisoning.

Burn Risk

This water heater’s vent-

ing system can become

hot enough to burn. Do not touch the

venng system while water heater is

on, or unl the water heater is turned

o and the venng allowed to cool.

Installaon Accessories

Figure 1 - Gas Water Heater Hook-Up Kit

Figure 2 - Install a Pressure Reducing Valve set

to 50 to 60 PSI.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 7

GETTING STARTED

Review all of the instrucons

before you begin work. If you

aren’t sure that you can safely

and properly do this work yourself, call

your Lowe’s® store to arrange for

Professional Installaon (you may also

call a quali ed person of your choice,

such as a licensed plumber, to have the

work done). Improper installaon can

damage the water heater, your home

and other property, and can present

risks of serious injury or death.

This water heater is design-

cered by CSA Internaonal

as a Category I, non-direct

vented water heater which takes its

combuson air either from the installa-

on area or from air ducted to the unit

from the outside. This water heater

must be installed according to all local

and state codes or, in the absence of

local and state codes, the “Naonal

Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edion. This is available

from the following:

CSA America, Inc.

8501 East Pleasant Valley Road

Cleveland, OH 44131

Naonal Fire Protecon Associaon

1 Baerymarch Park

Quincy, MA 02269

Check with local code ocials about

codes governing this installaon. Have

your installaon inspected by a code

ocial to ensure the installaon meets

all local codes.

NOTICE: If you lack the necessary skills

required to properly install this water

heater, or you have diculty follow-

ing the instrucons, you should not

proceed but have a qualied person

perform the installaon of this water

heater.

Massachuses code requires this water

heater to be installed in accordance

with Massachuses 248-CMR 2.00 and

248-CMR 5.00: State Plumbing Code.

Other local and state authories may

have similar requirements or other

codes applicable to the installaon of

this water heater.

Before you start, be sure you

have the following tools and

supplies:

• Common plumbing tools (depend-

ing on what type of water pipes

you have).

• Teon® tape or pipe joint com-

pound approved for potable water.

• For homes with copper pipes, you

may purchase a Gas Water Heater

Hook-Up Kit (available from

• Lowes®) with compression ngs

that don’t require soldering. This

kit includes two 12” ex water

lines, two compression ngs, an

18” exible gas line, two nipples,

and Teon® tape.

• For homes with plasc pipe, use

threaded connectors suitable for

the specic type of plasc pipe

used: CPVC or PEX (cross-linked

polyethylene). Do not use PVC

pipe.

• Non-corrosive gas leak detecon

soluon made from hand dish-

washing soap mixed with water (1

part soap to 15 parts water) or chil-

dren’s soap bubbles and a small,

so-bristled brush.

• An appliance dolly or hand truck to

move the water heater.

Recommended Accessories:

• A metal drain pan.

• Automac water leak detecon

and shut-o device.

• Pressure Reducing Valve.

• Thermal Expansion Tank.

• Thermostac Mixing Valves at each

point-of-use.

• Fuel gas and carbon monoxide

detector.

Combuson and

Venlaon Air Supply

Before installing the water heater, you

must determine the amount of air

needed to supply this water heater

and any other gas appliances in the

same area and provide adequate air for

combuson and venlaon. Consult a

qualied person if you’re unsure of the

proper way to supply air to your water

heater.

WARNING! This gas water heater

requires an adequate source of clean

air for combuson and venlaon.

Without sucient air, your water

heater will have frequent pilot outages

and may emit excessive and abnormal

amounts of carbon monoxide.

Before beginning:

Calculate total BTU/HR rang of all ap-

pliances.

To calculate the combuson air and

venlaon required, add up the total

BTU/HR rangs of all gas burning ap-

pliances (e.g., water heaters, furnaces,

clothes dryers) in the same area.

Your water heater’s BTU/HR rang is on

the data plate, located next to the gas

control valve/thermostat. The BTU/HR

rangs should be on the other appli-

ances’ data plates. If you have trouble

determining the BTU/HR rangs,

contact the manufacturer or have a

qualied person determine the venla-

on requirements. NOTICE: If you are

replacing your old water heater with

one that has a higher BTU/HR rang,

the amount of venlaon required may

be greater.

8 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

GETTING STARTED

Example:

Gas Burning Appliance BTU/HR Rang

Gas Water Heater 40,000

Furnace 75,000

Dryer 20,000

Total 135,000

Your Appliances:

Gas Burning Appliance BTU/HR Rang

Gas Water Heater

Total

Table 2 provides examples of minimum

square footage (area) required for

various BTU/HR totals. Areas used for

storage or which contain large objects

containing less air than is assumed for

the room sizes in Table 2 – see Opon

A for more specic calculaons.

Opon A: Installaon without

outside venlaon (not recom-

mended)

Venlaon with outside air is recom-

mended for all installaons. Even if

the water heater is installed in a large,

open room inside the house, outdoor

air is usually needed because modern

homes are very ghtly sealed and

oen do not supply enough air to the

water heater. However, when installed

in a large indoor space, it may be pos-

sible to provide enough air without

outside venlaon. If you are unsure if

your installaon locaon has enough

venlaon, contact your local gas

ulity company or code ocials for a

safety inspecon.

The following instrucons will help de-

termine if it may be possible to install

without outside venlaon. Even if

this may be possible, you will need to

conduct the vent dra test on pages

23-24 when installaon is nished. If

there is not enough venlaon, you

will need to venlate with outside air.

Check for Chemicals:

Installaons where corrosive chemi-

cals may be present require outside

air. Air for combuson and venlaon

must be clean and free of corrosive or

acid-forming chemicals such as sulfur,

uorine, and chlorine. Venlaon with

outside air will reduce these chemicals,

but it may not completely eliminate

them. Failure due to corrosive chemi-

cals is not covered by the warranty.

Examples of locaons that require

outside air due to chemicals include:

• Beauty salons

• Photo processing labs

• Indoor pools

• Laundry, hobby, or cra rooms

• Chemical storage areas

Products such as aerosol sprays, de-

tergents, bleaches, cleaning solvents,

gasoline, air fresheners, paint and

varnish removers, and refrigerants

should not be stored or used near the

water heater.

A1: Calculate the air volume of

the room

Air requirements depend on the size of

the room.

Floor Area (Square feet) X Ceiling

Height (feet) = Room Volume (cubic

feet)

If there are large objects in the room

(e.g., refrigerator, furnace, car), sub-

tract their volume from the volume of

the room to get a beer esmate of

the air available.

Room Volume – Object Volume = Air

Volume

Table 2

BTU/HR Minimum Square Typical Room

Input Feet with 8’ Ceiling 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

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 9

GETTING STARTED

A2: Calculate required air volume

A water heater installed in an unconned

ac or garage requires that the space

be at least 50 cubic feet per 1,000 BTU/

HR of the total input for all gas burning

appliances in the same area.

[Total BTU/HR/1000] x 50 = Cubic feet

of air required.

Example:

(135,000 / 1000) x 50 = 6,750

If the air volume of the room is less

than the required air volume, you must

provide two permanent outside air

openings that draw in sucient air. Use

Opon B.

If the air volume of the room is greater

than the required air volume, it may

be possible to install the water heater

without outside venlaon.

A3: Check that combuson ven-

laon is adequate

Because modern homes are oen well-

sealed to prevent dras, even a large

room may not provide enough combus-

on air without venlaon. To con-

rm that your installaon has enough

combuson air, conduct the vent dra

test on pages 23-24 when installaon is

nished.

Opon B: Install with outside

venlaon

Venlaon with outside air is recom-

mended, and, for most installaons, is

needed. There may be exisng venla-

on that is adequate, or you may need

to add more venlaon.

Supplying outside air to typically requires

two openings. One opening must be

within 12 inches from the oor and

the second opening must be within 12

inches from the ceiling. Although a single

opening is not preferred, you may use a

single opening to outside air if the mini-

mum free area is sized according to Table

3. Two openings must be used when

venlang with air from another room.

The outside air can be taken from a

crawl space or ac open to the out-

doors and adequately venlated. You

may use vercal or horizontal ducts.

B2: Determine type of venlaon

There are several types of venlaon

that can be used :

1. Direct to outdoors

2. Vercal ducts

3. Horizontal ducts

4. Single opening (not recom-

mended; must be at least 100

square inches. Not appropriate

for conned spaces smaller than

50 cubic feet per 1,000 BTU/HR as

calculated in secon A or when

geng air from another room.)

5. From a larger room inside the

house (not recommended – refer

to secon A above to determine if

the combined volume of the rooms

may be adequate).

B3: Determine minimum free

area required for each vent

opening

The size of the vent openings depends

on the total BTU/HR rang of all appli-

ances in the space (use your calculaon

from “Before beginning”) and the type

of vent used. Table 3 provides the mini-

mum free area for each vent opening

depending on the type of venlaon.

B4: Calculate minimum size of

vent openings and ducts

The vent cross-seconal area needed to

provide the free area depends on the

covering on the vent openings. Typical

vents use louvers or grilles to protect

the opening. The louver or grill itself

blocks some of the free area, so the

opening may need to be larger to meet

the minimum free area requirements.

Use the following formula to calculate

the required cross-seconal area:

Cross-seconal area = minimum free

area required ÷ percent free area of

covering (in decimals – e.g., 60% = .6)

Table 3

Minimum Free Area of Permanent Openings for Venlaon and Combuson Air

Supply – All Air from Outdoors Only.

Based on the total BTU/HR input rang for all gas burning appliances within a

conned space.

Opening Source Minimum Free Area

Per Opening (sq. in.)

*Direct to outdoors 1 sq. in. per 4,000 BTU/HR (see gure on page 10)

Vercal ducts 1 sq. in. per 4,000 BTU/HR (see gure on page 10)

Horizontal ducts 1 sq. in. per 2,000 BTU/HR (see gure on page 10)

Single Opening 1 sq. in. per 3,000 BTU/HR (see gure on page 10)

*These openings connect directly with the outdoors through a venlated ac, a

venlated crawl space, or through an outside wall.

10 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

GETTING STARTED

For example, an installaon area that

requires openings with 100 square

inches of free area would need 134

square inch openings if using metal

louvers rated at 75% free area (100 sq.

in. ÷ .75 = 134 sq. in.).

If you do not know the % free area for

your louver or grill, use the following

values:

• For wood louvers or grilles: 20%

• For metal louvers or grilles: 60%

Follow these rules to ensure that vents

and ducts provide adequate air ow:

• Each vent opening must be no

smaller than 100 square inches .

• Ducts must have the same cross-

seconal area as free area of the

opening.

• Rectangular ducts must have a

minimum dimension of no less

than three inches .

• All screens must have mesh ¼” or

larger.

• Moveable louvers must be locked

open or interconnected with the

equipment so that they open au-

tomacally during operaon.

• Keep louvers and grills clean and

free of debris or other obstruc-

ons.

B5: Check that air source is

clean and free of chemicals

Air for combuson and venlaon

must be clean and free of corrosive

or ammable chemicals. A failure due

to corrosive chemicals in the air is not

covered by the warranty. Combus-

on air must be free of acid-forming

chemicals such as sulfur, uorine, and

chlorine. Be sure that air at the vent

inlets is free of such chemicals.

B6: Check that combuson

venlaon is adequate

To conrm that your installaon has

enough combuson air, conduct the

vent dra test on pages 23-24 when

installaon is nished.

Combuson Air Supply Opons

Figure 3 - Direct to outdoors openings

Figure 4 - Vertical duct openings

Figure 5 - Horizontal duct openings

Figure 6 - Single opening

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 11

GETTING STARTED

Venng

WARNING! Carbon Monoxide

Hazard. This water heater must be

supplied with adequate air and vented

to outdoors. The vent system must be

installed by a qualied person.

Examples of a qualied person include

gas technicians, authorized gas

company personnel, and authorized

service technicians. Failure to properly

vent the water heater can result in

severe injury or death from carbon

monoxide poisoning.

The vent system must be installed

according to local and state codes, or

in the absence of local or state codes,

the current edion of the Naonal Fuel

Gas Code, ANSI Z223.1 (NFPA 54). Do

not common vent this water heater

with any power vented appliance. Do

not use a vent damper anywhere in the

vent system of this water heater.

To reduce the risk of carbon monoxide

poisoning, install a fuel gas and carbon

monoxide detector. Install and maintain

the detector in accordance with the

manufacturer’s instrucons and local

codes.

Replacing a Water Heater Using

the Exisng Vent System

Read the “Installing a New Vent Sys-

tem” secon of this manual and make

sure your vent system is properly in-

stalled. Inspect the exisng vent system

for obstrucons, corrosion, and proper

installaon. Repair or replace if neces-

sary. The exisng vent system must be

UL listed Type B double wall or single

wall metal vent pipe of either 3 inch or

4 inch diameter and installed according

to the vent manufacturer’s instrucons

and the terms of its lisng. Do not use

other materials such as dryer vent hose.

Installing a New Vent System

The vent pipe must meet the following

specicaons:

Type of Material

UL listed Type B double wall or single

wall metal vent pipe must be used.

Local codes may be more restricve

and may not allow single wall vent pipe.

Single-wall vent pipe cannot be used for

water heaters located in acs and may

not pass through ac spaces, crawl

spaces, or any conned or inaccessible

locaon. Single-wall vent pipe cannot

pass through any interior wall.

Clearance to Combusble Materials

The vent pipe cannot pass through any

ceiling, oor, rewall, or re paron.

Any part of the vent system must main-

tain the following clearances from any

combusble materials:

• Single-wall vent pipe must main-

tain a six inch clearance from

combusble materials.

• The clearance from combusble

materials of UL listed Type B dou-

ble-wall vent pipe is specied by

the manufacturer of the vent pipe.

UL listed Type B double-wall vent

pipe may pass through walls or par-

ons constructed of combusble

material if the minimum clearance

specied by the manufacturer of

the vent pipe is maintained.

Vent Installaon

To improve the ow of exhaust gases,

we recommend that a minimum of 12

inches of vercal vent pipe be installed

on the dra hood prior to any elbow.

A poron of the vent pipe (up to 75%

of the total vercal height) can be

horizontal, but the terminaon must

be vercal. For the horizontal secon,

install without dips or sags with an

upward slope of at least ¼ inch per

foot. Install pipe avoiding unnecessary

bends. Pipe joints must be fastened by

sheet metal screws or other approved

means. Support the pipe to maintain

clearances and to avoid separaon of

joints or other damage. Vent pipe must

be accessible for cleaning, inspecon,

and replacement.

Terminaons

If local codes allow, this water heater

may be terminated into an exisng

chimney using the instrucons below.

Otherwise, this water heater’s vent

must terminate vercally (sidewall or

other horizontal terminaons are not

allowed).

Chimney Terminaon

Figure 7 - Chimney termination vent system

NOTICE: Before connecng a vent to

a chimney, make sure the chimney

passageway is clear and free of obstruc-

ons. The chimney must be cleaned if

previously used for venng solid fuel

appliances or replaces. Also consult lo-

cal and state codes for proper chimney

sizing and applicaon or, in the absence

of local and state codes, the “Naonal

Fuel Gas Code”, ANSI Z223.1(NFPA

54)-current edion.

• The vent pipe must be installed

above the extreme boom of the

chimney to prevent potenally

blocking the ue gases.

12 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

GETTING STARTED

• The vent pipe must be rmly at-

tached and sealed to prevent it

from falling out.

• To aid in removing the vent pipe, a

thimble or slip joint may be used.

• The vent pipe 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.

Do not terminate the vent pipe in a

chimney that has not been cered

for this purpose. Some local codes may

prohibit the terminaon of vent con-

nectors in a masonry chimney.

Common (combined) venng is allow-

able with vercal Type B vent systems

and lined masonry chimneys as long

as proper dra for the water heater

is established under all condions of

operaon. Do not common vent this

water heater with any power vented

appliance.

Vercal Terminaon

NOTICE: The gas vent must be termi-

nated in a vercal posion to facilitate

the removal of exhaust gases.

Vercal exhaust vents must terminate

with a listed cap or other roof assem-

bly and be installed according to their

manufacturer’s instrucons. An unused

chimney ue or masonry enclosure

may be used as a passageway for the

installaon of vent pipe. Do not com-

mon vent this water heater with any

power vented appliance. The follow-

ing gures are examples of vent pipe

system installaons and may or may

not be suitable for your specic appli-

caon. Consult the “Naonal Fuel Gas

Code”, NFPA 54, ANSI Z223.1-current

edion and local codes.

Figure 8 - Vertical gas vent system with type B

double wall vent pipe

Figure 9 - Venting through a chimney with type

B double wall vent pipe

Gas Piping

Gas piping must be installed accord-

ing to local and state codes or, in the

absence of local and state codes,

the “Naonal Fuel Gas Code”, ANSI

Z223.1(NFPA 54)-current edion.

NOTICE: When installing gas piping,

apply pipe joint compound or Teon®

tape approved for fuel gases.

Figure 10 - Gas Piping

1. Install a readily accessible manual

shut-o valve in the gas supply line

as recommended by the local ul-

ity. Know the locaon of this valve

and how to turn o the gas to this

unit.

2. Install a Sediment Trap as shown

in the Gas Piping gure below. The

Sediment Trap must be no less than

three inches long for the accumula-

on of dirt, foreign material, and

water droplets.

3. Install a ground joint union be-

tween the gas control valve and

the manual gas shut-o valve. This

is to allow easy removal of the gas

control valve.

4. Turn the gas supply on and check

for leaks. Use a small, so-bristled

brush to apply a hand dishwash-

ing soap and water mixture (1

part soap to 15 parts water) or

children’s soap bubbles to all con-

necon points of the gas piping.

Saturate all the connecons and

check for gas leaks (which will ap-

pear as small bubbles). If any leaks

are detected, ghten the appropri-

ate connecon(s) and re-check.

Gas Pressure

NOTICE: When tesng gas pipes with

a test pressure of more than ½ psi (3.5

kPa), disconnect the gas line at the

manual shut o valve and cap the gas

line. Do not subject the water heater’s

gas control valve or manual shut o

valve to more than ½ psi (3.5 kPa)

pressure for any reason. If you are

pressure tesng the gas line with test

pressure of ½ psi (3.5 kPa) or less, you

may isolate the water heater from the

gas line by closing the manual shut o

valve.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 13

GETTING STARTED

Space Heang

Some water heater models are equipped

with inlet/outlet connecons for use with

space heang applicaons. If this water

heater is to be used to supply both space

heang and domesc potable (drinking)

water, the instrucons listed below must

be followed.

• This water heater is suitable for

combinaon water (potable) heang

and space heang and not suitable for

space heang applicaons only.

• 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 exisng boiler

installaon.

• 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 heang system requires

water temperatures in excess of 120°F,

install a Thermostac Mixing Valve

in the domesc (potable) hot water

supply at each point-of-use to limit the

risk of scald injury. Install the mixing

valve per its manufacturer’s instruc-

ons.

• Pumps, valves, piping, and ngs

must be compable with potable

water.

• A properly installed ow control valve

is required to prevent thermosiphon-

ing. Thermosiphoning is the result of a

connuous ow of water through the

air handler circuit during the o cycle.

• The domesc hot water line from the

water heater should be vercal past

any mixing valve or supply line to the

air handler to remove air bubbles from

the system. Otherwise, these bubbles

will be trapped in the air handler heat

exchanger coil, reducing eciency.

• Do not connect the water heater to

any system or components previously

used with non-potable water heat-

ing appliances when used to supply

potable water.

Solar Installaon

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. A Thermostac Mixing Valve or

other temperature liming valve must be

installed in the water supply line to limit

the supply temperature to 120°F. The

unit must be set to Standard Mode. (See

Operang Modes in Operaon secon,

pages 24 and 25.)

NOTICE: Solar water heang systems can

oen supply water with temperatures

exceeding 180°F and may result in water

heater malfuncon.

Figure 11 - Combustion Space Heating and Potable Water (Typical Installation)

REMOVE A

MUST BE VERTICAL TO

IR BUBBLES

OUT

COIL

AIR

HANDLER

AIR

HANDLER

SHUT-OFF

VALVE

EXPANSION TANK

VACUUM

RELIEF

VALVE

COLD WATER INLET

FLOW CONTROL

PUMP

SHUT-OFF

CHECK VALVE

†

(1/8” HOLE

DRILLED IN CLAPPER)

VALVE

CHECK

VALVE

†

TEMP/

PRESSURE

RELIEF

VALVE

TEMPERED WATER

TO FIXTURES

(MUST MEET TEMPS LISTED

IN MASS. CODE 248 CMR

†

)

MIXING VALVE

(MUST BE INSTALLED BELOW

TOP OF WATER HEATER

AS PER MANUFACTURER’S

RECOMMENDATIONS)

UNION

HOT

WATER

OUT

MASSACHUSETTS INSTALLATION REQUIREMENTS:

1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS

FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.

2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR

& 780 CMR).

3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.

† REQUIRED FOR MASSACHUSETTS.

‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.

WATER HEATER ACCEPTED

BY THE BOARD FOR

INSTALLATION IN

MASSACHUSETTS.

†

TYPICAL MIXING VALVE INSTALLATION

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

SEE

NOTE ‡

100’-0” MAXIMUM DISTANCE

FROM WATER HEATER

TO FAN COIL AND BACK

(DEVELOPED LENGTH) NOT

INCLUDING COIL IN HEATING UNIT.

†

14 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

INSTALLATION

Step 1:

✓

Verify that your

home is equipped

and up-to-date for

proper operaon

Installing a new water heater is the

perfect me to examine your home’s

plumbing system and make sure the

system is up to current code stan-

dards. There have likely been plumb-

ing code changes since the old water

heater was installed. We recommend

installing the following accessories

and any other needed changes to

bring your home up to the latest code

requirements. Updang your plumb-

ing system can help extend the life of

your water heater, avoid damage to

your home and property, and reduce

the risk of serious injuries or death.

Inspect your home and install any de-

vices you need to comply with current

codes and assure that your new water

heater performs at its best. Check

with your local plumbing ocial for

more informaon.

✓

Water pressure

Most codes allow a maximum

incoming water pressure of 80 psi

(we recommend a working pressure

no higher than 50-60 psi). Check your

home’s water pressure with a pressure

gauge and adjust if necessary. High

water pressure can damage the water

heater, piping, and other appliances.

HOW: Purchase an inexpensive water

pressure gauge from Lowe’s®. Con-

nect the water pressure gauge to

an outside faucet and measure the

maximum water pressure experienced

throughout a 24-hour period (highest

water pressures oen occur at night).

Figure 12 - Use a Water Pressure Gauge to make

sure your home’s water pressure is not too

high.

To adjust your home’s water pressure:

Locate your home’s Pressure Reduc-

ing Valve (PRV) on the main incoming

(cold) water supply line and adjust the

water pressure control to between

50 and 60 psi. If your home does not

have a Pressure Reducing Valve, install

a PRV on the home’s main water sup-

ply line and set it to between 50 and

60 psi. Pressure Reducing Valves are

available at Lowe’s®.

BACKGROUND: Over the years,

many ulies have increased water

supply pressures so they can serve

more homes. In some homes today,

pressures can exceed 100 psi. High

water pressures can damage water

heaters, causing premature leaks. If

you have replaced toilet valves, had

a water heater leak, or had to repair

appliances connected to the plumb-

ing system, pay parcular aenon

to your home’s water pressure. When

purchasing a PRV, make sure the PRV

has a built-in bypass.

✓

Water pressure

increase caused

by thermal expansion

Verify that you have a properly sized

Thermal Expansion Tank. We recom-

mend installing an expansion tank if

your home does not have one. Plumb-

ing codes require a properly pressur-

ized, properly sized Thermal Expan-

sion Tank in almost all homes.

Figure 13 - A Thermal Expansion Tank helps

protect the home’s plumbing system from pres-

sure spikes.

HOW: Connect the Thermal Expansion

Tank (available at at Lowe’s®) to the

cold water supply line near the water

heater. The expansion tank contains

a bladder and an air charge. To work

properly, the Thermal Expansion Tank

must be sized according to the water

heater’s tank capacity and pressurized

to match the home’s incoming water

pressure. Refer to the instrucons

provided with the Thermal Expansion

Tank for installaon details.

BACKGROUND: Water expands when

heated, and the increased volume

of water must have a place to go, or

thermal expansion will cause large

increases in water pressure (despite

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 15

INSTALLATION

the use of a Pressure Reducing Valve

in the home’s main water supply line).

The Safe Drinking Water Act of 1974

requires the use of backow preven-

ters and check valves to restrict water

from your home reentering the public

water system. Backow preventers are

oen installed in water meters and

may not be readily visible. As a result,

most all plumbing systems today are

now “closed,” and almost all homes

now need a Thermal Expansion Tank.

A Thermal Expansion Tank is a prac-

cal and inexpensive way to help avoid

damage to the water heater, washing

machine, dishwasher, ice maker, and

even toilet valves. If your toilet oc-

casionally runs for no apparent reason

(usually briey at night), that may be

due to thermal expansion increasing

the water pressure temporarily.

✓

Water Pipe and

Tank Leaks

METAL

DRAIN

PAN

AT LEAST 2” GREATER THAN THE

DIAMETER OF THE WATER HEATER.

PIPED TO AN

ADEQUATE DRAIN

6” MAXIMUM

AIR GAP

DISCHARGE PIPE

(DO NOT CAP OR PLUG)

Figure 14 - A metal drain pan piped to an ad-

equate drain can help protect flooring from leaks

and drips.

Leaks from plumbing pipes or from the

water heater itself can damage prop-

erty and could cause a re risk.

• Install an automac leak detec-

on and shuto device (available at

Lowe’s®). These devices can detect

water leaks and can shut o the

water heater’s water supply if a leak

occurs.

• Install a metal drain pan (available

at Lowe’s®) under the water heater

to catch condensaon or leaks from

the piping connecons or tank.

Most codes require, and we recom-

mend, installing the water heater in

a metal drain pan that is piped to an

adequate drain. The drain pan must

be at least two inches wider than

the diameter of the water heater.

Install the drain pan so the water

level would be limited to a maximum

depth of 1-3/4”. The pan must not

restrict air ow to the burner.

✓

Water Tempera-

ture Regulaon

Install Thermostac Mixing Valves to

regulate the temperature of the water

supplied to each point-of-use (for

example, kitchen sink, bathroom sink,

bath, shower). Install and adjust the

mixing valve according to its manufac-

turer’s instrucons.

WARNING! Even if the water

heater’s thermostat is set to a rela-

vely low temperature, hot water can

scald. Install Thermostac Mixing

Valves at each point-of-use to reduce

the risk of scalding.

Figure 15 - Thermostatic Mixing Valves installed

at each point-of-use can help avoid scalding

BACKGROUND: A Thermostac Mixing

Valve, installed at each point-of-use,

mixes hot water from the water heater

with cold water to more precisely

regulate the temperature of hot water

supplied to xtures. If you aren’t sure

if your plumbing system is equipped

with properly installed and adjusted

Thermostac Mixing Valves at each

point where hot water is used, contact

a qualied person.

16 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

INSTALLATION

Step 2:

Verify that the locaon

is appropriate

WARNING! Do not store or use

ammable materials, vapors, or

liquids in the same locaon where this

water heater is installed.

Before installing your water heater,

ensure that it will be located:

• Indoors in an area with adequate

air supply.

• In an area that will not freeze.

• As close as possible to a chimney

or vent.

• In a metal drain pan piped to an

adequate drain.

• In an area suitable for vercal

installaon.

• In an area with adequate space

(clearances) for periodic servicing

(there must be a minimum of 24

inches of front clearance).

• In an area that allows a minimum

clearance from combusble sur-

faces as stated on the data plate.

• On a oor that can support the

weight of a water heater full of

water.

• Within 19 feet of a 120VAC outlet.

Do not use an extension cord.

You will also want to follow these

guidelines while considering an appro-

priate locaon:

• Do not install near air-moving

devices such as exhaust fans,

venlaon systems, or clothes

dryers.

• Do not obtain venlang air for

the furnace/air handler from the

same space as the water heater.

Ensure that any return air ducts

near the water heater are sealed.

• If the water heater is located

in an area subject to lint, dust,

or oily vapors, at least annually

check and clean the air lter. See

Maintenance secon for steps on

cleaning the air lter.

• Do not install in a bathroom,

bedroom, or any occupied room

normally kept closed.

• If the water heater is installed di-

rectly on carpeng, it shall be in-

stalled on a metal or wood panel

extending beyond the full width

and depth of the water heater

by at least 3 in (76.2mm) in any

direcon. If the water heater is

installed in an alcove or closet,

the enre oor shall be covered

by the aforestated panel.

• If your area is prone to earth-

quakes, use special straps as

required by local building codes.

NOTICE: The state of California re-

quires bracing, anchoring, or strap-

ping the water heater to avoid its

moving during an earthquake. Contact

local ulies for code requirements in

your area, visit hp://www.dsa.dgs.

ca.gov, or call 1-916-445-8100 and

request instrucons. Other locaons

may have similar requirements. Check

with your local and state authories.

• Do not install in a locaon prone

to physical damage by vehicles,

ooding, or other risks.

Vehicle

Stop

Drain

Pan

Figure 16 - In a garage, install a vehicle stop to

avoid water heater damage.

• Avoid locaons such as acs, up-

per oors, or where a leak might

damage the structure or furnish-

ings. Due to the normal corrosive

acon of water, the tank will

eventually leak. To minimize prop-

erty damage from leaks, inspect

and maintain your water heater

in accordance with this manual’s

instrucons. Install a metal drain

pan under the water heater piped

to an adequate drain. Inspect the

drain pan, pipes, and surrounding

area regularly and x any leaks

found.

Step 3:

Removing the old

water heater

Read each installaon step and

decide if you have the neces-

sary skills to install the water

heater. Only proceed if you are comfort-

able you can safely perform the work. If

you are not sure, have a qualied person

perform the installaon.

On the old water heater, turn

the control knob on the gas

control valve to the

OFF posion. See Figure 17.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 17

INSTALLATION

Gas

control

knob

Figure 17 - Turn gas control/temperature knob OFF.

Turn the manual gas valve for

the water heater’s supply line

OFF.

Open a hot water faucet and

let the hot water run unl it is

cool (This may take 10 min

utes or longer).

Figure 18 - Let the hot water run until it is cool.

WARNING! Be sure the water runs

cool before draining the tank to reduce

the risk of scalding.

Connect a garden hose to the

drain valve and place the

other end of the hose in a

drain, outside, or in buckets. (Sedi-

ment in the boom of the tank may

clog the valve and prevent it from

draining. If you can’t get the tank to

drain, contact a qualied person.)

Turn the cold water supply

valve OFF.

Figure 19 - Cold water supply in off position.

Using a standard at-blade

screwdriver, open the drain

valve. Sediment build up in

the boom of the water heater may

hinder or prevent draining.

Figure 20 - Draining the old water heater.

Also open a hot water faucet

to help the water in the tank

drain faster.

When the tank is empty,

disconnect the Temperature &

Pressure (T&P) Relief Valve

discharge pipe. You may be able to

reuse the discharge pipe, but do not

reuse the old T&P Relief Valve. A new

T&P Relief Valve comes with your new

water heater.

Figure 21 - Removing the T&P Relief Valve

discharge pipe.

Allow the vent pipe and dra

hood to cool. Once cooled,

disconnect the vent pipe from

the dra hood. You may need to

support the vent pipe unl the new

water heater is in place.

Figure 22 - Disconnect the vent pipe from the

draft hood.

Disconnect the water pipes.

Many water pipes are con-

nected by a threaded union

which can be disconnected with

wrenches. If you must cut the water

pipes, cut the pipes close to the water

heater’s inlet and outlet connecons,

leaving the water pipes as long as

possible. If necessary, you can make

them shorter later when you install the

new water heater.

Conrm the manual gas valve

for the water heater’s supply

18 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

INSTALLATION

line is turned o. Disconnect the gas

line from the water heater’s gas

control valve and cap it.

Remove the old water heater.

Use an appliance dolly or

hand truck to move the water

heater.

WARNING! Use two or more

people to remove or install a water

heater. Failure to do so can result in

back or other injury.

Step 4:

Installing the New

Water Heater

Completely read all instruc-

ons before beginning. If you

are not sure you can safely

complete the installaon, seek assis-

tance from any of the following sources:

• Lowe’s® Professional Installaon

is available for this product and

the work is guaranteed. Call your

Lowe’s® store to have this water

heater installed.

• Schedule an appointment with

a qualied person to install your

water heater.

• Call our Technical Assistance Hotline

at 1-877-817-6750.

Install a metal drain pan that

is piped to an adequate drain.

METAL

DRAIN

PAN

AT LEAST 2” GREATER THAN THE

DIAMETER OF THE WATER HEATER.

PIPED TO AN

ADEQUATE DRAIN

Figure 23 - Metal drain pan piped to drain.

Set the water heater in place

taking care not to damage the

drain pan. When installing

directly on carpet, the water heater

must be installed on a wood or metal

base that extends beyond the dimen-

sions of the water heater (width and

depth) by at least 3 inches (76.2 mm)

in any direcon. If the water heater is

installed on carpet in an alcove or

closet, the enre oor must be covered

by a wood or metal panel.

NOTICE: Most codes require seng

the water heater in a metal drain pan

piped to an adequate drain. The drain

pan helps avoid property damage

which may occur from condensaon

or leaks in the piping connecons or

tank. The drain pan must be at least

two inches wider than the diameter

of the water heater. Install the drain

pan so the water level is limited to a

maximum depth of 1-3/4”.

Verify that the water heater is

set in place properly. Check

that:

• There is adequate space to install

the T&P Relief Valve discharge

pipe and that it can be piped to a

separate drain (and not into the

drain pan).

• There is adequate access and

space around the water heater

for future maintenance.

• The water heater is installed

vercally.

Step 5:

Check the Air Filter

This water heater is equipped with a

base-ring air filter. Before proceeding

to the next step, visually check the

filter to ensure it is properly seated in

the base-ring. Do not operate the

water heater without a clean air filter

in place.

Step 6:

Connect the Tempera-

ture and Pressure (T&P)

Relief Valve/Pipe

Most T&P Relief Valves are pre-

installed at the factory. In some cases,

they are shipped in the carton and

must be installed in the opening

marked “T&P Relief Valve” and ac-

cording to local codes.

Figure 24 - Temperature and Pressure Relief

Valve

WARNING! To avoid serious injury

or death from explosion, install a T&P

Relief Valve according to the following

instrucons:

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 19

INSTALLATION

If the T&P Relief Valve was not

factory installed, install the

new T&P Relief Valve that

came with your water heater. Do not

reuse an old T&P Relief Valve.

• The discharge pipe should be at

least 3/4” inside diameter and

sloped for proper drainage. Install

it to allow complete drainage of

both the T&P Relief Valve and the

discharge pipe.

ADEQUATE DRAIN

6” MAXIMUM

AIR GAP

DISCHARGE PIPE

(DO NOT CAP OR PLUG)

Figure 25 - Temperature and Pressure Relief

Valve Pipe (Discharge Pipe)

• The discharge pipe must not be

smaller than the pipe size of the

T&P Relief Valve. The pipe must

also be able to withstand 250°F

(121°C) without distoron. Use

only copper or CPVC pipe. Do not

use any other type of pipe, such as

PVC, iron, exible plasc pipe, or

any type of hose.

• Terminate the discharge pipe a

maximum of six inches above a

oor drain or outside the building.

Do not drain the discharge pipe

into the drain pan; instead pipe it

separately to an adequate drain.

In cold climates, terminate the dis-

charge pipe inside the building to

an adequate drain. Outside drains

could freeze and obstruct the

drain line—protect the discharge

pipe from freezing.

• Do not place any valve or other

restricon between the tank and

T&P Relief Valve. Do not cap,

block, plug, or insert any valve

between the T&P Relief Valve and

the end of the discharge pipe. Do

not insert or install any reducer in

the discharge pipe.

Step 7:

Install Shuto and Ther-

mostac Mixing Valves

If one is not already installed,

install a manual shuto valve

in the cold water line that

supplies the water heater. Install the

shuto valve near the water heater so

that it is readily accessible. Only use a

full-ow ball or gate valve compable

with potable water.

Install a Thermostac Mixing

Valve at each point-of-use (for

example, kitchen sink,

bathroom sink, bath, shower) per the

valve manufacturer’s instrucons.

Figure 26 - Install Thermostatic Mixing Valves at

each point where hot water will be used.

WARNING! Even if the water

heater’s thermostat is set to a rela-

vely low temperature, hot water can

scald. Install Thermostac Mixing

Valves at each point-of-use to reduce

the risk of scalding.

20 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

INSTALLATION

For water heaters that are fed

by a solar water heang

system (or any other pre-

heang system), always install a

Thermostac Mixing Valve or other

temperature liming device in the

inlet water supply line to limit water

supply inlet temperature to 120°F.

Solar water heang systems can

supply water with temperatures

exceeding 180°F and may result in

water heater malfuncon.

WARNING! Hot water provided by

solar heang systems can cause

severe burns instantly, resulng in

severe injury or death.

Step 8:

Connect the Water

Supply

Note that all piping and components

connected to the water heater must

be suitable for use with potable water.

Determine the type of water

pipes in your home. Most

homes use copper water

pipes, but some use CPVC or cross-

linked polyethylene (PEX). Use ngs

appropriate for the type of pipe in

your home. Do not use iron or PVC

pipe.

Connect the cold water

supply using 3/4 inch

Naonal Pipe Thread “NPT” to the

ng marked “C” (COLD).

For ease of removing the water heater

for service or replacement, con-

nect the water pipes with a coupling

called a union. We recommend using

a dielectric-type union (available at

Lowe’s®). Dielectric unions can help

prevent corrosion caused by ny elec-

tric currents common in copper water

pipes and can help extend the life of

the water heater

IF YOU HAVE COPPER PIPES:

If your home has copper water pipes,

you can solder the water pipe connec-

ons or use compression ngs which

don’t require soldering. Compression

ngs are easier to install than solder-

ing pipe. Check with local plumbing

ocials to determine what types of

pipe materials are suitable for your

locaon. Do not use lead-based solder.

NOTICE: Do not solder pipes while

they are aached to the water heater.

The water heater’s inlet and outlet

connecons contain non-metallic parts

which could be damaged. The proper

way to connect the water heater to

copper water pipes is as follows:

• Solder a short length of pipe (about

a foot or so) to a threaded adapter

using only 95/5 n-anmony or

equivalent solder. Aach the thread-

ed adapters to the water heater’s

connecons (using Teon® tape or

pipe joint compound). Connect the

home’s water pipes by soldering,

keeping the connecons at the water

heater cool with wet rags.

Compression ngs don’t require soldering.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 21

INSTALLATION

NOTICE: Most water heater models

contain energy saving heat traps in the

inlet and outlet connecons. Do not

remove the heat traps.

Connect the hot water supply

using 3/4 inch NPT to the

ng marked “H” (HOT).

Install insulaon (or heat

tape) on the water pipes

especially if the indoor

installaon area is subject to freezing

temperatures. Insulang the hot water

pipes can increase energy eciency.

Adjust (or install) the home’s

Pressure Reducing Valve to

50-60 psi and install a Thermal

Expansion Tank.

Figure 27 - A Pressure Reducing Valve is required

if your home’s water pressure is above 80 psi.

Figure 28 - The Thermal Expansion Tank should

be pressurized with air, using a hand pump, to

match the home’s incoming water pressure.

Step 9:

Verify Connecons and

Completely Fill Tank

To remove air from the tank and allow

the tank to ll completely with water,

follow these steps:

Remove the aerator at the

nearest hot water faucet. This

allows debris in plumbing

system to be washed out of the pipes.

Turn the cold water supply

back on and ll the tank.

Open a hot water faucet and

allow the water to run unl it

ows with a full stream.

Let the water run full stream

for three minutes.

Close the hot water faucet

and replace the aerator.

Check inlet and outlet connec-

ons and water pipes for leaks.

Dry pipes connecons so that

any drips or leaks will be apparent.

Repair any leaks. Almost all leaks occur

at connecons and are not a tank leak.

Step 10:

Install Dra Hood

Install the new dra hood by

aligning the legs and inserng

them into the slots on the ue

damper’s ange. (See Figure 29.) Do

not reuse the dra hood from the old

water heater, but rather use the new

one that came with your new water

heater.

Secure the dra hood by

bending the leg ps, but do not

alter the dra hood in any way.

Draft Hood

Flue Damper

Draft Hood

Leg Tip*

* Twist or bend the leg tips to secure the draft

hood to the flue damper.

* Damper orientation may vary.

Figure 29 - Install the new draft hood.

Aach the home’s exisng vent

pipe to the dra hood outlet

using an approved vent

adapter (not supplied). Read the

Venng secon on page 11. Make

sure your home’s venng system

complies with the instrucons in this

manual and is in good condion.

22 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

INSTALLATION

Step 11:

Make Gas Connecons

The Gas Water Heater Hook-Up

Kit (available at Lowe’s®) includes

a exible gas connector with

compression ngs to connect the

home’s gas line to the water heater’s

gas control valve. Follow the kit’s

installaon instrucons to aach the

exible gas connector.

Figure 30 - Flexible gas line connector.

Once you’ve made the gas connec-

ons, use a small, so-bristled brush

to apply a hand dishwashing soap

and water mixture or children’s soap

bubbles (1 part soap to 15 parts water)

to all connecon points of the gas line

and exible gas connector (if used).

Make sure to generously coat all the

connecons and check for gas leaks

(which will appear as small bubbles).

If any leaks are detected, turn the gas

supply o, ghten the leaking connec-

on and re-check.

BEFORE LIGHTING THE WATER

HEATER...

Make sure all checklist items have

been completed.

Water Heater Locaon

✓ Installaon area free of corrosive

or ammable materials, liquids or

vapors.

✓ Proper clearances from combusble

surfaces maintained and sucient

room to service the water heater.

✓ Not installed directly on a carpeted

oor.

✓ Metal drain pan installed and piped

to an adequate drain.

✓ Water heater not located near an

air moving device (fan, clothes

dryer).

✓ Not in a locaon with large

amounts of lint, dust, etc. (If so,

the air lter or ame arrestor

located on the boom of the water

heater will need to be cleaned

more oen.)

Combuson Air Supply and

Venlaon

✓ Adequate air supply for water

heater and any other nearby gas

appliances.

If the water heater is installed in a

closet or other small, enclosed space

or within the living space of the

house, air supply openings needed.

✓ Are the openings of sucient size?

✓ Ductwork is the same cross-sec-

onal area as the openings?

✓ Outside air openings are preferred

and may be required in ghtly built

homes.

Vent Pipe System

✓ New dra hood, properly installed.

✓ Vent pipe securely fastened to

dra hood with screws and sup-

ported properly.

✓ Vent pipe made of approved mate-

rial and either 3” or 4” in diameter.

✓ Vent system installed according

to local and state codes or, in the

absence of local and state codes,

the “Naonal Fuel Gas Code”, ANSI

Z223.1(NFPA 54)-current edion.

✓ Check exisng vent system for rust,

restricons/obstrucons.

Water System Piping

✓ Temperature and pressure relief

valve properly installed with a

discharge line run to an adequate

drain and protected from freezing.

✓ Water pipes free of leaks.

✓ Water heater completely lled with

water.

✓ Thermal Expansion Tank installed

✓ Water Pressure Reducing Valve

installed and adjusted to 50-60 psi.

✓ Thermostac Mixing Valves in-

stalled at each point-of-use.

Gas Supply and Piping

✓ Gas type is the same as that listed

on the water heater’s data plate.

✓ Gas line equipped with shut-o

valve.

✓ Adequate gas pipe size and ap-

proved gas pipe material.

✓ All gas connecons and ngs leak

checked and any leaks corrected.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 23

OPERATION

Lighng Instrucons

WARNING! Explosion Hazard –

Replace viewport if glass is missing or

damaged. Failure to do so can result

in death, explosion or re.

Read and understand these direcons

thoroughly before aempng to

put the water heater into operaon.

Make sure the viewport is not missing

or damaged. Make sure the tank is

completely lled with water before

lighng the pilot. Check the data plate

near the gas control valve to ensure the

correct gas type. Do not use this water

heater with any gas other than the one

listed on the data plate. If you have any

quesons or doubts, consult your gas

supplier or gas ulity company.

NOTICE! A newly installed water heater

will have air in the gas line. It may take

several lighng aempts to clear all the

air from the gas line and light the pilot.

Follow these steps to light the pilot:

Make sure the manual gas

valve for the water heater’s

supply line is ON.

Figure 31 - Gas valve in “on” position

Plug the water heater into a

grounded 120 VAC outlet.

Figure 32 - Move switch to ON position.

Move the ON/OFF switch on

the gas control valve to the ON

posion (Figure 32).

Turn the gas control valve to

the LOW temperature seng

(Figure 33). The water heater

will light automacally. Do not try to

light the pilot by hand.

Figure 33 - Set knob to LOW setting.

When the pilot is lit, the status

light will blink a heartbeat

(bright, dim, bright, dim, etc.).

Adjust the gas control knob to the HOT

seng.

If you receive a ash code (six ashes

followed by a single ash):

A.) Turn the power switch on the gas

valve to the OFF posion. B.) Unplug

the water heater from the wall outlet.

C.) Wait 10 minutes.

D.) Repeat steps 1 through 4.

Follow these steps if the Status

Light does not start ashing a

“heartbeat” aer three lighng

aempts: A.) Turn o gas to the water

heater at the manual shut-o valve.

B.) Move the gas valve’s ON/OFF switch

to the OFF posion.

C.) Refer to “Troubleshoong-No Hot

Water” on page 25.

• When a gas water heater is first lit

and the tank is cold, condensation

often forms inside the water heater.

You may hear drips or a sizzling sound

when the water heater is first lit, or

you may see a small puddle on the

floor. Condensation is not a leak and

will go away once the tank reaches

normal operating temperature.

• The air lter at the boom of the water

heater must be cleaned from me to

me. See the Maintenance secon for

steps on cleaning the air lter. If the air

lter is not cleaned as needed, an LDO

fault code may occur. (LDO faults are

diagnosed on page 30.)

Shut down Instrucons

Move the ON/OFF switch on the gas

control valve to the OFF posion. The

status light will stop blinking and stay on

for a short me aer the water heater is

turned o.

Emergency Shut down

Should overheang occur or the gas sup-

ply fail to shut o, follow these steps:

A.) Turn o gas to the water heater at

the manual shut-o valve.

B.) Move the gas valve’s ON/OFF switch

to the OFF posion.

C.) Turn o all electric power to the

water heater. (Unplug it from the 120

VAC outlet.)

Checking the Vent

System and Air Supply

Once the water heater is lit and the gas

control knob is set to the desired temper-

ature, the burner will light (if the tank is

cold). Perform an air supply and vent test

to make sure the unit is venng properly

and the air supply is adequate:

The main burner must be on

for this test. With a newly

installed water heater full of

cold water, turning the temperature

control knob to HOT should cause the

main burner to come on. You can view

the burner through the sight glass at

the base of the water heater.

Close all windows and doors

and turn on all gas appliances

and air-moving devices (range

hoods, bathroom exhaust fans, ceiling

24 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

OPERATION

fans, etc.) in your home. Also, close any

replace dampers.

Allow the water heater’s main

burner to operate for ve

minutes. Pass a newly exn-

guished match approximately one inch

from the dra hood’s relief opening.

Smoke from the match should be

steadily drawn into the opening indicat-

ing the water heater is geng adequate

air and the vent system is working.

Figure 34 - Test the air supply and vent to make

sure the water heater has adequate air and is

venting properly.

If the main burner has been

operang for ve minutes but

the match smoke dris around

or is blown away from the opening, a.)

turn o gas to the water heater at the

manual shut-o valve, b.) turn the gas

valve switch to the OFF posion, then c.)

unplug the water heater from the power

outlet. Inspect the vent system and

repair if necessary. In many cases, failure

to pass the air supply and vent test

indicates the water heater is not geng

enough air or there is a problem with

the vent system. It may be necessary to

increase the air supply by geng air

from outside (see page 7).

WARNING! Burn Hazard. Do not

touch the vent, doing so can cause

burns. If the dra hood does not draw

in smoke from a match aer ve

minutes of main burner operaon,

shut the gas supply o, and do not

operate the water heater unl the vent

system and air supply have been

checked by a qualied person and

repaired if necessary. Connuing to

operate the water heater in this

condion could lead to serious injury

or death from carbon monoxide

poisoning.

Temperature Control

System

Adjusng the Temperature

With the installaon steps completed,

you may adjust the water heater’s tem-

perature seng if desired.

Set the gas valve to the desired

temperature. The “HOT”

seng sets the water tem-

perature to approximately 120°F,

reducing the risk of scald injury. You

may wish to set a higher temperature to

provide hot water for automac

dishwashers or laundry machines, to

provide more hot water capacity, and to

reduce bacterial growth. Higher tank

temperatures (140° F) kill bacteria that

cause a condion known as “smelly

water” and can reduce the levels of

bacteria that cause water-borne

diseases.

Water usage paerns, as well as heat

from sources such as solar collectors,

ambient air, and the pilot light can

result in temperatures higher than the

thermostat set-point.

WARNING! Higher temperatures

increase the risk of scalding, but even at

120°F, hot water can scald (see Table 1).

Install Thermostac Mixing Valve(s) at

each point-of-use to reduce the risk of

scalding.

To adjust the water heater’s

thermostat:

Figure 35 - Adjust the gas control knob to “HOT”.

Turn the gas control knob on the gas

control valve to the desired seng.

• VAC 55°F

• LOW 91°F

• HOT 120°F

• A 130°F

• B 140°F

• C 150°F

• VERY HOT 155°F

NOTICE: The temperatures above are

approximates. The actual temperature

of the heated water may vary.

Wait for the water to heat up.

If you have no hot water aer

two hours, refer to the

Troubleshoong Secon ( page 25 ).

NOTICE: If the tank is full of cold water,

condensaon may form inside the

water heater. This condensaon may

drop on the burner causing a sizzling

sound. In some cases, you may see a

small puddle on the oor. Condensa-

on is normal and should go away once

the tank reaches its normal operang

procedure.

WARNING! If you have increased

the temperature seng and the

Thermostac Mixing Valves are not set

properly (or not installed) you could

scald yourself while checking the

temperature.

OPERATION

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 25

TROUBLESHOOTING

Check water temperature at

several points of use in your

home (for example, bathtub

faucet, shower, or lavatory sink) and

adjust the Thermostac Mixing Valves as

needed. If you aren’t sure how to adjust

the Thermostac Mixing Valve sengs,

or aren’t sure if you have Thermostac

Mixing Valves, contact a qualied

person.

Operang Modes

The gas control valve has two dier-

ent operang modes: Standard and

Vacaon. The Standard mode allows

you to adjust the water temperature

to your desired seng. The Vacaon

(VAC) mode sets the thermostat at

approximately 55°F and is recom-

mended when not using hot water for

an extended period of me. The VAC

seng also reduces energy losses and

keeps the tank from freezing during

cold weather but can cause a Hydrogen

gas build up. See cauon on page 6.

No Hot Water

Use the following step-by-step plan

as a guide to help determine why you

have no hot water:

Check the Status Light

The Status Light on the gas

control valve ashes once every four

seconds when there are no problems

and there is no call for heat.

Figure 36 - Status light.

If the Status Light is ashing once ev-

ery four seconds and you have no hot

water, make sure the gas control knob

is set to HOT.

If the Status Light ashes a dierent

paern than is described above, refer

to “LDO Module - Status Light Code”

on page 30.

If the Status Light is not ashing, go to

step 2.

Status Light is Not

Flashing

If the status light on the gas control valve

does not ash, the system may be locked

out. Refer to “Status Light Trouble-

shooting Flowchart” on page 30. Be

sure to read the notes at the top of

that flowchart.

Insucient Hot Water

or Slow Hot Water

Recovery

WARNING! Because of the increased

risk from scalding, if you set the water

heater’s gas control knob higher than

120°F, install Thermostac Mixing

Valves at each point-of-use. Due to the

increased risk of scalding, do not set the

temperature of the Thermostac

Mixing Valves above 120°F.

If the hot water is simply not warm

enough, there are several possible

causes:

• Faulty Thermostac Mixing Valve

in a faucet or shower control

(check other faucets in the house

for hot water).

• Water heater’s capacity too small

(or usage too high).

• Reversed plumbing connecons

or melted dip tube (usually found

soon aer new installaon).

• Plumbing leak.

• Sediment or lime build up in the

boom of the tank.

Thermostac Mixing Valves. If the

hot water is simply not warm enough,

make sure the faucet you are checking

doesn’t have a defecve Thermostac

Mixing Valve. Many shower controls

now have built-in mixing valves. If

these devices fail, they can reduce the

amount of hot water the shower or

faucet delivers even though there is

plenty of hot water in the tank. Always

check the water temperature at several

faucets to make sure the problem is not

in a faucet or shower control.

Undersized Water Heater. If your water

heater runs out of hot water quickly, it

may be too small for your needs. If the

water heater is old, consider replacing it

with a larger model. If the water heater

is in good condion, you may be able

to meet your family’s hot water needs

with the exisng water heater by install-

ing Thermostac Mixing Valves at each

point-of-use and then turning the gas

control knob to a higher seng.

You can also reduce your home’s hot

water needs by washing clothes in cold

water, installing ow restrictors on

shower heads, repairing leaky faucets,

and taking other conservaon steps.

Reversed Connecons or Melted Dip

Tube. Check the hot and cold water

connecons and make sure your

home’s hot water pipe is connected

to the hot water outlet on the water

heater. Usually, reversed connecons

are found soon aer the installaon

of a new unit. If copper pipes were

soldered while they were aached to

the water heater, the dip tube may

have melted. The dip tube is a long,

plasc tube inside the tank aached to

the cold water inlet. If the dip tube has

melted, it can be replaced by removing

the cold water inlet connecon, re-

moving the old dip tube and installing

a new one.

Plumbing Leak. Even a small leak

in the hot water side of the home’s

26 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

TROUBLESHOOTING

plumbing system can make it appear

that the water heater is producing

lile to no hot water. In this case, the

burner will be on all or almost all the

me, yet you will have very lile hot

water. Locate and repair the leak.

Sediment or Lime in Tank. With an ex-

isng water heater, if you have some

hot water but not as much as you’re

used to, there may be a build up of

sediment or lime on the boom of the

tank. Sediment or lime build up can

reduce the eciency of your water

heater. Heavy deposits can damage

the water heater. See the Mainte-

nance secon for steps on draining

and ushing the water heater.

Temperature Too High

Adjust the thermostat on the water

heater to a lower seng. Install or

adjust Thermostac Mixing Valves

for each point-of-use (see the valve

manufacturer’s instrucons).

Low Water Pressure

Check both the cold and hot water

at a sink to determine if the lower

pressure is only on the hot water side.

If both hot and cold faucets have low

pressure, call your local water ulity.

If the low pressure is only on the hot

water side, the primary causes are:

• Melted heat traps or dip tube. Sol-

dering copper pipes while they are

connected to the water heater can

melt the heat traps inside the hot

and cold water connecons or the

dip tube (cold water side). Melted

heat traps or a melted dip tube

can restrict the ow of hot water.

If that’s the case, replace the heat

traps or dip tube.

• Parally closed supply valve. Open

the water heater’s supply valve fully.

Drips from T&P Relief

Valve Discharge Pipe

A small amount of water dripping

from the Temperature and Pressure

(T&P) Relief Valve usually means the

home’s water pressure is too high

and/or you need a Thermal Expan-

sion Tank. See Step 1 in the Installa-

on secon of this manual for more

informaon.

A large amount of hot water coming

from the T&P discharge pipe may be

due to the tank overheang. If the

T&P relief valve is discharging large

amounts of very hot water, turn the

gas supply valve o and call a quali-

ed person.

WARNING! Do not cap or plug the

T&P Relief Valve or discharge pipe,

and do not operate the water heater

without a funconing T&P Relief

Valve—this could cause an explosion.

Water Pressure too High. High water

pressure can cause the T&P Relief

Valve to drip. Install a Pressure Re-

ducing Valve (PRV) on the main cold

water supply line. Adjust the PRV to

between 50 and 60 psi.

Thermal Expansion Tank. Install a

Thermal Expansion Tank. If a Thermal

Expansion Tank is already installed

and the T&P Relief Valve discharge

pipe drips, the home’s water pressure

may be too high or the Thermal Ex-

pansion Tank may be defecve. Refer

to the instrucons that came with

the Thermal Expansion Tank for more

informaon.

Debris. In rare cases, debris can sck

inside the T&P Relief Valve prevenng

the valve from sealing fully. In that

case, the T&P Relief Valve discharge

pipe will drip. You may be able to

clear debris from the T&P Relief Valve

by manually operang the valve,

allowing small quanes of water to

ush out the debris. See the label on

the T&P Relief Valve for instrucons.

WARNING! When manually

operang the temperature-pressure

relief valve, make sure that no one is

in front of or around the discharge

outlet. The water may be extremely

hot and could cause severe burns.

Also ensure that the water discharge

will not cause property damage.

If the water pressure is between 50

and 60 psi, a Thermal Expansion Tank

is installed and properly pressurized,

and the valve has been cleared of any

debris, and it sll drips, the valve may

be broken—have a qualied person

replace the T&P Relief Valve.

Water Odor

Harmless bacteria normally present in

tap water can mulply in water heat-

ers and give o a “roen egg” smell.

Although eliminang the bacteria that

causes “smelly water” is the only sure

treatment, in some cases, the stan-

dard anode rod that came with your

water heater can be replaced with a

special zinc anode rod which may help

reduce or eliminate the odor. Contact

a qualied person.

NOTICE: To protect the tank, an anode

rod must be installed in the water

heater at all mes or the warranty is

void.

In cases where the “roen egg” smell

is very strong, you could increase the

tank temperature to 140°F in order to

reduce bacterial growth in the tank.

WARNING! Because higher

temperatures increase the risk of

scalding, if you set the thermostat(s)

higher than 120°F, Thermostac

Mixing Valves at each point-of-use

are parcularly important.

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 27

TROUBLESHOOTING

GAS CONTROL VALVE / THERMOSTAT - STATUS LIGHT CODE-

TROUBLESHOOTING FLOWCHART (OVERVIEW)

LED FLASH SEQUENCE CONTROL STATUS

No Flash Lock out. (Check the status light on the LDO module and refer to the LDO

Status Light Troubleshooting Flowchart on page 30. The location of the

LDO module is shown on page 2.)

Short ash once every four second IDLE (No call for heat, no fault condions)

“Heartbeat”, alternates bright/dim Call for Heat (No fault condions)

One Flash, three second pause Low Flame Signal (control connues to operate)

Two Flash, three second pause End Switch Failed Closed

Three Flash, three second pause End Switch Failed Open

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

Five Flash, three second pause Flame Out of Sequence

Six-One Flash, three second pause So Lockout* - Retry Limit - Failed TFI (Trial for Ignion)

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

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

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

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

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

Eight-Two Flash, three second pause Temperature Sensor Fault Detected (No Light)

Eight-Three Flash, three second pause Electronic Fault Detected

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

EXAMPLE: An “Eight-Four Flash” will show eight flashes, then four flashes, followed by a three second pause.

The pattern will then repeat.

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

NOTICE:

• These codes apply to the gas control valve. The locaon of the gas control valve is shown on page 2.

• Refer to the following pages for detailed troubleshoong procedures.

28 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

TROUBLESHOOTING

STATUS LIGHT TROUBLESHOOTING FLOWCHART

GasControlValve/Thermostat-StatusLightCode

LED FLASH SEQUENCE GAS CONTROL

VALVE STATUS

CORRECTIVE ACTION

No Flash Lock out Check the status light on the LDO module and refer to the LDO Status Light Troubleshooting

Flowchart on page 30. The location of the LDO module is shown on page 2.

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

conditions)

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

One Flash, three second pause Low Flame Signal

(control continues to operate)

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

from the power outlet.

1. Check the incoming gas line pressure to ensure adequate supply to the water heater. If

incoming gas supply pressure is adequate, proceed to step 2.

2. Check all wiring connections and ensure all harness and wire connections are seated

firmly and provide proper electrical contact. If no connection problems are found, proceed

to step 3. Firmly seat any loose connections found. If any connections are found to be

damaged, consult the replacement parts list for the appropriate replacement. After any

connection problems are fixed, restart the water heater by following the lighting instructions

on page 23. If the problem persists, proceed to step 3.

3. Check the condition of the base ring filter and flame arrestor. If they are clogged, follow

the instructions for cleaning on page 36. If parts are not clogged, proceed to step

4. After cleaning, follow the instructions for lighting on page 23. If problem persists,

proceed to step 4.

4. Follow the instructions on page 35 to remove the burner assembly. Once the burner

assembly has been removed, inspect the manifold tube and burner for any obstructions. If

any clogs or obstructions are present, clear them. Inspect the pilot assembly’s electrode/

flame sense rod for corrosion buildup, degradation, or damage. If there is evidence of any

damage to the electrode/flame sense rod, replace the igniter/pilot assembly. Follow the

directions on page 35 to re-install the burner assembly into the combustion chamber.

Follow the instructions for lighting on page 23. If the problem persists, contact a certified

service representative.

Two Flash, three second pause End Switch Failed Closed Look at the top of water heater to see if the damper is open (Figure 29, page 21). If the

damper is open, ensure there is no obstruction that would prevent the damper from closing. If

there are any obstructions, turn the power switch on the gas valve to the “OFF” position, then

remove the obstruction. If the damper closes, turn the power switch on the gas valve to the

“ON” position. If there are no obstructions present, turn the power switch on the gas valve to the

“OFF” position. Observe the damper to see if the damper closes. If the damper does not close,

unplug the power cord from the power outlet and proceed to step 1. If the damper closes turn

the power switch on the gas valve to the “ON” position.

1. Check all wiring connections to ensure all harness and wire connections are seated firmly

and provide proper electrical contact. If no connection problems are found, replace the

damper. Firmly seat any loose connections found. If any connections are found to be

damaged, consult the replacement parts list on for the appropriate replacement. After any

connection problems are fixed, restart the water heater by following the lighting instructions

on page 23. If the problem persists, replace the damper.

Three Flash, three second pause End Switch Failed Open

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

from the power outlet.

1. Follow the lighting instructions on page 24. Observe the damper during initial startup. If

there is a call for heat and the damper opens, allow the unit to continue to perform and

monitor any change in status. If there is a call for heat and the damper does not open,

procede to step 2.

2. Check all wiring connections to insure all harness and wire connections are seated firmly

and provide proper electrical contact.If no connection problems are found replace the

damper.Firmly seat any loose connections found. If any connections are found to be

damaged, consult the replacement parts list on page 39. After any connection problems

are fixed, restart the water heater by following the lighting instructions on page 24. If the

problem persists, replace the damper.

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

then turn the power switch on the gas control valve to the “ON” position. If the problem

persists, replace the gas control valve. (See page 34.)

Five Flash, three second pause Flame Out of Sequence 1. Turn the power switch on the gas control valve to the “OFF” position. Wait 10 minutes,

then follow the lighting instructions on page 23. If the problem persists, replace the gas

control valve. (See page 34.)

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 29

TROUBLESHOOTING

STATUS LIGHT TROUBLESHOOTING FLOWCHART (CONTINUED)

GasControlValve/Thermostat-StatusLightCode

LED FLASH SEQUENCE CONTROL STATUS CORRECTIVE ACTION

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

Failed TFI (Trial for Ignition)

Turn the power switch on the gas valve to the OFF position. Unplug the water heater from the

wall outlet. Plug the power cord back in, then follow the lighting instructions on page 23. If that

does not work, turn the power switch on the gas control valve to the “OFF” position, unplug the

power cord from the power outlet, then follow the steps below.

1. Check the incoming gas line pressure to ensure adequate supply to the water heater. If

incoming gas supply pressure is adequate, proceed to step 2.

2. Check all wiring connections and ensure all harness and wire connections are seated

firmly and provide proper electrical contact. If no connection problems are found, proceed

to step 3. Firmly seat any loose connections found. If any connections are found to be

damaged, consult the replacement parts list for the appropriate replacement. After any

connection problems are fixed, restart the water heater by following the lighting instructions

on page 23. If the problem persists, proceed to step 3.

3. Check the condition of the base ring filter and flame arrestor. If they are clogged, follow

the instructions for cleaning on page 36. If parts are not clogged, proceed to step

4. After cleaning, follow the instructions for lighting on page 23. If problem persists,

proceed to step 4.

4. Follow the instructions on page 35 to remove the burner assembly. Once the burner

assembly has been removed, inspect the manifold tube and burner for any obstructions. If

any clogs or obstructions are present, clear them. Inspect the pilot assembly’s electrode/

flame sense rod for corrosion buildup, degradation, or damage. If there is evidence of any

damage to the electrode/flame sense rod, replace the igniter/pilot assembly. Follow the

directions on page 35 to re-install the burner assembly into the combustion chamber.

Follow the instructions for lighting on page 23. If the problem persists, contact a

qualified service representative.

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

Lost - END Switch Fails

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

from the power outlet.

1. Check all wiring connections to ensure all harness and wire connections are seated firmly

and provide proper electrical contact. If no connection problems are found, replace the

damper. Firmly seat any loose connections found. If any connections are found to be

damaged, consult the replacement parts list for the appropriate replacement. After any

connection problems are fixed, restart the water heater by following the lighting instructions

on page 23. If the problem persists, replace the damper.

Six-Three Flash, three second

pause

Soft Lockout* - Recycle Limit - Flame

Lost

* Soft Lockout - 20 minute wait before

returning to normal mode.

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

from the power outlet.

1. Check the incoming gas line pressure to ensure adequate supply to the water heater. If

incoming gas supply pressure is adequate, proceed to step 2.

2. Check all wiring connections and ensure all harness and wire connections are seated

firmly and provide proper electrical contact. If no connection problems are found, proceed

to step 3. Firmly seat any loose connections found. If any connections are found to be

damaged, consult the replacement parts list for the appropriate replacement. After any

connection problems are fixed, restart the water heater by following the lighting instructions

on page 23. If the problem persists, proceed to step 3.

3. Check condition of the base ring filter and flame arrestor. If they are clogged, follow the

instructions for cleaning on page 36. If the parts are not clogged, proceed to step

4. After cleaning, follow instructions for lighting on page 23. If the problem persists,

proceed to step 4.

4. Follow the instructions on page 35 to remove the burner assembly. Once the burner

assembly has been removed, inspect the manifold tube and burner for any obstructions. If

any clogs or obstructions are present, clear them. Inspect the pilot assembly’s electrode/

flame sense rod for corrosion buildup, degradation, or damage. If there is evidence of any

damage to the electrode/flame sense rod, replace the igniter/pilot assembly. Follow the

directions on page 35 to re-install the burner assembly into the combustion chamber.

Follow the instructions for lighting on page 23. If the problem persists, contact a

qualified service representative.

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

Sequence Sensed

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

from the power outlet. Wait 10 minutes, then follow the lighting instructions on page 23. If the

problem persists, replace the gas control valve. (See page 34.)

30 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

STATUS LIGHT TROUBLESHOOTING FLOWCHART (CONTINUED)

TROUBLESHOOTING

STATUS LIGHT TROUBLESHOOTING FLOWCHART

• These codes apply to the LDO module. See page 2 for the locaon of the LDO module.

• If the status light on the gas control valve is not ashing, check the status light on the LDO module

and refer to the table below.

NOTICE:

Status LDO Status

Gas Control

ValveStatus

CorrectiveAction

Normal Operaon

1 sec.

Heart Beat None Needed

Burner Failure

4 sec.

No Light

• Replace Burner

• Press and hold reset button on LDO module for 3 sec-

onds to clear the fault code.

Lint Build-Up

Detected

1 sec.

No Light

• Remove Lint and Dust Build-up.

• Ensure gas supply pressure is correct.

• Requires main power to be cycled in order to clear fault

code.

Chamber Sensor

Failure

4 sec.

No Light

• Ensure sensor is connected properly to LDO module.

• Replace Chamber Sensor.

See Figure 50.

• Fault code clears immediately when condition clears.

LED FLASH SEQUENCE CONTROL STATUS CORRECTIVE ACTION

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

Lockout

1. Do not touch any electrical switch, do not use any phone in the building, and do not try to

light any appliance.

2. Smell around the water heater to ensure there are no gas leaks at the gas control valve or

in the supply gas line or for any other type of flammable vapors in the area.

3. Carefully inspect the area surrounding the water heater for any substances such as

gasoline, paint, paint thinners, varnish, or cleaners that could emit flammable vapors.

Remove anything that can potentially emit flammable vapors from the area and store it

properly in a different location.

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

Eight-One Flash, three second

pause

Flammable Vapor Sensor (FVS) Fault

Detected

Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds, then

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

replace the gas valve.

Eight-Two Flash, three second

pause

Temperature Sensor Fault Detected Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds, then

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

replace the gas valve.

Eight-Three Flash, three second

pause

Electronic Fault Detected Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds, then

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

replace the gas valve.

Eight-Four Flash, three second

pause

Gas Control Valve/Thermostat Fault

Detected

Turn the power switch on the gas control valve to the “OFF” position, wait 10-20 seconds, then

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

replace the gas valve.

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

GasControlValve/Thermostat-StatusLightCode

LDO Module - Status Light Code

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 31

TROUBLESHOOTING

SEQUENCE OF OPERATIONS CHART

Apply Power

to Appliance.

Is Damper

Closed?

Is there a

Call for Heat.

Is Damper

Open?

Will not attempt to light. 2

flash error code.

Damper Energizes.

Gas Valve attempts to open damper

for 30 seconds, displays 3 flash error

code, and then waits 2 minutes before

attempting to open damper again.

Pilot Valve

Energizes

Does Pilot

Valve Open?

Spark Electrode

is Energized

Pilot Flame

Sensed Within

1.5 min. ?

Main Valve

Energized

Does Main

Valve Open?

Is Main

Flame Sensed?

Is Demand for

Heat Satisfied?

Pilot & Main

Valve De-Energize.

Is Flame

Sensed?

Damper Energizes

and Closes.

Will not light. 8-4 flash

error code.

Will not light. 8-4 flash

error code.

Will not light. 8-4 flash

error code.

Will not light. 8-4 flash

error code.

Water heater will continue to

operate normally until

demand is satisfied.

Wait for flame lost, 5 flash

error code.

Damper closes, displays 6-4

Flash Error Code, and gas

control valve goes into 20

minute lockout.

32 • Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide

MAINTENANCE

Roune Maintenance

Roune maintenance will help your

water heater last longer and work bet-

ter. If you can’t perform these roune

maintenance tasks yourself, contact a

qualied person.

Draining and Flushing the

Water Heater

Tap water contains minerals that can

form sediment in the boom of the

tank. The amount of sediment formed

depends on the hardness of your tap

water, the temperature sengs, and

other variables. We recommend drain-

ing and ushing the water heater aer

the rst six months of operaon to de-

termine the amount of sediment build

up. If there is lile sediment, drain and

ush the tank annually. If there is a lot

of sediment, drain and ush the tank

more oen. Draining sediment extends

the life of the water heater.

To Drain and Flush the Tank:

Turn the power switch on the

gas control valve to the OFF

posion.

Figure 37 - Turn gas control/temperature knob

OFF.

Turn the manual gas valve for

the water heater’s supply line

OFF.

Open a hot water faucet and

let the hot water run unl it is

cool (This may take 10

minutes or longer).

Figure 38 - Let the hot water run until it is cool.

WARNING! Be sure the water runs

cool before draining the tank to

reduce the risk of scalding.

Connect a garden hose to the

drain valve and place the

other end of the hose in a

drain, outside, or in buckets. Note that

sediment in the boom of the tank

may clog the valve and prevent it from

draining. If you can’t get the tank to

drain, contact a qualied person.

Turn the cold water supply

valve OFF.

Open the drain valve on the

water heater.

Figure 39 - Draining the water heater.

Also open a hot water faucet

to help the water in the tank

drain faster.

Remove and inspect the

anode rod and replace if

depleted. The anode rod

requires a 1-1/16” socket.

Figure 40 - Anode rods from new (top) to par-

tially depleted (middle) to fully depleted stage

(bottom).

Anode Rod. The anode rod is a sacri-

cial metal rod that helps avoid corro-

sion and premature failure (leaks) in

the tank. The anode rod is a consum-

able item. Inspect the anode rod aer

the rst six months of operaon when

you drain and ush the tank. Replace

the anode rod if it is substanally worn

out or depleted. Thereaer, inspect the

anode rod annually or more frequently

if needed. If you use a water soener,

your anode rod will deplete faster than

normal. Inspect the anode rod more

frequently, replacing the anode rod

if it is depleted. Obtain a new anode

rod from Lowe’s® or have a qualied

person replace it. (Anode rods are a

consumable item and are not covered

under warranty).

If a large amount of sediment

was present when the tank

was drained, ush the tank by

opening the cold water supply valve

and leng the water run unl no more

sediment drains from the tank. Close

Residenal Standard Gas Ultra Low Nox Water Heater Use and Care Guide • 33

MAINTENANCE

the drain valve when you are done.

Rell the tank by opening the

cold water supply valve. Make

sure a hot water faucet is open

and the drain valve is closed. Allow a

hot water faucet to run full for at least

three minutes to make sure the tank

has all the air removed and is complete-

ly full of water. Once you are certain the

tank is completely full of water, close

the hot water faucet.

Put the water heater back into

operaon by following the

lighng instrucons on page

23. Adjust the gas control knob to

the desired temperature. It may take an

hour or more for the tank of cold water

to heat up.

Visual Inspecon

On an annual basis, visually inspect the

venng and air supply system, piping

systems, main burner, pilot burner, and

the air lter.

Check the water heater for the following:

• Obstrucons, damage, or deterio-

raon in the venng system. Make

sure the venlaon and combus-

on air supplies are not obstruct-

ed. Check the air lter for dust or

other debris and clean if needed.

• Build up of soot and carbon on

the main burner and pilot burner.

The burner may be cleaned with

soap and hot water.

• Inspect the burner ames through

the viewport and compare them

to Figure 41. The ames should

be very small with a blue haze and

small amount of yellow or orange

at the edges. Aer several minutes

of operaon, the burner screen

may glow red. If large ames are

observed at any me, shut-o the

unit and call a qualied person.

Figure 41 - Burner Flames

• Leaking or damaged water and gas

piping.

• Remove any ammable, corrosive

or combusble materials near the

water heater.

If you lack the necessary skills required

to properly perform this visual inspec-

on or if the burner needs to be cleaned,

get help from a qualied person.

T&P Relief Valve Maintenance

Figure 42 - T&P Relief Valve.

Read and follow the operang and an-

nual maintenance instrucons provided

by the manufacturer of the T&P Relief

Valve (yellow label aached to T&P

Relief Valve). Minerals in the water can

form deposits that cause the valve to

sck or create blocked passages, mak-

ing the T&P Relief Valve inoperave.

Follow these guidelines:

• At least annually, operate the T&P

Relief Valve manually to ensure the

waterways are clear and the valve

mechanism moves freely (above).

Before operang the valve manually,

check that it will discharge in a place

for secure disposal.

WARNING! Hot water will be released.

Before operang the T&P relief valve

manually, check that it will discharge in a

safe place. If water does not ow freely

from the end of the discharge pipe, turn

the gas control knob to the OFF posion

and call a qualied person to determine

the cause.

• At least every ve years, have a

qualied person inspect the T&P

Relief Valve and discharge pipe.

Damage caused by corrosive water

condions, mineral deposits, or

AO Smith G12-UFDT5040NV Signature 300 50-Gallon Tall 12-Year Warranty 40000-BTU Natural Gas Water Heater

Product's Documents

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