AO Smith G6-DMH4032NV Signature 100 Tall 40-Gallon 6-Year User Manual

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED

BY THIS WATER HEATER.

• Safety Instructions

• Installation

• Operation

October 2016

DO NOT RETURN THIS UNIT TO THE STORE. To obtain technical, warranty, or service assistance during or after the

installation of this water heater, visit our website at:

http:// www.AOSmithAtLowes.com or call toll free 1-877-817-6750

— Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch;

do not use any phone in your

building.

• Immediately call your gas supplier

from a neighbor’s phone. Follow

the gas supplier’s instructions.

• If you cannot reach your gas

supplier, call the fire department.

— Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.

WARNING: If the information in these

instructions is not followed exactly, a fire

or explosion may result causing property

damage, personal injury or death.

RESIDENTIAL DIRECT VENT GAS WATER HEATERS

Installation Instructions and Use & Care Guide

INSTALLER:

• AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO

THE WATER HEATER.

OWNER:

• RETAIN THESE INSTRUCTIONS AND WARRANTY FOR

FUTURE REFERENCE. RETAIN THE ORIGINAL RECEIPT

AS PROOF OF PURCHASE.

WARNING: Gas leaks can not always be detected by

smell.

Gas suppliers recommend that you use a gas detector

approved by UL or CSA.

For more information, contact your gas supplier.

If a gas leak is detected, follow the “WHAT TO DO IF YOU

SMELL GAS” instructions.

• Care and Maintenance

• Troubleshooting

• Parts List

LOW LEAD

NTENT

• SHIPPED SET FOR NATURAL GAS AND CONVERTIBLE

TO L.P. (PROPANE) GAS. ALL PARTS INCLUDED.

• FOR POTABLE WATER HEATING ONLY. NOT SUITABLE

FOR SPACE HEATING.

• FOR DIRECT VENT INSTALLATION IN A MANUFACTURED

HOME (MOBILE HOME) ONLY.

• FOR USE ONLY WITH VENTING SYSTEMS SUPPLIED

WITH THE WATER HEATER, WHETHER A NEW

INSTALLATION OR A REPLACEMENT INSTALLATION.

2000536053 (VER 00) 100277328 (REV A)

Flammable Vapors

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other

flammable vapors and liquids in the vicinity of this

or any other appliance. Storage of or use of

gasoline or other flammable vapors or liquids in the

vicinity of this or any other appliance can result in

serious injury or death.

Read and follow water heater warnings and instructions.

WARNING

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of

a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning

of each safety message is understood by you and others who install, use or service this water heater.

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and

how to avoid the risk of injury.

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

IMPORTANT DEFINITIONS

• Qualiﬁ ed Technician: A qualiﬁ ed technician must have ability equivalent to a licensed tradesman in the ﬁ elds of plumbing, air supply,

venting, and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the

installation of gas ﬁ red water heaters. The qualiﬁ ed technician must also be familiar with the design features and use of ﬂ ammable vapor

ignition resistant water heaters, and have a thorough understanding of this instruction manual.

• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the ﬁ elds of plumbing, air supply, venting

and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of

gas ﬁ red water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform

repairs strictly in accordance with the service guidelines provided by the manufacturer.

• Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this

application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural

gas meter or propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

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

result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result

in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result

in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous

situation which, if not avoided, could result in property damage.

NOTICE Indicates information considering important but not hazard related.

SAFE INSTALLATION, USE AND SERVICE

Fire or Explosion Hazard

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

Read instruction manual before

installing, using or servicing

water heater.

Avoid all ignition sources if you smell Natural or LP gas.

Do not expose water heater control to excessive gas

pressure.

Use only gas shown on rating plate unless the water heater

has been properly converted.

Maintain required clearances to combustibles.

Keep ignition sources away from faucets after extended

period of non-use.

Follow conversion instructions listed in manual when

converting to opposite gas.

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of the water heater air intake.

Water temperature over 125°F

(52°C) can cause servere burns

instantly resulting in severe injury or

death.

Children, the elderly, and the

physically or mentally disabled are at

highest risk for scald injury.

Feel water before bathing or

showering.

Temperature limiting valves are

available.

Read instruction manual for safe

temperature setting.

DANGER

Do not use this water heater with any gas other than the

one listed on the rating plate unless the water heater has

been properly converted.

Refer to the “Gas Conversion” section of this manual to

convert from one gas to another. Failure to use the

correct gas can cause problems which can result in

death, serious bodily injury or property damage. If you

have any questions or doubts, consult your gas supplier

or gas utility company. Water heaters using bottled

propane or liquefied petroleum gas (LPG) are different

from natural gas models. A natural gas water heater will

not function safely on bottled propane or liquefied

petroleum gas (LPG) and a propane gas water heater will

not function safely on natural gas.

SAFE INSTALLATION, USE AND SERVICE..................................2

GENERAL SAFETY.....................................................................2-3

TABLE OF CONTENTS ..................................................................4

INTRODUCTION ............................................................................4

Preparing for the New Installation .............................................4

TYPICAL INSTALLATION ............................................................5-6

LOCATING THE NEW WATER HEATER .......................................7

Facts to Consider About Location ..........................................7-8

Insulation Blankets ....................................................................9

INSTALLING THE NEW WATER HEATER ...............................9-20

Water Heater Installation ......................................................9-10

Securing Water Heater to Floor and Wall ................................10

Roof Jack Installation .........................................................11-12

Manufactured Home installed Over Basement or

Crawlspace-Air Intake Through an Outside wall ................12-13

Cutting Opening Through an Outside Wall and

Collar Installation ................................................................13

Cementing PVC, ABS or CPVC Pipe and Fittings ..............13-14

Water Piping ............................................................................14

T & P Valve and Pipe Insulation .........................................14-15

Water Piping Pressure Test .....................................................15

Temperature Pressure Relief Valve ....................................15-16

Filling the Water Heater ...........................................................16

Gas Requirements ..................................................................17

Gas Piping ...............................................................................17

Gas Pressure/Gas Pressure Testing .......................................17

LP Gas Only ............................................................................18

Sediment Traps .......................................................................18

Installation Requirements for Massachusetts ..........................20

INSTALLATION CHECKLIST .......................................................21

GAS CONVERSION ................................................................21-22

LIGHTING INSTRUCTIONS .........................................................23

TEMPERATURE REGULATION ..................................................24

FOR YOUR INFORMATION ....................................................25-26

Start Up Conditions ............................................................25-26

Condensate ........................................................................25

Smoke/Odor .......................................................................25

Thermal Expansion ............................................................25

Strange Sounds ..................................................................25

Operational Conditions ............................................................25

Smelly Water ......................................................................25

“Air” in Hot Water Faucets ..................................................26

Safety Shut Off System ......................................................26

MAINTENANCE OF YOUR WATER HEATER ........................27-31

LEAKAGE CHECKPOINTS ..........................................................32

TROUBLESHOOTING GUIDELINES ......................................33-34

PILOT LIGHT TROUBLESHOOTING CHART .............................35

REPAIR PARTS LIST ...................................................................36

NOTES ....................................................................................37-39

WARRANTY ............................................................................Insert

Thank You for purchasing this water heater. Properly installed and

maintained, it should give you years of trouble free service.

Abbreviations Found In This Instruction Manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

This gas-fired water heater is design certified by CSA

INTERNATIONAL under American National Standard/CSA Standard

for Gas Water Heaters (ANSI Z21.10.1 • CSA 4.1 - current edition).

IMPORTANT: This water heater is shipped from the factory as a

natural gas unit. However, it may be converted to use LP gas. See

the Gas Conversion section for more information.

PREPARING FOR THE INSTALLATION

1. Read the General Safety section (pages 2 & 3) of this manual ﬁ rst and

then the entire manual carefully. If you don’t follow the safety rules,

the water heater will not operate properly. It could cause DEATH,

SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation,

and maintenance of the gas-ﬁ red water heater. It also contains

warnings throughout the manual that you must read and be

aware of. All warnings and all instructions are essential to the

proper operation of the water heater and your safety. Since we

cannot put everything on the ﬁ rst few pages, READ THE ENTIRE

MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE

THE WATER HEATER.

2. Instructions to Manufactured Home Manufacturers:

The installation must conform with the Manufactured Home

Construction and Safety Standards Title 24 CFR, Part 3280.

Instruction for replacement installation:

The installation must conform with these instructions and the local

code authority having jurisdiction. In the absence of local codes,

installations shall comply with the National Fuel Gas Code ANSI

Z223.1/NFPA 54. This publication is available from the Canadian

Standards Association, 8501 East Pleasant Valley Rd., Cleveland

Ohio 44131, or The National Fire Protection Association,

1 Batterymarch Park, Quincy, MA 02269.

3. If after reading this manual you have any questions or do not

understand any portion of the instructions, call the local gas utility

or the manufacturer whose name appears on the rating plate.

4. Carefully plan the place where you are going to put the water

heater. Correct combustion, vent action, and vent pipe installation

are very important in preventing death from possible carbon

monoxide poisoning and ﬁ res. See Figures 1 and 2.

Examine the location to ensure the water heater complies with

the “Locating the New Water Heater” section in this manual.

5. For California installation this water heater must be braced,

anchored, or strapped to avoid falling or moving during an

earthquake. See instructions for correct installation procedures.

Instructions may be obtained from California’s Ofﬁ ce of the

State Architect, 1102 Q Street, Suite 5100, Sacramento, CA

95811. Instructions can also be downloaded to your computer

at www.dsa.dgs.ca.gov/Pubs.

6. Massachusetts Code requires this water heater to be installed in

accordance with Massachusetts 248-CMR 2.00: State Plumbing

Code and 248-CMR 5.00.

7. Complies with SCAQMD rule #1121 and Districts having equivalent

NOx requirements.

8. Service to the water heater should only be performed by a qualiﬁ ed

technician. Examples of a qualiﬁ ed technician include: licensed

plumbers, authorized gas company personnel, and authorized

service personnel.

INTRODUCTION

TABLE OF CONTENTS

TYPICAL INSTALLATION

DISCHARGE PIPE

(DO NOT CAP

OR PLUG.)

A Flue Reducer

B Anode

C Hot Water Outlet

D Insulation

E Gas Supply Piping

F Manual Gas Shut-off Valve

G Ground Joint Union

H Sediment Trap

I Inner Door

GET TO KNOW YOUR WATER HEATER - GAS MODELS

J Outer Door

K Union

L Inlet Water Shut-off Valve

M Cold Water Inlet

N Inlet Dip Tube (Not Shown)

O Temperature-Pressure Relief Valve

P Rating Plate

Q Flue Baffle

S Drain Valve

T Manifold/Burner Assembly

U Flue

V Metal Drain Pan

W Piezo Igniter (bottom, Left-hand

Side of Gas Control Valve/Thermostat)

X Roof Jack *

Air Duct Assembly **

R Gas Control Valve/Thermostat

(T) MANIFOLD/BURNER ASSEMBLY

MANIFOLD

TUBE

IGNITER WIRE

MAIN BURNER

PILOT TUBE

THERMOCOUPLE

MANIFOLD DOOR

INSTALL THERMAL

EXPANSION TANK

IF WATER HEATER

IS INSTALLED IN

A CLOSED WATER

SYSTEM*

VACUUM RELIEF

VALVE*

INSTALL PER

LOCAL CODES

•

INSTALL IN ACCORDANCE

WITH LOCAL CODES.

•

SEDIMENT TRAP AS REQUIRED

BY LOCAL CODES.

• SECURE WATER HEATER TO

FLOOR AND WALL AS DESCRIBED

IN THIS MANUAL.

•

INSTALLATION SHOULD COMPLY

WITH THE INSTRUCTIONS IN THIS

MANUAL.

•

ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

DRAIN LINE MUST PASS

THROUGH THE STRUCTURAL

FLOOR AND DISCHARGE

EXTERNAL TO THE BUILDING.

IN COLD CLIMATES, IT IS

RECOMMENDED THAT THE

DRAIN LINE BE TERMINATED

AT AN ADEQUATE DRAIN

INSIDE THE BUILDING.

* CERTIFIED ROOF JACK FROM THE MANUFACTURER

MUST BE ORDERED SEPARATELY ACCORDING TO

LENGTH NEEDED. SEE ROOF JACK INSTALLATION

SECTION IN THIS MANUAL FOR INSTRUCTIONS AND

PART NUMBERS.

**AIR DUCT ASSEMBLY IS FURNISHED WITH THE WATER

HEATER. ANY ADDITIONAL PLUMBING AND VENTING

MATERIALS ARE NOT FURNISHED

PILOT

(Y) AIR DUCT ASSEMBLY*

GAS CONTROL KNOB

WATER TEMPERATURE DIAL

(ADJUSTING DIAL)

TOP VIEW

“OFF”

POSITION

“PILOT”

POSITION

“ON”

POSITION

(R) GAS CONTROL VALVE/

THERMOSTAT: WHITE-RODGERS

CONVERSION

FITTING

FIGURE 1.

Figure 1.

This appliance has been design certiﬁ ed as complying with American

National Standard/CSA Standard ANSI Z21.10.1 • CSA 4. 1 for water

heaters and is considered suitable for:

Water (Potable) Heating: All models are considered suitable for water

(potable) heating, but not suitable for space heating applications.

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to

a temperature which will satisfy clothes washing, dish washing, and

other sanitizing needs can scald and permanently injure you upon

contact. Some people are more likely to be permanently injured by

hot water than others. These include the elderly, children, the inﬁ rm,

or physically/mentally handicapped. If anyone using hot water in your

home ﬁ ts into one of these groups or if there is a local code or state

law requiring a certain temperature water at the hot water tap, then

you must take special precautions. In addition to using the lowest

possible temperature setting that satisﬁ es your hot water needs,

a means such as a *mixing valve should be used at the hot water

taps used by these people or at the water heater. Mixing valves are

available at plumbing supply or hardware stores. Consult a Qualiﬁ ed

Installer or Service Agency. Follow mixing valve manufacturer’s

instructions for installation of the valves. Before changing the factory

setting on the thermostat, read the “Temperature Regulation” section

in this manual. See Figure 32.

TYPICAL INSTALLATION

Figure 2.

* MIXING VALVE USAGE

FACTS TO CONSIDER ABOUT THE LOCATION

Whether replacing an old water heater or putting the water heater

in a new location, the following critical points must be observed.

This manufactured home gas-ﬁ red water heater is for use in a

manufactured home. You should carefully choose an indoor location

for the new water heater, because the placement is a very important

consideration for the safety of your occupants in the building and

for the most economical use of the appliance. This water heater

is for use only in a manufactured home and not intended for

outdoor installation.

This water heater has been designed and certiﬁ ed as a direct vent

(sealed combustion) unit and no draft diverter is to be used.

Minimum clearances between the water heater and combustible

surfaces are stated on the label adjacent to the gas control

valve/thermostat. The water heater is certified for installation

on a combustible floor. Minimum vent clearances: 6” (15.2 cm).

Provide 24” (61 cm) front clearance for servicing and adequate

clearance between the jacket top and ceiling for servicing the ﬂ ue area.

Roof jack: surface of outer pipe has a minimum clearance of 0” (0 cm).

The combustion and ventilation air ﬂ ow must not be obstructed.

Combustion air shall not be supplied from occupied spaces. Instead,

combustion air must be supplied from outside the manufactured

home by way of the furnished air intake duct assembly. The air

intake duct assembly is 3” (7.62 cm) in diameter for 30 and 40 Gallon

models or 4” (10.2 cm) in diameter for 50 Gallon models.

A 3-1/2” (8.89 cm) diameter ﬂ oor opening beneath the water heater

is required to accommodate the air intake duct assembly for 30

and 40 Gallon models. A 4-1/2” (11.43 cm) diameter ﬂ oor opening

is required beneath the water heater for 50 Gallon models. The

weight of the water heater itself seals the water heater to the air

intake duct assembly.

When a manufactured home is skirted, an air intake opening with

a minimum free area of 32 square inches (206.45 cm²) must be

provided in the skirt. If the opening is covered by louvers or screen,

the total free area must be 32 square inches (206.45 cm²). Other gas

ﬁ red appliance in the home will require additional free air openings;

consult these manufacturers for correct sizing. See Figure 3.

FIGURE 3.

If the manufactured home is installed over a basement or crawlspace,

combustion air must be supplied from outside the manufactured

LOCATING THE NEW WATER HEATER

home. The combustion air intake piping can be 3” (76 mm) PVC for

30 and 40 gallon models and 4” (102 mm) PVC for 50 Gallon models.

The air intake piping cannot exceed the lengths shown in Table 1 (page

12), including vertical and horizontal runs, or have more than 3 elbows.

All horizontal runs require adequate support at 3-1/2 foot (106.68 cm)

intervals. See Figure 4.

FIGURE 4.

The water heater should be secured to the ﬂ oor and to the wall of the

enclosure with the mounting brackets provided. For bracket location,

refer to Securing Water Heater to Floor and Wall.

Installation of the water heater must be accomplished in such a

manner that if the tank or any connections should leak, the ﬂ ow

will not cause damage to the structure. For this reason, it is not

advisable to install the water heater in an attic or upper ﬂ oor. When

such locations cannot be avoided, a suitable metal drain pan should

be installed under the water heater. Metal drain pans are available at

your local hardware store. Such a drain pan must have a minimum

length and width of at least 2 inches (51 mm) greater than the water

heater dimensions and must be piped to an adequate drain. The pan

must not restrict combustion air ﬂ ow. When a drain pan is required,

see installation instructions on page 9.

Water heater life depends upon water quality, water pressure and

the environment in which the water heater is installed. Water heaters

are sometimes installed in locations where leakage may result in

property damage, even with the use of a metal drain pan piped to a

drain. However, unanticipated damage can be reduced or prevented

by a leak detector or water shut-off device used in conjunction with

a piped drain pan. These devices are available from some plumbing

supply wholesalers and retailers, and detect and react to leakage

in various ways:

• Sensors mounted in the drain pan that trigger an alarm or turn off

the incoming water to the water heater when leakage is detected.

• Sensors mounted in the drain pan that turn off the water supply

to the entire home when water is detected in the drain pan.

• Water supply shut-off devices that activate based on the water

pressure differential between the cold water and hot water pipes

connected to the water heater.

• Devices that will turn off the gas supply to a gas water heater

while at the same time shutting off its water supply.

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS

(VAPORS) ARE LIKELY TO BE PRESENT OR STORED

(GARAGES, STORAGE AND UTILITY AREAS, ETC.): Flammable

liquids (such as gasoline, solvents, propane [LP or butane, etc.] and

other substances such as adhesives, etc.) emit ﬂ ammable vapors

which can be ignited by a gas water heater’s pilot light or main burner.

The resulting ﬂ ashback and ﬁ re can cause death or serious burns

to anyone in the area, as well as property damage. Gasoline and

other ﬂ ammable substances should never be stored or used in the

same room or area containing a gas water heater or other open

ﬂ ame or spark producing appliance. Additionally, do not store or use

gasoline or other ﬂ ammable vapors and liquids in the vicinity of the

water heater air intake. NOTE: Flammable vapors may be drawn

by air currents from other areas of the structure to the appliance.

Also, the water heater must be located and/or protected so it is not

subject to physical damage by a moving vehicle.

This water heater must not be installed directly on carpeting.

Carpeting must be protected by metal or wood panel beneath the

appliance extending beyond the full width and depth of the appliance

by at least 3 inches (76.2 mm) in any direction, or if the appliance is

installed in an alcove or closet, the entire ﬂ oor must be covered by

the panel. Failure to heed this warning may result in a ﬁ re hazard.

IMPORTANT: Keep combustibles such as boxes, magazines,

clothes, etc., away from the water heater area.

A gas water heater cannot operate properly without the correct

amount of air for combustion. Provide ventilation and combustion

air by means of an air intake duct assembly as stated in “Water

Heater Installation”. Never obstruct the ﬂ ow of ventilation air. If you

have any doubts or questions at all, call your gas supplier. Failure

to provide the proper amount of combustion air can result in a ﬁ re or

explosion and cause death, serious bodily injury, or property damage.

If this water heater will be used in beauty shops, barber shops,

cleaning establishments, or self-service laundries with dry cleaning

equipment, it is imperative that the water heater or water heaters

be installed so that combustion and ventilation air be taken from

outside these areas.

Propellants of aerosol sprays and volatile compounds, (cleaners,

chlorine based chemicals, refrigerants, etc.) in addition to being

highly ﬂ ammable in many cases, will also change to corrosive

hydrochloric acid when exposed to the combustion products of

the water heater. The results can be hazardous and also cause

product failure.

• Do not obstruct water heater air

intake with insulating blanket.

• Gas and carbon monoxide detec-

tors are available.

• Install water heater in accordance

with the instruction manual.

INSULATION BLANKETS

Insulation blankets are available to the general public for external

use on gas water heaters but are not necessary with these products.

The purpose of an insulation blanket is to reduce the standby heat

loss encountered with storage tank heaters. Your water heater

meets or exceeds the National Appliance Energy Conversation Act

standards with respect to insulation and standby loss requirements,

making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you

should follow these instructions (For identiﬁ cation of components

mentioned below, see Figure 1). Failure to follow these instructions

can restrict the air ﬂ ow required for proper combustion, potentially

resulting in ﬁ re, asphyxiation, serious personal injury or death.

• Do not apply insulation to the top of the water heater, as this will

interfere with safe operation of the draft hood.

• Do not cover the outer door, the gas control valve/thermostat or

the temperature & pressure relief valve.

• Do not allow insulation to come within 2” (50.8 mm) of the ﬂ oor to

prevent blockage of combustion air ﬂ ow to the burner.

• Do not cover the instruction manual. Keep it on the side of the

water heater or nearby for future reference.

• Do obtain new warning and instruction labels from the manufacturer

for placement on the blanket directly over the existing labels.

• Do inspect the insulation blanket frequently to make certain it

does not sag, thereby obstructing combustion air ﬂ ow.

INSTALLING THE NEW WATER HEATER

WATER HEATER INSTALLATION

1. To locate the position of the 3-1/2” (8.9 cm) or 4-1/2” (11.4 cm)

hole to be cut in the ﬂ oor, see Figures 5 and 6.

METAL

DRAIN

PAN

“A” = 4-3/8” (11.11 cm) 30 GAL.

“A” = 5-3/8” (13.65 cm) 40 GAL.

“A” = 5-3/8” (13.65 cm) 50 GAL.

CENTERLINE

OF WATER

HEATER

3-1/2” (8.89cm) DIA. HOLE

(30 & 40 GALLON)

4-1/2” (11.43cm) DIA. HOLE

(50 GALLON)

APPLY 4” (10.2 cm) OR

5” (12.7 cm) CIRCLE OF

SILICONE AROUND THE

BOTTOM OF PLATE

FOR PROPER WATER

TIGHT SEALING

AFTER ADJUSTING LENGTH OF DUCT

ASSEMBLY AS SHOWN ABOVE, CAULK

ALL AROUND PIPING WITH RTV SILICON

SEALANT FOR AIR TIGHT SEAL BEFORE

INSTALLING IN FLOOR CAVITY.

ALTERNATIVE: USE 2” (5 cm) WIDE BAND

OF .002 ALUMINUM TAPE.

SCREWS (2)

2-1/2” (6.35 cm) MIN.

BOTTOM OF FLOOR

FIGURE 5.

FIGURE 6.

2. If you have found that the water heater is being installed in an

area which, if the water heater was to leak, would cause damage

and have elected to install a metal drain pan, refer to Figures 7, 8

and 9 on page 10. If you are not installing a drain pan, go directly

to the next step.

NOTE: Clearances from combustible or non combustible surface to

jacket will change template dimensions.

FIGURE 7.

4” (10.16 cm) MIN. - 30 GAL.

0” MIN. - 40 & 50 GAL.

0” MIN.

BASE DIAMETER

14” (35.56 cm) 30 GAL.

16” (40.64 cm) 40 GAL.

16” (40.64 cm) 50 GAL.

JACKET DIAMETER

18” (45.72 cm) 30 GAL.

20” (50.8 cm) 40 GAL.

22” (55.88 cm) 50 GAL.

30 GAL. T&P LOC.

40 & 50 GAL.

T&P LOC.

GAS CONTROL VALVE /

THERMOSTAT

AIR INTAKE

4” (10.2 cm) MIN.

2-1/2” (6.35cm)

4-13/32” (11.2 cm) - 30 GAL.

5-13/32” (13.7 cm) - 40 GAL.

5-13/32” (13.7 cm) - 50 GAL.

30 GALLON:

13-13/32” (34 cm) MIN.

40 GALLON:

15-13/32” (39.1 cm) MIN.

50 GALLON:

16-13/32” (41.7 cm) MIN.

9” (22.86 cm) MIN. - 30 GAL.

10” (25.4 cm) MIN. - 40 GAL.

11” (27.9 cm) MIN. - 50 GAL.

0” MIN.

9” (22.86 cm) MIN. - 30 GAL.

10” (25.4 cm) MIN. - 40 GAL.

11” (27.9 cm) MIN. - 50 GAL.

FIGURE 8.

2-7/32”

(5.59 cm)

GAS CONTROL VALVE / THERMOSTAT

4”

(10.16 cm)

BASE DIA. - 14”

(35.56 cm)

JACKET DIA. - 18”

(45.72 cm)

12-13/16”

(32.54 cm)

9”

(22.86 cm)

0” MIN.

3-13/16”

(9.68 cm)

FIGURE 9.

3. Insert the duct assembly as shown in Figure 10 with lip facing

forward, and using only nails, secure the duct assembly to the

ﬂ oor.

FRONT

APPLY 4” (10.16 cm) OR 5” (12.7 cm)

CIRCLE OF SILICONE AROUND OPENING

FOR AIR TIGHT SEAL.

FIGURE 10.

4. Set the water heater in place against the lip of the duct assembly

as shown in Figure 11.

FIGURE 11.

5. Secure the water heater to the duct assembly using the screw

provided.

NOTE: See pages 12 and 13 for installing an air intake through

an outside wall when the manufactured home is located over a

basement or crawl space.

SECURING WATER HEATER TO FLOOR AND WALL

(USE METHOD A OR B)

The water heater must be secured to the ﬂ oor and to the wall of the

enclosure.

METHOD A: use the three mounting brackets and screws packaged

in the carton with the water heater. The two small brackets are used to

attach the water heater to the ﬂ oor and the one large bracket is used

to secure the top of the water heater to the wall.

METHOD B: use metal tape also called “plumbers tape” to secure the

water heater to the enclosure. See the ﬁ gure below as reference for

attaching the tape.

Because of installation variances, these brackets can be located at

any points around the circumference of the jacket. When the bracket

locations are determined, use a 1/8 inch SAE drill bit to set a pattern.

Drill only through the outer jacket of the water heater. Then using the

screws provided, secure the bracket to the water heater, ﬂ oor and

wall. See Figure 12.

ONE LARGE MOUNTING

BRACKET AT TOP

TWO SMALL MOUNTING

BRACKETS AT BOTTOM

TWO STRAPS OF METAL

TAPE AT THE TOP

TWO STRAPS OF METAL

TAPE AT THE BOTTOM

METHOD A METHOD B

FIGURE 12.

ROOF JACK INSTALLATION

ROOF JACK KIT MODELS VENT KIT- 12 INCH (9002964005), VENT KIT - 32 INCH (9002965005),

VENT KIT - 60 INCH (9002966005) AND VENT KIT - 95 INCH (9002967005)

VENT KIT / 95” (241.3 cm)

VENT KIT / 60”

(152.4 cm)

VENT KIT / 32” (81.28 cm)

VENT KIT / 12” (30.48 cm)

95” (241.3 cm) MAX.

36” (91.4 cm) MIN.

60” (152.4 cm) MAX.

32” (81.28 cm) MIN.

32” (81.28 cm) MAX.

18” (45.72 cm) MIN.

12” (30.48 cm) MAX.

2” (5 cm) MIN. 2” (5 cm) MIN. 2” (5 cm) MIN. 2” (5 cm) MIN.

136” (345.44 cm) MAX.

55” (139.7 cm) MIN.

100” (254 cm) MAX.

40” (101.6 cm) MIN.

72” (182.88 cm) MAX.

25” (63.5 cm) MIN.

52” (132.08 cm) MAX.

18” (45.72 cm) MIN.

23” (58.42 cm) MAX.

ROOF JACK: SURFACE OF OUTER PIPE

HAS A MINIMUM CLEARANCE OF 0” (0 CM).

INLET VENT: SURFACE OF PIPE HAS MINIMUM CLEARANCE OF 0” (0 CM)

FIGURE 13.

A certiﬁ ed roof jack (vent kit) from the manufacturer must be

installed with the water heaters covered by this manual. Roof jack

kits are ordered separately. See Figure 13 to determine which roof

jack is needed for the installation.

NOTE: An optional Roof jack Extension Pipe (9002588005) is required

when the roof pitch is 5-1/2” (14 cm) or greater, or where local codes

require the roof jack cap (outlet) to terminate above the peak of the roof.

IMPORTANT: DO NOT common vent this water heater with any other

appliance.

1. Cut a 5-1/2” (14 cm) diameter hole through the roof and ceiling

directly in line with the ﬂ ue connection on top of the water heater.

For a sloped roof, the roof hole may have to be enlarged to allow

the roof jack to be installed vertically.

2. Telescope down the ﬂ ue pipe in the roof jack assembly to a length

that will project at least 6” (15.24 cm) below the ﬁ nished ceiling

before installing the roof jack assembly.

NOTE: Flue pipe joints have silicone seals that must remain in place.

A soapy water solution sprayed around the seal area will enable the

ﬂ ue pipe and outer pipe below to telescope more freely.

3. Telescope down the outer pipe of the roof jack assembly to a length

that will project at least 2” (5 cm) below the ﬁ nished ceiling before

installing the roof jack assembly. See Figure 14.

FIGURE 14.

4. Ease the roof jack assembly through the roof and ceiling openings. The

roof jack ﬂ ashing tilts up to 22.6° degrees for use on a sloping roof.

5. Use sealant or caulk on the roof to seal under ﬂ ashing of the roof

jack assembly. Use roof nails or screws on wood construction or

sheet metal screws on metal roofs (nails and screws not provided).

See Figure 15.

FIGURE 15.

Continued on the next page.

6. Extend the ﬂ ue pipe downward until it is close to the ﬂ ue reducer.

See Figure 16.

FIGURE 16.

7. Fit the bottom opening of the pipe over the top opening of the

ﬂ ue reducer. See Figure 17. Ensure that there is no gap and

that the seal is complete.

8. Secure the ﬂ ue pipe to the reducer with three (3) evenly-spaced

sheet metal screws (Figure 17). Do not leave any open holes

in the ﬂ ue reducer or ﬂ ue pipe.

NOTE: All joints for vent piping between roof jack and water

heater are sealed from the manufacturer. No additional sealing

of vent pipe is necessary.

FIGURE 17.

MANUFACTURED HOME INSTALLED OVER

BASEMENT OR CRAWL SPACE -

AIR INTAKE THROUGH AN OUTSIDE WALL

ALL 30 AND 40 GALLON MODELS

3” (76 mm) PVC Schedule 40 intake air vent piping:

Optional Kit No. 9002986005 contains a 3” (76 mm) PVC Schedule

40-45° vent cap with screen and two 3” (76 mm) wall collars.

ALL 50 GALLON MODELS

4” (102 mm) PVC Schedule 40 intake air vent piping:

Optional Kit no. 9002987005 contains a 4” (102 mm) PVC Schedule

40-45° vent cap with screen and two 4” (102 mm) wall collars.

ALL MODELS

1. PVC, ABS or CPVC Schedule 40 piping and fittings are

acceptable materials for the air intake vent system.

2. The intake air vent system must terminate horizontally to the outdoors.

3. Remove the screws which attach the wind bafﬂ e to the existing

metal air intake vent pipe underneath the home. Discard the wind

bafﬂ e and screws. See Figure 18.

FIGURE 18.

4. Attach a 3” (76 mm) or 4” (102 mm) PVC street elbow to the metal

air intake vent using 3 sheet metal screws. Continue PVC piping

to outside wall and terminate with vent cap and screen. See

Figure 19 and Table 1.

3” (76 mm) size - 30 and 40 gallon models.

4” (102 mm) size - 50 gallon models.

See pages 13 and 14 for cementing instructions

SEE MAXIMUM

COMBINED

LENGTHS IN

TABLE 1.

SLOPE INLET PIPING

DOWNWARD TOWARD

VENT CAP TO PREVENT

CONDENSATION BUILDUP.

FIGURE 19.

NOTE: Vent cap must be located a minimum of 12” (30.48 cm) above

the ground or anticipated snow level.

TABLE 1: AIR INTAKE VENT PIPING REQUIREMENTS

Water Heater Gas

Vent

Dia.

Do Not Exceed:

30 Gallon NAT 3” (76mm) 17 ft. (5.18 m) length; 3 elbows

30 Gallon LP 3” (76mm) 12 ft. (3.66 m) length; 3 elbows

40 Gallon NAT 3” (76mm) 30 ft. (9.1 m) length; 3 elbows

40 Gallon LP 3” (76mm) 20 ft. (6.1 m) length; 3 elbows

50 Gallon NAT 4” (102mm) 30 ft. (9.1 m) length; 3 elbows

50 Gallon LP 4” (102mm) 30 ft. (9.1 m) length; 3 elbows

5. Vertical and horizontal runs must be securely supported at 3-1/2

foot (1.06 m) intervals. See Figure 20.

SLOPE INLET PIPING

DOWNWARD TOWARD

VENT CAP TO PREVENT

CONDENSATION BUILDUP.

FIGURE 20.

6. The intake air vent piping can be installed with no more than 3

elbows. See Figure 21.

FIGURE 21.

CUTTING OPENING THROUGH AN OUTSIDE WALL

AND COLLAR INSTALLATION

Determine the location for the opening in the wall. For a 30 or 40

gallon model, cut a 3-3/4” (9.5 cm) hole through the outside wall. For

a 50 Gallon model, cut a 4-3/4” (12 cm) hole through the outside wall.

The 3” (76 mm) or 4” (102 mm) PVC, ABS or CPVC Schedule 40

vent pipe can be run from the water heater through the wall or from

the wall to the water heater, whichever is most convenient. The vent

pipe must extend a minimum of 1-1/2” (3.81 cm) through the exterior

wall. Note that the inside collar must be slipped over the vent piping

before locating the pipe through the wall. Before securing the inside

and outside collars to the wall, use a silicone sealer between pipe

and opening to ensure a water and air tight seal. See Figure 22.

INSTALLATION SHOWING USE

OF PVC, ABS OR CPVC PIPE

FIGURE 22.

NOTE: Wall collars are for aesthetic purposes and are not required

for the heater to operate.

CEMENTING PVC, ABS OR CPVC PIPE AND FITTINGS

Read and observe all safety information printed on primer, cleaner,

and cement containers.

Primer, cleaner, and cements are extremely ﬂ ammable. They are

harmful or fatal if swallowed. The vapors are harmful. They may

irritate eyes and skin and can be absorbed through the skin.

Always store primer, cleaner, and cements in cool, dry, well ventilated

places. Keep containers closed. Use them in well ventilated areas.

Wear impervious clothing while handling. Do not smoke, eat, or drink

while handling. Wash thoroughly after handling and before eating.

Wear eye protection when handling. If swallowed, drink water, do

not induce vomiting, and call a physician or poison control center

immediately. If inhaled, get fresh air and seek medical attention if ill

feelings persist. In case of eye and skin contact, immediately ﬂ ush

with plenty of water for 15 minutes and seek medical attention if

irritation persists. KEEP OUT OF REACH OF CHILDREN.

All primers, cleaners, and cements must meet all local codes and

applicable standards of the American Society For Testing Materials

Standards.

Before using primers, cleaners and cements, stir or shake, making sure

contents are liquid. Do not use if found to be lumpy or jelly-like.

1. Cut pipe ends squarely removing all burrs and dirt.

2. Dry ﬁ t pipe and ﬁ ttings to be connected for proper ﬁ t.

3. Clean pipe and ﬁ tting with primer/cleaner.

4. Apply a thin coat of cement to ﬁ tting, avoiding puddling inside.

5. Apply a liberal coat of cement to pipe, leaving no voids.

6. QUICKLY assemble parts while cement is ﬂ uid! If you wait too

long, recoat pipes.

7. Push pipe completely into socket of ﬁ tting, turning as it goes until

it bottoms.

8. Hold pipe and ﬁ tting together for 30 seconds. Then carefully clean

off excess with a cloth. Allow connections a sufﬁ cient time to cure

before disturbing.

9. Remember that vent pipes must be adequately and securely

supported.

TABLE 2: APPROX. SETTING TIME FOR 2-1/2” (63.5mm)

TO 4” (102mm) PIPE JOINTS

MOVEMENT

OF JOINT

COMPLETE

SET

90°F (32.2°C) TO 150°F (65.6°C) 3/4HR. 8 HRS.

50°F (10°C) TO 90°F (32.2°C) 1 HR. 15 HRS.

0°F (-17.77°C) TO 50°F (10°C) 1-1/3 HR. 18 HRS.

WATER PIPING

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water heated to

a temperature which will satisfy space heating, clothes washing,

dish washing, cleaning and other sanitizing needs can scald and

permanently injure you upon contact. Some people are more likely

to be permanently injured by hot water than others. These include

the elderly, children, the inﬁ rm, or physically/mentally handicapped.

If anyone using hot water in your home ﬁ ts into one of these groups

or if there is a local code or state law requiring a certain temperature

water at the hot water tap, then you must take special precautions. In

addition to using the lowest possible temperature setting that satisﬁ es

your hot water needs, a means such as a mixing valve should be used

at the hot water taps used by these people or at the water heater.

See Figure 2. Valves for reducing point of use temperature by mixing

cold and hot water are also available. Consult a Qualiﬁ ed Installer or

Service Agency. Follow manufacturer’s instructions for installation

of the valves. Before changing the factory setting on the thermostat,

read the “Temperature Regulation” section in this manual.

This water heater shall not be connected to any heating systems or

component(s) used with a non-potable water heating appliance.

Toxic chemicals, such as those used for boiler treatment shall not

be introduced into this system.

As water is heated, it expands (thermal expansion). In a closed

system, the volume of water will grow. As the volume of water grows,

there will be a corresponding increase in water pressure due to

thermal expansion. Thermal expansion can cause premature tank

failure (leakage). This type of failure is not covered under the limited

warranty. Thermal expansion can also cause intermittent temperature-

pressure relief valve operation: water discharged from the valve due

to excessive pressure build up. The temperature-pressure relief valve

is not intended for the constant relief of thermal expansion. This

condition is not covered under the limited warranty.

A properly-sized thermal expansion tank should be installed on all

closed systems to control the harmful effects of thermal expansion.

Contact a plumbing service agency or your retail supplier regarding

the installation of a thermal expansion tank.

Also, the water supply pressure should not exceed 80 PSI (551.58 kPa).

If this occurs, a pressure reducing valve with a bypass should be installed

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

house in order to maintain equal hot and cold water pressures.

NOTE: To protect against untimely corrosion of hot and cold

water ﬁ ttings, it is strongly recommended that dielectric unions

or couplings be installed on this water heater when connected

to copper pipe.

Figure 23 shows the typical attachment of the water piping to the

water heater. The water heater is equipped with 3/4 inch NPT water

connections.

FIGURE 23.

WATER PIPING PRESSURE TEST

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This section is only for the manufacturer installing the water heater

when the installation is to comply with H.U.D. standards.

When testing the waterways, H.U.D. standards state:

“Water Distribution System: All water piping in the water distribution

system shall be subjected to a pressure test. The test shall be made

by subjecting the system to air or water at 100 psi (689.48 kPa) for

15 minutes without loss of pressure. When air pressure is used,

the water heater shall not be connected during the test.”

NOTE: If water piping system is to be air pressure tested, the water

heater must be disconnected from the water piping system. Failure

to disconnect the water heater during air pressure testing of water

piping system could result IN DEATH, SERIOUS BODILY INJURY,

OR PROPERTY DAMAGE.

FIGURE 24.

TEMPERATURE-PRESSURE RELIEF VALVE

Explosion Hazard

 Temperature-pressure relief

valve must comply with ANSI

Z21.22-CSA 4.4 and ASME code.

 Properly sized temperature-

pressure relief valve must be

installed in opening provided.

 Do not plug, block, or cap the

discharge line.

 Failure to follow this warning

can result in excessive tank

pressure, serious injury or

death.

This heater is provided with a properly certified combination

temperature - pressure relief valve by the manufacturer.

The valve is certiﬁ ed by a nationally recognized testing laboratory

that maintains periodic inspection of production of listed equipment

of materials as meeting the requirements for Relief Valves and

Automatic Gas Shut-off Devices for Hot Water Supply Systems, ANSI

Z21.22 • CSA 4.4, and the code requirements of ASME.

If replaced, the valve must meet the requirements of local codes, but

not less than a combination temperature and pressure relief valve

certiﬁ ed as indicated in the above paragraph.

The valve must be marked with a maximum set pressure not to

exceed the marked hydrostatic working pressure of the water heater

(150 psi = 1,035 kPa) and a discharge capacity not less than the

water heater input rate as shown on the model rating plate.

For safe operation of the water heater, the relief valve must not be

removed from its designated opening nor plugged.

The temperature-pressure relief valve must be installed directly into

the ﬁ tting of the water heater designed for the relief valve. Position

the valve downward and provide tubing so that any discharge will exit

only at any distance below the structural ﬂ oor. Be certain that no

contact is made with any live electrical part. The discharge opening

must not be blocked or reduced in size under any circumstances.

Excessive length, over 30 feet (9.14 m), or use of more than four

elbows can cause restriction and reduce the discharge capacity of

the valve. See Figure 25.

No valve or other obstruction is to be placed between the relief valve

and the tank. To prevent bodily injury, hazard to life, or property

damage, the relief valve must be allowed to discharge water in

quantities should circumstances demand. If the discharge pipe is

not connected to a drain or other suitable means, the water ﬂ ow may

cause property damage.

The Discharge Pipe:

• Shall not be smaller in size than the outlet pipe size of the valve, or

have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both the

temperature-pressure relief valve, and the discharge pipe.

• Shall pass through the structural ﬂ oor and terminate external to the

building. In cold climates, it is recommended that the discharge

pipe be terminated at an adequate drain inside the building.

• Shall not have any valve between the relief valve and tank.

The temperature-pressure relief valve must be manually operated

at least once a year. Caution should be taken to ensure that (1) no

one is in front of or around the outlet of the temperature-pressure

relief valve discharge line, and (2) the water manually discharged

will not cause any bodily injury or property damage because the

water may be extremely hot.

If after manually operating the valve, it fails to completely reset and

continues to release water, immediately close the cold water inlet

to the water heater, follow the draining instructions, and replace the

temperature-pressure relief valve with a new one.

FIGURE 25.

FILLING THE WATER HEATER

Never use this water heater unless it is completely full of water.

To prevent damage to the tank, the tank must be ﬁ lled with water.

Water must ﬂ ow from the hot water faucet before turning “ON” gas

to the water heater.

To ﬁ ll the water heater with water:

1. Close the water heater drain valve by turning the handle to the

right (clockwise). The drain valve is on the lower front of the water

heater.

2. Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open when

the water heater is in use.

3. To ensure complete ﬁ lling of the tank, allow air to exit by opening

the nearest hot water faucet. Allow water to run until a constant

ﬂ ow is obtained. This will let air out of the water heater and the

piping.

4. Check all water piping and connections for leaks. Repair as

needed.

Explosion Hazard

• Use a new CSA approved gas supply line.

• Install a shut-off valve.

• Do not connect a natural gas water heater to an

L.P. gas supply.

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

natural gas supply.

• Failure to follow these instructions can result in

death, explosion, or carbon monoxide poisoning.

WARNING

GAS REQUIREMENTS

IMPORTANT: Read the rating plate to be sure the water heater is made

for the type of gas you will be using in your home. This information

will be found on the rating plate located near the gas control valve/

thermostat. If the information does not agree with the type of gas

available, do not install or light. Call your dealer.

NOTE: An odorant is added by the gas supplier to the gas used by

this water heater. This odorant may fade over an extended period of

time. Do not depend upon this odorant as an indication of leaking gas.

GAS PIPING

The gas piping must be installed according to all local and state

codes or, in the absence of local and state codes, the “National Fuel

Gas Code”, ANSI Z223.1 (NFPA 54)-current edition. Manufactured

home manufacturers must conform with “The Manufactured Home

Construction and Safety Standard, Title 24 CFR, Part 3280”.

Tables 3 and 4 on page 19 provide a sizing reference for commonly

used gas pipe materials. Consult the “National Fuel Gas Code” for

the recommended gas pipe size of other materials.

NOTE: Use pipe joint compound or Teﬂ on

tape marked as be-

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

Refer to Figure 27 as you review the following items:

1. Install a readily accessible manual shut-off valve in the gas

supply line as recommended by the local utility. Know the

location of this valve and how to turn off the gas to this unit.

2. Install a sediment trap (if not already incorporated as part of

the water heater) as shown. The sediment trap must be no

less than three inches long for the accumulation of dirt, foreign

material, and water droplets. See also Sediment Traps.

3. Install a ground joint union between the gas control valve/

thermostat and the manual shut-off valve. This is to allow easy

removal of the gas control valve/ thermostat.

4. Turn the gas supply on and check for leaks. Test all connections

by brushing on an approved noncorrosive leak-detection

solution. Bubbles will show a leak. Correct any leak found.

Teﬂ on

is a registered trademark of E. I. du Pont de Nemours and Company.

CHECK WITH

LOCAL UTILITY

FOR MINIMUM HEIGHT

3” (7.62cm) MINIMUM

SEDIMENT TRAP

GROUND

JOINT

UNION

MANUAL GAS

SHUT-OFF VALVE

FIGURE 27.

GAS PRESSURE

WARNING

Explosion Hazard

• Gas leaks can not always be detected by smell.

• Gas suppliers recommend that you use a gas

detector approved by UL or CSA.

• For more information, contact your gas supplier.

• If a gas leak is detected, follow the “What to do if you

smell gas” instructions on the cover of this manual.

IMPORTANT: The gas supply pressure must not exceed the maxi-

mum supply pressure as stated on the water heater’s rating plate.

The minimum supply pressure is for the purpose of input adjustment.

GAS PRESSURE TESTING

IMPORTANT: This water heater and its gas connection must be leak

tested before placing the appliance in operation.

• If the code requires the gas lines to be tested at a pressure

exceeding 14” W.C. (3.5 kPa), the water heater and its manual

shut-off valve must be disconnected from the gas supply piping

system and the line capped.

• If the gas lines are to be tested at a pressure less than 14” W.C.

(3.5 kPa), the water heater must be isolated from the gas supply

piping system by closing its manual shut-off valve.

U.L. recognized fuel gas and carbon monoxide (CO) detectors are

recommended in all applications and should be installed using the

manufacturer’s instructions and local codes, rules and regulations.

NOTE: Air may be present in the gas lines and could prevent the pilot

from lighting on initial start-up. The gas lines should be purged of air

by a qualiﬁ ed technician after installation of the gas piping system.

While purging the gas piping system of air, ensure that the fuel is not

spilled in the area of the water heater installation, or any source of

ignition. If the fuel is spilled while purging the piping system of air

follow the “WHAT TO DO IF YOU SMELL GAS” instructions on the

cover of this manual.

LP GAS ONLY

Liqueﬁ ed petroleum gas is over 50% heavier than air and in the

occurrence of a leak in the system, the gas will settle at ﬂ oor level.

Basements, crawl spaces, skirted areas under mobile homes (even

when ventilated), closets and areas below ground level will serve

as pockets for the accumulation of gas. Before lighting an L.P. gas

water heater, smell all around the appliance at ﬂ oor level. If you smell

gas, follow the instructions as given in the warning on the front page.

When your L.P. tank runs out of fuel, turn off the gas at all gas

appliances including pilot lights. After the tank is reﬁ lled, all appliances

must be re-lit according to their manufacturer’s instructions.

WARNING

Explosion Hazard

Have a qualified technician make sure that the L.P.

gas operating pressure does not exceed 13” water

column (3.237 kilopascals).

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

Sediment Traps

A sediment trap shall be installed as close to the inlet of the water

heater as practical at the time of water heater installation. The sediment

trap shall be either a tee ﬁ tting with a capped nipple in the bottom

outlet or other device recognized as an effective sediment trap. If a

tee ﬁ tting is used, it shall be installed in conformance with one of the

methods of installation shown in Figures 28, 29, and 30.

FIGURE 27. GAS PIPING WITH FLEXIBLE CONNECTOR

FIGURE 28. GAS PIPING WITH ALL

BLACK IRON PIPE TO GAS CONTROL VALVE/THERMOSTAT

FIGURE 29. ALTERNATIVE SEDIMENT TRAP LOCATION

Contaminants in the gas lines may cause improper operation of

the gas control valve/thermostat that may result in ﬁ re or explosion.

Before attaching the gas line be sure that all gas pipe is clean on the

inside. To trap any dirt or foreign material in the gas supply line, a

sediment trap (sometimes called a drip leg) must be incorporated in

the piping. The sediment trap must be readily accessible. Install in

accordance with the “Gas Piping” section. Refer to the current edition

of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

INSTALLATION REQUIREMENTS FOR THE

COMMONWEALTH OF MASSACHUSETTS

For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed

in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by

the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ¿ nished grade in the

area of the venting, including but not limited to decks and porches, the following requirements shall be satis¿ ed:

INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas

fueled equipment, the installing plumber or gas¿ tter shall observe that a hard wired carbon monoxide detector with an alarm

and battery back-up is installed on the À oor level where the gas equipment is to be installed. In addition, the installing plumber

or gas¿ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each

additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall

be the responsibility of the property owner to secure the services of quali¿ ed licensed professionals for the installation of hard

wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired

carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent À oor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall

have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a bat-

tery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above

provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certi¿ ed.

SIGNAGE A metal or plastic identi¿ cation plate shall be permanently mounted to the exterior of the building at a minimum height

of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appli-

ance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW.

KEEP CLEAR OF ALL OBSTRUCTIONS.”

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

installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance

with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

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

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

as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the

dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product

Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with

the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall

include:

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

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

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of

a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the À ue gases,

but identi¿ es “special venting systems,” the following requirements shall be satis¿ ed by the manufacturer:

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

instructions; and

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

parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting

instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or

equipment at the completion of the installation.

GAS CONVERSION

WATER HEATER LOCATION

Water heater location is important and can affect system

performance. Please check the following:

□ Installation area free of corrosive elements and flammable

materials.

□ Centrally located with the water piping system (For new

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

system as possible.

□ Located indoors and in a vertical position. Protected from

freezing temperatures.

□ Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted floor.

□ Provisions made to protect the area from water damage. Metal

drain pan installed and piped to an adequate drain or external

to the building.

□ Sufficient room to service the water heater. See the “Facts to

Consider About the Location” section of this manual.

□ Water heater not located near an air moving device.

□ Water heater securely anchored.

GAS SUPPLY AND PIPING

□ Gas supply is the same type as listed on the water heater rating

plate.

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

□ Approved pipe joint compound used.

□ Adequate pipe size and of approved material.

□ Chloride-free soap and water solution or other approved

means used to check all connections and fittings for possible

gas leaks.

COMBUSTION AIR SUPPLY / VENT PIPE SYSTEM

□ Sufficient fresh air supply provided from outdoors as described

in this manual, free of corrosive elements and flammable

vapors.

□ All venting installed according to applicable codes and

manufacturers’ instructions.

□ Vent pipe and fittings of approved material; approved roof jack.

□ 12” (30.48 cm) Min. above grade/snow level.

WATER SYSTEM PIPING

□ Temperature and pressure relief valve properly installed with

a discharge line. (Discharge line must be run to an adequate

drain or external to the building and protected from freezing.)

□ All piping properly installed and free of leaks.

□ Heater completely filled with water.

□ Closed system pressure build-up precautions installed (i.e.,

thermal expansion tank).

□ Mixing valve installed per manufacturer’s instructions.

INSTALLATION CHECKLIST

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a ﬂ ammable vapor ignition incident. The

new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist

and make any required installation upgrades or changes.

Questions? Contact Residential Technical Assistance.

This water heater is originally shipped for use with Natural

Gas but can be converted to LP (Propane) Gas by following

the instructions outlined below. To convert this water heater,

you must change both the conversion fitting in the gas control

valve/thermostat AND manifold/burner assembly (supplied).

Both the gas valve and the manifold burner assembly must

be correct for the type of gas used. If you are unsure about

converting this water heater to use a different type of gas,

contact a qualified person such as a plumber or your gas

supplier.

1. Contact your gas company to determine the type of gas

supplied to your home.

2. Check the setting of the conversion fitting in the gas

control valve.

3. Check the label on the manifold burner assembly door.

4. Make sure both the conversion fitting and the manifold

burner assembly (see door label) are for the type of gas

supplied to your home.

5. If you are converting this water heater from Natural to LP

or from LP to Natural, follow these steps and instructions:

• Remove manifold/burner assembly (instructions below).

• Convert the gas control valve/thermostat to same type of

gas (instructions on page 22).

• Install the replacement manifold/burner assembly (for

conversion; instructions on page 22).

• Place sticker next to data plate showing the type of gas

this water heater has been converted to use.

WARNING

Explosion Hazard

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Remove any fiberglass between gasket and combustion

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Replace viewport if glass is missing or damaged.

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Replace manifold component block if missing or removed.

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Replace door gasket if damaged.

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supply.

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supply.

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Failure to follow these instructions can result in death,

explosion, or fire.

A. Remove the Manifold/Burner Assembly

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

shut-off valve (Figure 26). This valve is typically located be-

side the water heater. Note the position of the shut-off valve

in the open/on position, then proceed to turn it off.

2. On the lower front of the water heater, locate the gas control

valve/thermostat (Figure 30). Before per forming any mainte-

nance, it is important to turn the temperature dial on the gas

control valve/thermostat to its lowest setting.

3. On top of the gas control valve/thermostat, turn the gas

control knob to the “OFF” position.

4. Remove the outer door.

5. Remove the two screws securing the manifold/burner as-

sembly to the combustion chamber (Figure 30).

6. Disconnect the following items from the gas control valve/

thermostat: thermocouple, pilot tube, and manifold tube

(each has right-hand threads). See Figure 30.

7. Disconnect the igniter wire from the piezo igniter button. See

Figure 30.

8. Grasp the manifold tube and push down slightly to free the

manifold, pilot tube, and thermocouple.

9. Carefully remove the manifold/burner assembly from the

burner compartment.

NOTICE: Be sure not to damage internal parts

B. Convert the Gas Control Valve/Thermostat

1. Remove the cap (shown in Figure 31), then remove the con-

version fitting by turning it counter-clockwise with an adjust-

able wrench.

2. Thread the opposite end of the conversion fitting into the

opening by turning it clockwise, then tighten it hand tight.

A. If you are converting the unit to use LP gas (propane),

verify that the “LP” arrow on the fitting is pointing toward

the gas control valve/thermostat. The red band on the

fitting should touch the metal boss. See Figure 31.

B. If you are converting the unit to use natural gas, verify

that the “NAT” arrow on the fitting is pointing toward the

gas control valve/thermostat. The blue band on the

fitting should touch the metal boss. See Figure 31.

3. Replace the cap.

C. Install the Conversion Manifold/Burner Assembly

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

installation. See Figure 42.

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

3. Insert the replacement manifold/burner assembly into the

burner compartment, making sure that the tip of the manifold

tube engages in the slot of the bracket inside the combustion

chamber. See Figure 43.

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

insulation between the gasket and the combustion chamber.

5. Replace the two screws which secure the manifold/burner

assembly door to the combustion chamber and tighten se-

curely. Once the manifold/burner assembly door is tightened,

visually inspect the door gasket between the manifold/burner

assembly door and the combustion chamber for spaces or

gaps that would prevent a seal.

WARNING! Do not operate the water heater if the door gas-

ket does not create a seal between the manifold door and the

combustion chamber. Failure to observe this warning could

lead to personal injury or death.

6. Reconnect the manifold tube, pilot tube, and thermocouple

to the gas control valve/thermostat. See Figure 30. Do not

cross-thread or apply any thread sealant to these fittings.

The thermocouple nut should be started and turned all the

way in by hand. Tighten an additional quarter turn with a

7/16” open-end wrench.

NOTICE: If you were supplied with a new ferrule nut in a

parts kit, follow these steps to connect the pilot tube:

A.) Install the ferrule nut into the gas valve at the pilot tube

location, hand tight only. B.) Insert the pilot tube into the fer-

rule nut until the tube bottoms out, then tighten the nut with

a 7/16” wrench until the crimp connection seals to the pilot

tube. C.) Continue to tighten until the nut is tight in the gas

valve.

7. Reconnect the igniter wire.

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

9. With the burner lit, check the gas control valve/ thermostat

supply line, manifold component block, manifold tube, and

pilot tube connections for leaks. Check for leaks by brush-

ing on an approved non-corrosive leak detection solution.

Bubbles forming indicate a leak. Correct any leak found.

WARNING! All leaks must be fixed immediately. Failure to

do so could lead to personal injury or death.

10. Verify proper operation; replace outer door.

11. Place the conversion label next to the rating plate. (The

conversion label shows the type of gas that your water heater

has been converted to use.)

THERMOCOUPLE

MANIFOLD TUBE

PILOT

TUBE

WITH

FERRULE

NUT

GAS CONTROL VALVE / THERMOSTAT

MANIFOLD

SCREWS (2)

MANIFOLD

TUBE

THERMOCOUPLE

VIEW PORT

TWO PIECE

WIRE CONNECTOR

MANIFOLD

DOOR

THERMAL

SWITCH

PILOT

TUBE

PIEZO

IGNITER

BUTTON

GAS CONTROL VALVE/

THERMOSTAT

CONVERSION FITTING

CAP

LP GAS:

“LP” ARROW POINTS TOWARD THE

GAS CONTROL VALVE/ THERMOSTAT.

RED BAND TOUCHES METAL BOSS.

NATURAL GAS:

“NAT” ARROW POINTS TOWARD THE GAS

CONTROL VALVE/ THERMOSTAT.

BLUE BAND TOUCHES METAL BOSS.

FIGURE 30.

FIGURE 31.

LIGHTING INSTRUCTIONS

WARNING

Explosion Hazard

Replace view port if glass is missing

or damaged.

Failure to do so can result in death,

explosion or fire.

Read and understand these directions thoroughly before attempt-

ing to light or re-light the pilot. Make sure that the view port (sight

glass) is not missing or damaged. (See Figure 40.) Make sure the

tank is completely ﬁ lled with water before lighting the pilot. Check

the rating plate near the gas control valve/thermostat for the correct

gas. Do not use this water heater with any gas other than the one

listed on the rating plate unless the water heater has been properly

converted. Refer to the “Gas Conversion” section of this manual. If

you have any questions or doubts, consult your gas supplier or gas

utility company.

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

LIGHTING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

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

A. This appliance has a pilot which is lit by a piezo-electric

spark gas ignition system. Do not open the inner door

of the appliance and try to light the pilot by hand.

B. BEFORE LIGHTING smell all around the appliance

area for gas. Be sure to smell next to the floor because

some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any

phone in your building.

• Immediately call your gas supplier from a neighbor's

phone. Follow the gas supplier's instructions.

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

department.

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

knob. Never use tools. If the knob will not push in or turn

by hand, do not try to repair it, call a qualified service

technician. Force or attempted repair may result in a fire

or explosion.

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

underwater. Immediately contact a qualified installer or

service agency to replace a flooded water heater. Do not

attempt to repair the unit! It must be replaced!

1. STOP! Read the safety information above on this label.

2. Set thermostat to lowest setting by turning thermostat

dial fully clockwise .

3. Push the gas control knob down slightly and turn

clockwise to "OFF". SEE FIGURE 'A'. NOTE: Knob

cannot be turned from "PILOT" to "OFF" unless knob is

pushed down slightly. Do not force.

4. Remove the outer burner door located below the gas

control.

5. Wait five (5) minutes to clear out any gas. If you then

smell gas, STOP! Follow "B" in the safety information

above on this label. If you don't smell gas, go to next

step.

6. This unit is equipped with a push button pilot ignitor,

which is used to light the pilot. Locate the ignitor on the

gas control.

7. Turn gas control knob counterclockwise to "PILOT".

SEE FIGURE 'B'.

8. The pilot is located on the left side of the burner. It can

be located by looking through the glass view port while

pressing the piezo ignitor button several times. Look

for a spark at the pilot location, Figure "D".

9. Once the pilot has been found, push the gas knob all

the way down. Immediately press and release the pilot

ignitor button continuously up to (10) times. If the pilot

will not light, repeat steps (3) through (9).

10. Continue to hold the gas control knob down for about

one (1) minute after the pilot is lit. Release the gas

control knob and it will pop back up. Pilot should

remain lit. If it goes out, repeat step (9). It may take

several minutes for air to clear the lines before the pilot

will light.

• If knob does not pop up when released, stop and

immediately call your service technician or gas

supplier.

• If the pilot will not stay lit after several tries, turn the

gas control knob clockwise to 'OFF' and call your

service technician or gas supplier. SEE FIGURE 'A'.

11. Once the pilot flame is established replace the outer

burner door.

12. At arm's length away, turn gas control knob

counterclockwise to 'ON'. SEE FIGURE 'C'.

13. Set thermostat to desired setting.

FIGURE "D"

THERMOCOUPLE

PILOT

ELECTRODE

TOP KNOB

"ON" POSITION

FIGURE 'C'

"PILOT" POSITION

FIGURE 'B'

"OFF" POSITION

FIGURE 'A'

GAS CONTROL

KNOB

THERMOSTAT

DIAL

GAS CONTROL

PIEZO

IGNITOR

1. Turn the thermostat dial to lowest setting (PILOT

LIGHTING).

2. Push gas control knob down slightly and turn

clock-wise to 'OFF'. Do not force. SEE FIGURE 'A'.

TEMPERATURE REGULATION

Water temperature over 125°F (52°C)

can cause servere burns instantly

resulting in severe injury or death.

Children, the elderly, and the

physically or mentally disabled are at

highest risk for scald injury.

Feel water before bathing or

showering.

Temperature limiting valves are

available.

Read instruction manual for safe

temperature setting.

Due to the nature of the typical gas water heater, the water

temperature in certain situations may vary up to 30°F

(16.7 °C) higher or lower at the point of use such as, bathtubs,

showers, sink, etc.

HOTTER WATER CAN SCALD: Water heaters are intended to

produce hot water. Water heated to a temperature which will

satisfy clothes washing, dish washing, and other sanitizing needs

can scald and permanently injure you upon contact. Some people

are more likely to be permanently injured by hot water than others.

These include the elderly, children, the infirm, or physically/mentally

handicapped. If anyone using hot water in your home fits into one of

these groups or if there is a local code or state law requiring a certain

temperature water at the hot water tap, then you must take special

precautions. In addition to using the lowest possible temperature

setting that satisfies your hot water needs, a means such as a mixing

valve should be used at the hot water taps used by these people

or at the water heater. Mixing valves are available at plumbing

supply or hardware stores. See Figure 2. Follow manufacturer’s

instructions for installation of the valves. Before changing the factory

setting on the thermostat, see Figure 32. Using the lowest hot water

temperature that meets your needs will also provide the most energy

efficient operation of the water heater.

Never allow small children to use a hot water tap, or to draw their own

bath water. Never leave a child or handicapped person unattended

in a bathtub or shower.

NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is

recommended by most dishwasher manufacturers.

The thermostat is adjusted to the pilot position when it is shipped

from the factory. Water temperature can be regulated by moving

the temperature dial to the preferred setting. The preferred starting

point is 120°F at the “HOT” setting. Align the knob with the desired

water temperature as shown in Figure 34. There is a hot water scald

potential if the thermostat is set too high.

NOTE:

• If the knob is set to a higher temperature setting than 120°F

(48.9°C), a mixing valve should be installed to limit the temperature

of the water to 120°F (48.9°C) at the fixtures.

• Temperatures shown on the gas control valve/thermostat are

approximates. The actual temperature of the heated water may

vary.

IMPORTANT: Adjusting the thermostat past the 120°F (48.9°C)

mark on the temperature dial will increase the risk of scald injury.

Hot water can produce first degree burns within:

Water

Temperature

°F (°C)

Time for 1st

Degree Burn

(Less Severe Burns)

Time for

Permanent Burns

2nd & 3rd Degree

(Most Severe Burns)

110 (43)

116 (47)

122 (50)

131 (55)

140 (60)

149 (65)

154 (68)

(normal shower temp.)

(pain threshold)

35 minutes

1 minute

5 seconds

2 seconds

1 second

Instantaneous

45 minutes

5 minutes

25 seconds

5 seconds

2 seconds

1 second

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

INDEX BAR

155°F

GAS CONTROL KNOB

(OFF-PILOT-ON)

150°F

140°F

130°F

120°F

TEMPERATURE DIAL

TEMPERATURES SHOWN ARE APPROXIMATES AND MAY VARY

PILOT

LIGHTING

LOW

VERY

HOT

FIGURE 32.

Should overheating occur or the gas supply fail to shut off, turn off the

manual gas control valve to the appliance.

NOTE: During low demand periods when hot water is not being

used, a lower thermostat setting will reduce energy losses and may

satisfy your normal hot water needs. If hot water use is expected to

be more than normal, a higher thermostat setting may be required to

meet the increased demand. When leaving your home for extended

periods (vacations, etc.) turn the temperature dial to its lowest setting.

This will maintain the water at low temperatures with minimum energy

losses and prevent the tank from freezing during cold weather.

FOR YOUR INFORMATION

START UP CONDITIONS

CONDENSATE

Whenever the water heater is ﬁ lled with cold water, some condensate

will form while the burner is on. A water heater may appear to be

leaking when in fact the water is condensation. This usually happens

when:

a. A new water heater is ﬁ lled with cold water for the ﬁ rst time.

b. Burning gas produces water vapor in water heaters, particularly

high efﬁ ciency models where ﬂ ue temperatures are lower.

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

water in the tank is very cold.

Moisture from the products of combustion condense on the cooler

tank surfaces and form drops of water which may fall onto the burner

or other hot surfaces to produce a “sizzling” or “frying” noise.

Excessive condensation can cause pilot outage due to water running

down the ﬂ ue tube onto the main burner and putting out the pilot.

Because of the suddenness and amount of water, condensation water

may be diagnosed as a “tank leak”. After the water in the tank warms

up (about 1-2 hours), the condition should disappear.

Do not assume the water heater is leaking until there has been enough

time for the water in the tank to warm up.

An undersized water heater will cause more condensation. The water

heater must be sized properly to meet the family’s demands for hot

water including dishwashers, washing machines and shower heads.

Excessive condensation may be noticed during the winter and early

spring months when incoming water temperatures are at their lowest.

Good venting is essential for a gas ﬁ red water heater to operate

properly as well as to carry away products of combustion and water

vapor.

SMOKE / ODOR

It is not uncommon to experience a small amount of smoke and odor

during the initial start-up. This is due to burning off of oil from metal

parts, and will disappear in a short while.

THERMAL EXPANSION

As water is heated, it expands (thermal expansion). In a closed

system, the volume of water will grow. As the volume of water grows,

there will be a corresponding increase in water pressure due to

thermal expansion. Thermal expansion can cause premature tank

failure (leakage). This type of failure is not covered under the limited

warranty. Thermal expansion can also cause intermittent temperature-

pressure relief valve operation: water discharged from the valve due to

excessive pressure build up. The temperature-pressure relief valve is

not intended for the constant relief of thermal expansion. This condition

is not covered under the limited warranty.

A properly-sized thermal expansion tank should be installed on all

closed systems to control the harmful effects of thermal expansion.

Contact a plumbing service agency or your retail supplier regarding

the installation of a thermal expansion tank.

STRANGE SOUNDS

Possible noises due to expansion and contraction of some metal parts

during periods of heat-up and cool-down do not necessarily represent

harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area

during heating and cooling periods and should be considered normal.

See “Condensate” in this section.

OPERATIONAL CONDITIONS

SMELLY WATER

In each water heater there is installed at least one anode rod (see

parts section) for corrosion protection of the tank. Certain water

conditions will cause a reaction between this rod and the water. The

most common complaint associated with the anode rod is one of a

“rotten egg smell” in the hot water. This odor is derived from hydrogen

sulﬁ de gas dissolved in the water. The smell is the result of four factors

which must all be present for the odor to develop:

a. A concentration of sulfate in the supply water.

b. Little or no dissolved oxygen in the water.

c. A sulfate reducing bacteria which has accumulated within the water

heater (this harmless bacteria is nontoxic to humans).

d. An excess of active hydrogen in the tank. This is caused by the

corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater

models by replacing the anode(s) with one of less active material, and

then chlorinating the water heater tank and all hot water lines. Contact

the local water heater supplier or service agency for further information

concerning an Anode Replacement Kit and this chlorination treatment.

If the smelly water persists after the anode replacement and

chlorination treatment, we can only suggest that chlorination or

aeration of the water supply be considered to eliminate the water

problem.

Do not remove the anode leaving the tank unprotected. By doing

so, all warranty on the water heater tank is voided.

“AIR” IN HOT WATER FAUCETS

HYDROGEN GAS: Hydrogen gas can be produced in a hot water

system that has not been used for a long period of time (generally

two weeks or more). Hydrogen gas is extremely ﬂ ammable and

explosive. To prevent the possibility of injury under these conditions,

we recommend the hot water faucet, located farthest away, be

opened for several minutes before any electrical appliances which are

connected to the hot water system are used (such as a dishwasher

or washing machine). If hydrogen gas is present, there will probably

be an unusual sound similar to air escaping through the pipe as the

hot water faucet is opened. There must be no smoking or open ﬂ ame

near the faucet at the time it is open.

SAFETY SHUT OFF SYSTEM

This water heater is designed to automatically shut off in the event

of the following:

1. When the pilot flame is extinguished for any reason.

A thermocouple is used to determine if a pilot ﬂ ame is present

and will shut off the gas supply to the main burner and pilot if

the ﬂ ame is absent.

2. When the water temperature in the tank exceeds 189°F (87°C).

The gas control valve\thermostat includes a temperature

limiting ECO (Energy Cut Off) system that activates when

excessive water temperatures are present. If this occurs, the

system cannot be reset. The gas control valve/thermostat

must be replaced.

MAINTENANCE OF YOUR WATER HEATER

IMPORTANT: If you do not have the skills and training to perform a

maintenance procedure, do not attempt it. Get help from a qualiﬁ ed

technician.

BURNER FLAME INSPECTION

Inspect the burner ﬂ ames through the viewport and compare them to

the drawing in Figure 36. A properly operating burner should produce

a soft blue ﬂ ame. Blue tips with yellow inner cones are satisfactory.

The tips of the ﬂ ame may have a slight yellow tint. The ﬂ ame should

not be all yellow or have a sharp blue-orange color. Contaminated air

may cause an orange colored ﬂ ame. Contact a qualiﬁ ed technician

if the ﬂ ame is not satisfactory.

FIGURE 33.

R O U T I N E P R E V E N T I V E M A I N T E N A N C E

At least annually, a visual inspection should be made of the venting

and air supply system, piping systems, main burner, and pilot burner.

Check the water heater for the following:

• Obstructions, damage, or deterioration in the venting system.

Make sure the ventilation and combustion air supplies are not

obstructed.

• Soot and/or carbon on the main burner and pilot burner.

Contact a qualified technician.

• Leaking or damaged water and gas piping.

• Presence of flammable or corrosive materials in the installation

area.

• Presence of combustible materials near the water heater.

• After servicing this water heater, check to make sure that it is

working properly.

IMPORTANT: If you lack the necessary skills required to properly

perform this visual inspection, you should not proceed, but get help

from a qualiﬁ ed technician.

A N O D E R O D I N S P E C T I O N

Each water heater contains at least one anode rod, which will slowly

deplete (due to electrolysis) prolonging the life of the water heater

by protecting the glass-lined tank from corrosion. Adverse water

quality, hotter water temperatures, high hot water usage, and water

softening methods can increase the rate of anode rod depletion. Once

the anode rod is depleted, the tank will start to corrode, eventually

developing a leak.

Anode Rod Depletion

FIGURE 34.

Certain water conditions will cause a reaction between the anode

rod and the water. The most common complaint associated with

the anode rod is a “rotten egg smell” produced from the presence

of hydrogen sulﬁ de gas dissolved in the water. IMPORTANT: Do not

remove this rod permanently as it will void any warranties. A special

anode rod may be available if water odor or discoloration occurs.

NOTE: This rod may reduce but not eliminate water odor problems.

The water supply system may require special ﬁ ltration equipment

from a water conditioning company to successfully eliminate all water

odor problems.

Artiﬁ cially softened water is exceedingly corrosive because the process

substitutes sodium ions for magnesium and calcium ions. The use

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

The anode rod should be inspected after a maximum of three years

and annually thereafter until the condition of the anode rod dictates

its replacement. NOTE: Artiﬁ cially softened water requires the anode

rod to be inspected annually. The following are typical (but not all)

signs of a depleted anode rod:

• The majority of the rods diameter is less than 3/8” (9.5 mm).

• Signiﬁ cant sections of the support wire (approx. 1/3 or more of the

anode rod’s length) are visible.

If the anode rod show signs of either or both it should be replaced.

NOTE: Whether re-installing or replacing the anode rod, check for

any leaks and immediately correct if found. In replacing the anode:

1. Turn off gas supply to the water heater.

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

depressurize the water tank.

3. Drain approximately 5 gallons (18.9 liters) of water from tank. (Refer

to “Draining and Flushing” for proper procedures.) Close drain valve.

4. Remove old anode rod.

5. Use Teﬂ on

tape or approved pipe sealant on threads and install

new anode rod.

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

air from water system. Check for any leaks and immediately

correct any if found.

7. Restart the water heater as directed in this manual.

See the Repair Parts illustration for anode rod location.

Teﬂ on

is a registered trademark of E. I. du Pont de Nemours and Company.

TEMPERATURE-PRESSURE RELIEF VALVE OPERATION

Explosion Hazard

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Manually operate the temperature and pressure relief valve at least

once a year to make sure it is working properly. To prevent water

damage, the valve must be properly connected to a discharge line

that passes through the structural ﬂ oor and terminates external to

the building. In cold climates, it is recommended that the discharge

line be terminated at an adequate drain inside the building. See

Figure 1. Standing clear of the outlet (discharged water may be

hot), slowly lift and release the lever handle on the temperature and

pressure relief valve to allow the valve to operate freely and return

to its closed position. See Figure 35. If the valve fails to completely

reset and continues to release water, immediately close the manual

gas shut-off valve and the cold water inlet valve and call a qualiﬁ ed

technician. Do not plug the temperature-pressure relief valve or

discharge line.

TEMPERATURE AND PRESSURE

RELIEF VALVE

DISCHARGE LINE TO DRAIN

MANUAL RELIEF

VALVE

FIGURE 35.

Draining and Flushing

It is recommended that the tank be drained and flushed

every 6 months to remove sediment which may build up during

operation. The water heater should be drained if being shut down

during freezing temperatures. To drain the tank, perform the following

steps:

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

valve.

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

3. Close the cold water inlet valve.

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

drain or external to the building.

5. Open the water heater drain valve and allow all of the water to

drain from the tank. Flush the tank with water as needed to remove

sediment.

6. Close the drain valve, reﬁ ll the tank, and restart the heater as

directed in this manual. If the water heater is going to be shut

down for an extended period, the drain valve should be left open.

IMPORTANT: Condensation may occur when reﬁ lling the tank and

should not be confused with a tank leak.

REMOVING THE MANIFOLD/BURNER ASSEMBLY

1. Turn the gas control/temperature knob to the “OFF” position

(Figure 35).

2. Before performing any maintenance, it is important to turn off

the gas supply to the water heater at the manual gas shut-off

valve. This valve is typically located beside the water heater.

Note the position of the shut-off valve in the open/on position,

then proceed to turn it off (Figure 27).

3. With the unit shut-off, allow sufficient time for the water heater to

cool before performing any maintenance.

THERMOCOUPLE

MANIFOLD TUBE

PILOT

TUBE

WITH

FERRULE

NUT

GAS CONTROL VALVE / THERMOSTAT

FIGURE 36.

4. Remove the outer door.

5. Disconnect the following from the gas control valve/thermostat:

pilot tube (7/16” SAE wrench), igniter wire (from the igniter lead

wire), and manifold tube (3/4” SAE wrench). See Figure 36.

6. Disconnect the white and red wires from the gas control valve/

thermostat (Figure 39). Use needle nose pliers to grip the

connector(s). IMPORTANT: Grip the connector carefully to

prevent damage. Do not grip or pull the wires themselves.

7. Grasp the manifold tube and push down slightly to free the

manifold tube and pilot tube.

8. Remove the screws (1/4” SAE nut driver) securing the manifold/

burner assembly to the combustion chamber. See Figure 37.

9. Carefully remove the manifold/burner assembly from the

combustion chamber. BE SURE NOT TO DAMAGE ANY

INTERNAL PARTS.

MANIFOLD

SCREWS (2)

TWO PIECE

WIRE CONNECTOR

MANIFOLD

DOOR

THERMAL

SWITCH

PILOT

TUBE

PIEZO

IGNITER

BUTTON

GAS CONTROL VALVE/

THERMOSTAT

MANIFOLD

TUBE

THERMOCOUPLE

VIEW PORT

FIGURE 37.

REMOVING THE BURNER FROM THE

MANIFOLD/BURNER ASSEMBLY

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

underneath the burner.

2. Check the burner to see if it is dirty or clogged. The burner

may be cleaned with soap and hot water (Figure 41).

BURNER

(BOTTOM VIEW)

SCREWS

PILOT ASSEMBLY

(BOTTOM VIEW)

NOTE: SCOOP NOT PRESENT

ON SOME MODELS

FIGURE 38.

REPLACING THE PILOT/ THERMOCOUPLE

ASSEMBLY

1. Remove the manifold door assembly as described in “Removing

the Manifold/Burner Assembly” section.

2. Remove the burner to access the pilot/thermocouple assembly.

Remove and keep the screws securing the burner to the

manifold (Figure 41). IMPORTANT: DO NOT remove the orifice.

3. Remove the screw securing the pilot/thermocouple assembly to

the pilot bracket and keep for reuse later (Figure 42).

4. Lift the retainer clip straight up from the back of the manifold

component block (using a ﬂ at-blade screwdriver), then remove

the manifold component block from the manifold door (Figure 42).

IMPORTANT: Be careful not to bend or alter the position of the

pilot tube. It will be used as a bending template for the new pilot

assembly. Note the placement/order of the wires in the manifold

component block.

5. Lift the pilot/thermocouple assembly (including the igniter wire)

from the manifold assembly.

OTHER FITTINGS

NOT SHOWN

FOR CLARITY

IGNITER WIRE

THERMOCOUPLE

TWO PIECE

WIRE CONNECTOR

RETAINER

CLIP

PILOT TUBE

PILOT BRACKET

PILOT

MANIFOLD TUBE

MANIFOLD/BURNER

DOOR OPENING

FERRULE NUT

FIGURE 39.

6. Read this step carefully before proceeding. Using the old pilot/

pilot tube assembly as a guide, bend the new pilot tube to match

the old one. Make only the bends closest to the pilot before going

to the next step.

FIRST BEND(S)

OTHER FITTINGS

NOT SHOWN

FOR CLARITY

PILOT TUBE

THERMOCOUPLE

IGNITER WIRE

SCREW

OLD PILOT ASSEMBLY

FIGURE 40.

7. Route the new pilot tube and wires through the opening in the

manifold door. See Figure 41.

8. Using the pilot screw removed earlier, attach the new pilot/

thermocouple assembly. Reattach the burner to the manifold

using the screws removed earlier. NOTE: If the burner has a

scoop, make sure that the scoop is oriented to the pilot side of

the manifold tube (Figure 41).

9. Reinstall the manifold component block in the manifold door.

Ensure that the pilot tube and wires are positioned as shown in

Figure 44.

10. Carefully bend the new pilot tube to match the bend of the

manifold tube. NOTE: When bending, DO NOT crimp or crease

the pilot tube.

11. Before you proceed to the next step, install the new brass ferrule

nut in the gas control valve/thermostat’s pilot tube opening, HAND

TIGHT ONLY.

12. Install the manifold/burner assembly. Refer to the “Replacing

the Manifold/Burner Assembly” section for instructions.

TWO PIECE WIRE CONNECTOR

PILOT TUBE

IGNITER WIRE

THERMOCOUPLE

FIGURE 41.

C L E A N I N G T H E C O M B U S T I O N C H A M B E R

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

Assembly”.

2. Use a vacuum cleaner/shop vac to remove all loose debris in

the combustion chamber (Figure 45).

3. Reassemble following the procedure under “Replacing the

Manifold/Burner Assembly.”

DOOR GASKET

COMBUSTION CHAMBER

FOR CLARITY, THE INLET AIR OPENING IS NOT SHOWN.

FIGURE 42.

REPLACING THE MANIFOLD/BURNER ASSEMBLY

WARNING

Explosion Hazard

 Tighten both manifold door screws securely.

 Remove any fiberglass between gasket and

combustion chamber.

 Replace viewport if glass is missing or damaged.



removed.

 Replace door gasket if damaged.

 Failure to follow these instructions can result in

death, explosion, or fire.

Replace manifold component block if missing or

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

installation (Figure 45).

2. Inspect the viewport for damage and replace as required

(Figure 40).

3. Insert the new manifold/burner assembly into the burner

compartment, making sure that the tab of the manifold tube

engages the slot of the bracket inside the combustion chamber

(Figure 46).

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

fiberglass insulation between the gasket and the

combustion chamber (Figure 45).

5. Tighten the two screws that secure the manifold/burner

assembly to the combustion chamber. (Use a 1/4” SAE nut

driver.) There should be no space between the gasket part of

the manifold door and combustion chamber.

IMPORTANT: Do not operate the water heater if the door

gasket does not create a seal between the manifold door and

the combustion chamber.

6. Reconnect the manifold tube (3/4” SAE wrench) and pilot

tube (7/16” SAE wrench) to the gas control valve/thermostat

(Figure 39). Do not cross-thread or apply any thread sealant

to the fittings.

IMPORTANT: If you were supplied with a new ferrule

nut in a parts kit, follow these steps to connect the

pilot tube:

1.) Install the ferrule nut into the gas valve at the pilot tube

location, hand tight only. 2.) Insert the pilot tube into the ferrule

nut until the tube bottoms out, then tighten the nut with a 7/16”

SAE wrench until the crimp connection seals to the pilot tube.

3.) Continue to tighten until the nut is tight in the gas valve.

7. Connect the white and red wires to the gas control valve/

thermostat as shown in Figure 39.

8. Reconnect the igniter wire (Figure 39).

9. Turn on the gas supply to the water heater at the manual gas

shut-off valve (Figure 27).

10. Follow the lighting instructions on the front of the water heater.

With the main burner lit, check for leaks at the manifold and

pilot connections by brushing on an approved noncorrosive leak

detection solution. If such a solution is not available, use a mixture

of hand dish washing soap and water (one part soap to 15 parts

water) or children’s soap bubble solution. Bubbles forming indicate

a leak. Correct any leak found.

11. Verify proper operation, then replace the outer door.

MANIFOLD TUBE

TIP

BRACKET

SLOT

CLOSE-UP INSIDE VIEW OF

THE COMBUSTION CHAMBER.

FIGURE 43.

PIEZOELECTRIC IGNITER SYSTEM

The piezoelectric igniter system consists of the igniter button,

electrode, and wire. The pilot is ignited by an electric spark

generated when the igniter button is pressed. See Figure 44.

SNAP-ON CONNECTOR

IGNITER

BUTTON

WIRE

ELECTRODE

THERMOCOUPLE

PILOT

BRACKET

ELECTRODE

TIP

.125” *

* NOTE: SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT.

FIGURE 44.

TESTING THE IGNITER SYSTEM

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

Watch the electrode tip while activating the igniter. A visible spark

should jump from the electrode. To avoid shock, do not touch the burner

or any metal part on the pilot or pilot assembly. If no spark is visible,

check the wire connections and make sure the electrode is not broken.

Replace the igniter if defective. Dirt and rust on the pilot or electrode

tip can prevent the igniter spark. Wipe clean with a damp cloth and

dry completely. Rust can be removed from the electrode tip and metal

surfaces by lightly sanding with an emery cloth or ﬁ ne grit sandpaper.

REMOVING AND REPLACING THE

G A S C O N T R O L VA LV E / T H E R M O S TAT

IMPORTANT: This gas control valve/thermostat is shipped from the

factory as a natural gas unit. However, it may be converted to use LP

gas. Before installing this gas control valve/ thermostat, make sure

that it is conﬁ gured for the type of gas that you are using. Refer to the

“Gas Conversion” section.

Removing the Gas Control Valve/Thermostat:

1. Turn the gas control/temperature knob to the “OFF” position

(Figure 34).

2. Turn off the gas at the manual shut-off valve on the gas supply

pipe (Figure 27).

3. Drain the water heater. Refer to the section of “Draining and

Flushing” and follow the procedure.

4. Disconnect the igniter wire from the igniter lead wire. Use

needle nose pliers to disconnect the red (+) and white (-)

thermocouple wires. Disconnect the pilot tube (7/16” SAE

wrench) and manifold tube (3/4” SAE wrench) at the gas control

valve/thermostat. See Figure 36.

5. Refer to “Gas Piping” (Figure 27) and disconnect the ground

joint union in the gas piping. Disconnect the remaining pipe

from the gas control valve/thermostat.

6. To remove the gas control valve/thermostat, thread

a 4” (10.16 cm) section of gas pipe into the inlet and use it to turn

the gas control valve/thermostat (counterclockwise.) Do not use

a pipe wrench or equivalent to grip body. Damage may result,

causing leaks. Do not insert any sharp objects into the inlet or

outlet connections. Damage to the gas control valve/thermostat

may result.

Replacing the Gas Control Valve/Thermostat:

To replace the gas control valve/thermostat, reassemble in reverse

order. When replacing the gas control valve/thermostat, thread a 4”

(10.16 cm) section of gas pipe into the inlet and use it to turn the gas

control valve/thermostat (clockwise). DO NOT OVER TIGHTEN;

damage may result.

• Be sure to use approved Teflon

tape or pipe joint

compound on the gas piping connections and fitting on the

back of the gas control valve that screws into the tank.

• Be sure to remove the pilot ferrule nut from the new gas control

valve/thermostat.

• Turn the main gas supply on and check the gas supply

connections for leaks. Correct any leak found. Next, light

the pilot and main burner, then check the manifold tube and

pilot tube connections for leaks. Correct any leak found. Use

an approved noncorrosive leak detection solution. If such a

solution is not available, use a mixture of hand dish washing

soap and water (one part soap to 15 parts water) or children’s

soap bubble solution. Bubbles forming indicate a leak.

• Be sure tank is completely filled with water before lighting and

activating the water heater. Follow the “Lighting Instructions” on

the front of the water heater.

• If additional information is required, contact Residential

Technical Assistance.

TEFLON

is a registered trademark of E.I. Du Pont De

Nemours and Company.

SERVICE CHECKLIST

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Manifold component block properly installed.

4. No leaks at pilot and manifold connection.

5. Manifold door screws securely tightened.

LEAKAGE CHECKPOINTS

FIGURE 45.

Use this guide to check a “Leaking” water heater. Many suspected

“Leakers” are not leaking tanks. Often the source of the water can

be found and corrected.

If you are not thoroughly familiar with gas codes, your water heater,

and safety practices, contact your gas supplier or qualiﬁ ed installer to

check the water heater.

Read this manual ﬁ rst. Then before checking the water heater make

sure the gas supply has been turned “OFF”, and never turn the gas

“ON” before the tank is completely full of water.

A. *Condensation may be seen on pipes in humid weather or pipe

connections may be leaking. NOTE: The location of the hot water

outlet has been modiﬁ ed for clarity.

B. *The anode rod ﬁ tting may be leaking. NOTE: The location of the

anode has been modiﬁ ed for clarity.

C. Small amounts of water from temperature-pressure relief valve

may be due to thermal expansion or high water pressure in your

area.

D. *The temperature-pressure relief valve may be leaking at the

tank ﬁ tting.

E. Water from a drain valve may be due to the valve being slightly

opened.

F. *The drain valve may be leaking at the tank ﬁ tting.

G. Combustion products contain water vapor which can condense

on the cooler surfaces of the tank. Droplets form and drip onto

the burner or run on the ﬂ oor. This is common at the time of

start-up after installation and when incoming water is cold.

H. Water in the water heater bottom or on the ﬂ oor may be from

condensation, loose connections, or the relief valve. DO NOT

replace the water heater until a full inspection of all possible

water sources is made and necessary corrective steps taken.

Leakage from other appliances, water lines, or ground seepage

should also be checked.

* To check where threaded portion enters tank, insert cotton

swab between jacket opening and ﬁ tting. If cotton is wet, follow

“Draining and Flushing” instructions in this manual and then

remove ﬁ tting. Put pipe dope or Teﬂ on

tape on the threads and

replace. Then follow “Filling the Water Heater” instructions in

the “Installing the New Water Heater” section.

Teﬂ on

is a registered trademark of E. I. du Pont de Nemours and Company.

TROUBLESHOOTING GUIDELINES

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER WILL NOT IGNITE 1. Pilot not lit

2. Thermostat set too low

3. No gas

4. Dirt in the gas lines

5. Pilot line clogged

6. Main burner line clogged

7. Non-functioning thermocouple

8. Non-functioning thermostat

9. Heater installed in a confined area

1. Light pilot

2. Turn temp. dial to desired temperature

3. Check with gas utility company

4. Notify utility-install trap in gas line

5. Clean, locate source and correct

6. Clean, locate source and correct

7. Replace thermocouple

8. Replace thermostat

9. Provide fresh air ventilation

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

BURNER FLAME YELLOW-

LAZY

1. Insufficient secondary air

2. Low gas pressure

3. Water heater flue or vent system

blocked

4. Main burner line clogged

5. Heater installed in a confined area

6. Obstruction in main burner orifice

7. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Provide ventilation to water heater

2. Check with gas utility company

3. Clean, locate source and correct

4. Clean, locate source and correct

5. Proper fresh air ventilation

6. Clean or replace orifice

7. Contact a qualified technician.

PILOT WILL NOT LIGHT OR

REMAIN LIT

1. Non-functioning igniter

2. The thermal switch tripped

3. Wire lead connection at thermal switch

loose

4. Thermocouple connection loose

5. Air in gas line

6. Low gas pressure

7. No gas

8. Dirt in gas lines

9. Cold drafts

10. Thermostat ECO switch open

11. Pilot line or orifice clogged

12. Non-functioning thermocouple

13. Air for combustion obstructed

14. Flammable vapors incident, FVIR

function actuated

15. Base-ring filter obstructed

1. Replace igniter pilot assembly

2. See Pilot Light Troubleshooting Flowchart section

3. Remove and reconnect the wire leads at

thermal switch, confirm connections are tight

and not loose

4. Finger tighten; then 1/4 turn with wrench

5. Bleed the air from the gas line

6. Check with gas utility company

7. Check with gas utility company

8. Notify utility-install dirt trap in gas line

9. Locate source and correct

10. Replace thermostat

11. Clean, locate source and correct

12. Replace thermocouple

13. See maintenance section for inspection and

cleaning of flame arrester

14. Replace water heater, eliminate flammable vapors

source. Contact Residential Technical Assistance.

15. Inspect and clean base-ring filter. See “External

Inspection & Cleaning of the Base-Ring Filter.”

HIGH OPERATION COSTS 1. Thermostat set too high

2. Sediment or lime in tank

3. Water heater too small for job

4. Wrong piping connections

5. Leaking faucets

6. Gas leaks

7. Wasted hot water

8. Long runs of exposed piping

9. Hot water piping in exposed wall

1. Set temperature dial to lower setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

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

5. Repair faucets

6. Check with utility-repair at once

7. Advise customer

8. Insulate piping

9. Insulate piping

INSUFFICIENT HOT WATER 1. Thermostat set too low

2. Sediment or lime in tank

3. Water heater too small

4. Wrong piping connections

5. Leaking faucets

6. Wasted hot water

7. Long runs of exposed piping

8. Hot water piping in outside wall

9. Low gas pressure

10. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Turn temperature dial to desired setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

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

5 Repair faucets

6. Advise customer

7. Insulate piping

8. Insulate piping

9. Check with gas utility company

10. Contact a qualified technician.

SLOW HOT WATER

RECOVERY

1. Insufficient secondary air

2. Water heater flue or vent system

blocked

3. Low gas pressure

4. Improper calibration

5. Thermostat set too low

6. Water heater too small

7. Wrong piping connections

8. Wasted hot water

9. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Provide ventilation to water heater. Check flue

way, flue baffle, and burner

2. Clean flue, locate source and correct

3. Check with gas utility company

4. Replace thermostat

5. Turn temperature dial to desired setting

6. Install adequate heater

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

8. Advise customer

9. Contact a qualified technician.

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

DRIP FROM RELIEF VALVE 1. Excessive water pressure

2. Heater stacking

3. Closed water system

1. Use a pressure reducing valve and relief valve

2. Lower the thermostat setting

3. See “Closed System/Thermal Expansion”

THERMOSTAT FAILS TO

SHUT-OFF

1. Thermostat not functioning properly

2. Improper calibration

1. Replace thermostat

2. Replace thermostat

COMBUSTION ODORS 1. Insufficient secondary air

2. Water heater flue or vent system

blocked

3. Heater installed in a confined area

1. Provide ventilation to water heater. Check flue

way, flue baffle, and burner

2. Clean, locate source and correct

3. Provide fresh air ventilation

SMOKING AND CARBON

FORMATION (SOOTING)

1. Insufficient secondary air

2. Low gas pressure

3. Water heater flue or vent system

blocked

4. Thermostat not functioning properly

5. Heater installed in a confined area

6. Burner flame yellow-lazy

7. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Provide ventilation to water heater. Check flue

way, flue baffle, burner

2. Check with gas utility company

3. Clean, locate source and correct

4. Replace thermostat

5. Provide fresh air ventilation

6. See “Burner Flame Yellow-Lazy”

7. Contact a qualified technician.

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

“Condensation” sub-section in “Operational

Conditions.”

BURNER FLAME FLOATS

AND LIFTS OFF PORTS

1. Orifice too large

2. High gas pressure

3. Water heater flue or vent system

blocked

4. Cold drafts

5. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Replace with correct orifice

2. Check with gas utility company

3. Clean flue and burner-locate source and correct

4. Locate source and correct

5. Contact a qualified technician.

BURNER FLAME TOO HIGH 1. Orifice too large

2. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Replace with correct orifice

2. Contact a qualified technician.

FLAME BURNS AT ORIFICE 1. Thermostat not functioning properly

2. Low gas pressure

3. Incorrect gas conversion (if unit was

converted to use a different type of gas)

1. Replace thermostat

2. Check with gas utility company

3. Contact a qualified technician.

PILOT FLAME

TOO SMALL

1. Pilot line or orifice clogged

2. Low gas pressure

1. Clean, locate source and correct

2. Check with gas utility company

TROUBLESHOOTING GUIDELINES

PILOT LIGHT TROUBLESHOOTING CHART

Have you bled all the air

from the pilot tube and

gas supply line?

While repeatedly depressing the igniter

button, push in and hold the gas control/

temperature knob until the pilot is lit and

maintains a stable flame (status light will

blink). It may take up to 90 seconds of

pilot operation before status light blinks.

Once status light blinks, release the gas

control/temperature knob.

Section A: Pilot light will not light (new installation).

Is the manual gas shut-off valve,

located in the supply line to the

water heater, in the on position?

YES

Turn the manual gas shut-off valve to

the on position and follow the lighting

instructions on the front of the water heater.

Is the igniter producing a

spark?

YES

Follow the “Testing the Igniter

System” section in this manual.

YES

Set thermostat to desired temperature.

Section B: Pilot light repeatedly goes out.

Check the air intake for blockage.

Is the air intake clear of

obstructions ?

Clear the obstruction.

YES

Does the diagnostic status light on the

gas control valve/thermostat give

a two flash error code?

Attempt to return the heater to service.

Does the pilot remain lit?

YES

Set to desired temperature.

YES

Refer to the “Replacing the Pilot/Ther-

mopile Assembly” instructions in the

manual.

Reassemble and restore to service.

Contact Residential

Technical Assistance.

NOTE: If you are still experiencing difficulties after following

the steps in sections A and B, please contact Residential

Technical Assistance.

REPAIR PARTS LIST

MANIFOLD/BURNER ASSEMBLY

METAL DRAIN PAN

Key No. Part Description

1 10” Extension Pipe (Optional)

2 Air Duct Assembly (14.5” to 24” [36.8cm to 61cm] Long)

3 Angle Bracket

4 Angle Bracket (2 Required)

5 Anode Rod

6 Burner

7 Burner Oriﬁ ce (Natural Gas)

7 Burner Oriﬁ ce (Propane [L.P.] Gas)

8 Drain Valve

9 Gas Control Valve / Thermostat

10 Inlet Tube

11 Inner Door Gasket

12 Manifold Component Block w/ Clip

13 Manifold/Burner Assembly (Natural Gas)

13 Manifold/Burner Assembly (Propane [L.P.] Gas)

14 Metal Drain Pan

15 Nipple w/Heat Traps

#16 Optional 3” (76mm) Outside Wall Intake Air Vent Kit 9002986

#16 Optional 4” (102mm) Outside Wall Intake Air Vent Kit 9002987

17 Outer Door

18 Pilot Assembly with Tubing and Fittings

*19 Pipe Insulation

20 Roof Jack 12” / 30.48 cm (9002964005)

20 Roof Jack 32” / 81.28 cm (9002965005)

20 Roof Jack 60” / 152.4 cm (9002966005)

20 Roof Jack 95” / 241.3 cm (9002967005)

21 Flue Reducer

*22 T & P Insulation

23 Temperature-Pressure Relief Valve (T & P Valve)

* These parts available at most hardware stores.

# Not Shown.

Now that you have purchased this water heater, should a need ever exist

for repair parts or service, simply contact the company it was purchased

from or direct from the manufacturer listed on the rating plate on the

water heater.

Be sure to provide all pertinent facts when you call or visit.

Selling prices will be furnished on request or parts will be shipped

at prevailing prices and you will be billed accordingly.

The model number of your Gas Water Heater will be found on the rating

plate located above the gas control valve/thermostat.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING

INFORMATION:

• MODEL NUMBER

• TYPE GAS (NATURAL OR PROPANE (L.P.)

• SERIAL NUMBER

• PART DESCRIPTION

THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.

METAL DRAIN PAN

MET

DRA

PAN

[36.8cm to 61cm] Lon

lip

ral

as)

ane [L.P.]

)

Intake Air Vent Kit 9002986

l Intake Air Vent Kit 900298

Fittin

64005

)

65005

)

66005

)

6700

e (

P Val

ve)

stores

r, should a need ever exist

ompan

it was purchased

n the ratin

plate on the

u call or visit.

or parts will be shipped

ccordin

will be

ound on the ratin

mostat.

NOTES

AO Smith G6-DMH4032NV Signature 100 Tall 40-Gallon 6-Year Warranty 32000-BTU Natural Gas/Liquid Propane Water Heater

Product's Documents

Installation Manual

Specifications

AO Smith G6-DMH4032NV Questions and Answers