100263112
January 2015
Residential Gas
Water Heater
Installa on Instruc ons and
Use & Care Guide
Keep this manual in the pocket on heater for future reference whenever maintenance, adjustment or service is required.
Retain your original receipt as proof of purchase.
Residen al Atmospheric Gas Water Heater
with the Flammable Vapor Igni on Resistant
Safety System
Read this manual and the labels on the water heater before you install,
operate, or service it. If you have diffi culty following the direc ons, or
aren’t sure you can safely and properly do any of this work yourself:
• Call our Technical Assistance Hotline at 1-800-527-1953 . We can help you with in-
stalla on, opera ons, troubleshoo ng, or maintenance. Before you call, write down
the model and serial number from the water heater’s data plate.
Incorrect installa on, opera on, or service can damage the water heater, your house
and other property, and present risks including fi re, scalding, electric shock, and
explosion, causing serious injury or death.
Do not store or use gasoline or other
fl ammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your build-
ing.
• Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instruc ons.
• If you cannot reach your gas sup-
plier, call the fi re department.
Installa on and service must be per-
formed by a qualifi ed installer, service
agency or the gas supplier.
WARNING: If the informa on in
these instruc ons is not followed
exactly, a fi re or explosion may
result causing property damage,
personal injury or death.
LOW LEAD
CONTENT
Table of Contents Page
IMPORTANT SAFETY INFORMATION ............................................. 3
GETTING STARTED ........................................................................ 7
INSTALLATION ............................................................................. 14
OPERATION ................................................................................. 23
TROUBLESHOOTING ................................................................... 25
MAINTENANCE ........................................................................... 28
NOTES ......................................................................................... 31
REPAIR PARTS ............................................................................. 35
COMPLETED INSTALLATION TYPICAL
Expansion
tank
(Connect to
cold water
supply)
Hot
water
line
T&P
relief
valve
Cold water
shut off
Dra hood
T&P
discharge
pipe
Drain pan
discharge
pipe
Metal drain pan
Gas control
valve/thermostat
Cold
water
line
Gas supply
shut off
Vent
pipe
Drain valve
Gas supply
Sediment Trap
Residen al Standard Gas Water Heater Use and Care Guide • 3
SAFETY
IMPORTANT SAFETY INFORMATION
Important informa on to keep
Fill out this sec on and keep this
manual in the pocket of the water
heater for reference.
Date Installed:
Model number:
Serial number:
Maintenance performed:* Date:
This is the safety alert symbol. It is used to alert you to
poten al physical injury hazards. Obey all safety mes-
sages that follow this symbol to avoid possible property
damage, serious injury or death. Do not remove any
permanent instruc ons, labels, or the data plate from either the outside of
the water heater or on the inside of the access panels. Keep this manual
near the water heater.
DANGER
Read and follow all safety messages and instruc ons in
this manual.
DANGER indicates hazardous situa-
on that, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous
situa on that, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous
situa on that, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE indicates prac ces not
related to physical injury.
WARNING! If the informa on in these instruc ons is not followed exactly,
a fi re or explosion may result causing property damage, personal injury or
death. Do not store or use gasoline or other fl ammable vapors and liquids in
the vicinity of this or any other appliance.
An odorant is added by the gas supplier to the gas used by this water heater.
This odorant may fade over an extended period of me. Do not depend upon
this odorant as an indica on of leaking gas. We recommend installing a fuel gas
and carbon monoxide detector.
The California Safe Drinking Water and Toxic Enforcement Act requires the
Governor of California to publish a list of substances known to the State of
California to cause cancer, birth defects, or other reproduc ve harm, and
requires businesses to warn of poten al exposure to such substances.
WARNING! This product contains a chemical known to the State of California
to cause cancer, birth defects, or other reproduc ve harm.
This water heater can cause low-level exposure to some of the substances
included in the act.
*Drain and fl ush tank and remove and
inspect anode rod a er fi rst six months
of opera on and at least annually
therea er. Operate the Temperature
and Pressure Relief Valve (T&P) annu-
ally and inspect T&P valve every 2-4
years (see the label on the T&P valve for
maintenance schedule). See the Main-
tenance sec on for more informa on
about maintaining this water heater.
4 • Residen al Standard Gas Water Heater Use and Care Guide
SAFETY
4 • Residen al Standard Gas Water Heater Use and Care Guide
IMPORTANT SAFETY INFORMATION
T
o reduce the risk of property
damage, serious injury or death,
read and follow the precau ons below,
all labels on the water heater, and
the safety messages and instruc ons
throughout this manual.
RISKS DURING
INSTALLATION AND
MAINTENANCE
Li ing Risk
WARNING! The
water heater is heavy.
Follow these precau-
ons to reduce the
risk of property damage, injuries from
li ing or impact injuries from dropping
the water heater.
• Use at least two people to li the
water heater.
• Be sure you both have a good grip
before li ing.
• Use an appliance dolly or hand
truck to move the water heater.
Explosion Risk
WARNING! Read the water heater’s
data plate to determine the type of
gas required. Failure to follow these
instruc ons can result in serious injury
or death from explosion, fi re or
carbon monoxide poisoning.
• Do not connect a natural gas water
heater to an L.P. gas supply.
• Do not connect an L.P. gas water
heater to a natural gas supply.
• Use a new CSA approved gas
supply line.
• Install a shut-off valve on the gas
supply line.
Gas Pressure
WARNING! The gas supply pressure
must not exceed the maximum supply
pressure as stated on the water
heater’s data plate. The minimum
supply pressure is for the purpose of
input adjustment. L.P. gas supply
pressure must not exceed 13” water
column. Have a qualifi ed person
(licensed plumber, gas company
personnel, or authorized service
technician) check for proper L.P. gas
pressure. L.P. gas pressures exceeding
13” water column can result in serious
injury or death from explosion or fi re.
RISKS DURING
OPERATION
Scalding Risk
This water heater
can make water hot
enough to cause severe burns instantly,
resul ng in severe injury or death.
• Feel water before bathing or
showering.
• To reduce the risk of scalding,
install Thermosta c Mixing Valves
(temperature limi ng valves) at
each point-of-use. These valves
automa cally mix hot and cold
water to limit the temperature at
the tap. Follow manufacturer’s
instruc ons for installa on and
adjustment of the valves.
• The gas control valve on this water
heater has been factory set to its
lowest se ng to reduce the risk
of scalding. Higher temperatures
increase the risk of scalding, but
even at 120°F, hot water can scald.
If you choose a higher tempera-
ture se ng, Thermosta c Mixing
Valves located at each point-of-use
are par cularly important to help
avoid scalding.
Table 1
Temperature
Time to Produce
a Serious Burn
120°F (49°C) More than 5 minutes
125°F (52°C) 1½ to 2 minutes
130°F (54°C) About 30 seconds
135°F (57°C) About 10 seconds
140°F (60°C) Less than 5 seconds
145°F (63°C) Less than 3 seconds
150°F (66°C) About 1½ seconds
155°F (68°C) About 1 second
For informa on about changing the
factory temperature se ng, refer to
the “Adjus ng the Temperature” sec-
on in this manual .
Even if you set the water heater’s gas
control valve to a low se ng, higher
water temperatures may occur in cer-
tain circumstances:
• In some cases, repeated small draws
of water can cause the hot and cold
water in the tank to “stack” in layers.
If this happens, the water can be as
much as thirty degrees ho er than
the gas control valve se ng. This
temperature varia on is the result
of your usage pa ern and is not a
malfunc on.
• Water temperature will be ho er if
someone adjusted the gas control
valve to a higher se ng.
• Problems with the gas control valve
or other malfunc ons may result in
higher than expected water tem-
peratures.
• If the water heater is in a hot envi-
ronment, the water in the tank can
become as hot as the surrounding
air, regardless of the temperature
se ng.
Residen al Standard Gas Water Heater Use and Care Guide • 5
SAFETY
Residen al Standard Gas Water Heater Use and Care Guide • 5
IMPORTANT SAFETY INFORMATION
• If the water supplied to the water
heater is pre-heated (for example,
by a solar system) the temperature
in the tank may be higher than the
water heater’s temperature se ng.
• Should overhea ng occur or the
burner fail to shut off , turn off the
manual gas supply valve to the water
heater and call a qualifi ed person.
To reduce the risk of unusually hot wa-
ter reaching the fi xtures in the house,
install Thermosta c Mixing Valves at
each point-of-use.
If anyone in your home is at par cular
risk of scalding (for example, the elder-
ly, children, or people with disabili es)
or if there is a local code or state law
requiring a certain water temperature
at the hot water tap, these precau ons
are par cularly important.
According to a na onal standard (ASSE
1070) and many local plumbing codes,
the water heater’s gas control valve
should not be used as the sole means
to regulate water temperature and
avoid scalds.
Properly adjusted Thermosta c Mixing
Valves installed at each point-of-use al-
low you to set the tank temperature to
a higher se ng without increasing risk
of scalds. A higher temperature se ng
allows the tank to provide much more
hot water and can help provide proper
water temperatures for appliances such
as dishwashers and washing machines.
Higher tank temperatures (140°F)
also kill bacteria that cause a condi-
on known as “smelly water” and can
reduce the levels of bacteria that cause
water-borne diseases.
Water Contamina on Risk
Do not use chemicals that could con-
taminate the potable water supply. Do
not use piping that has been treated
with chromates, boiler seal, or other
chemicals.
Fire Risk
This water heater is
equipped with a Flam-
mable Vapor Igni on
Resistance (FVIR) system.
FVIR is designed to reduce the risk of
fl ammable vapor-related fi res. FVIR
makes this product more sensi ve to
installa on errors or improper installa-
on environments. The FVIR system will
not prevent a possible fi re/explosion if
the igniter is depressed and fl ammable
vapors have accumulated in the combus-
on chamber with the pilot light off .
Do not a empt to light this appliance,
or depress the igniter bu on, if you
suspect fl ammable vapor have accumu-
lated inside or outside the appliance.
Immediately call a qualifi ed person to
inspect the appliance. Water heaters
subjected to a fl ammable vapors inci-
dent will show a discolora on on the
fl ame arrestor and require replacement
of the en re water heater. Improper
installa on or an inadequate air supply
can also cause the FVIR system to dis-
able the water heater.
WARNING! This water heater has a
rese able thermal switch installed as
part of the FVIR system. Do not
a empt to disable or modify this
feature in any way. Doing so can lead
to fi re, explosion or excessive and
abnormal produc on of carbon
monoxide.
To reduce the risk of a fi re that could
result in property damage, or serious
injury or death:
• Do not store things that can burn
easily such as paper or clothes next
to the water heater.
• Do not store or use gasoline or other
fl ammable substances in the vicinity
of this or any other appliance.
• Keep the water heater from becom-
ing wet. Immediately shut the water
heater off and have it inspected by a
qualifi ed person if you fi nd that the
wiring, thermostat(s) or surround-
ing insula on have been exposed
to water in any way (e.g., leaks from
plumbing, leaks from the water
heater itself can damage property
and could cause a fi re risk). If the
water heater is subjected to fl ood
condi ons or the thermostat(s) have
been submerged in water, the en re
water heater must be replaced.
• Replace the water heater’s viewport
if glass is missing or damaged. Repair
the combus on chamber door seals
if damaged.
Explosion Risk
High temperatures and
pressures in the water
heater tank can cause an explosion re-
sul ng in property damage, serious in-
jury or death. A new Temperature and
Pressure (T&P) Relief Valve is included
with your water heater to reduce risk
of explosion by discharging hot water.
Addi onal temperature and pressure
protec ve equipment may be required
by local codes.
A na onally recognized tes ng labo-
ratory maintains periodic inspec on
of the valve produc on process and
cer fi es that it meets the requirements
for Relief Valves for Hot Water Supply
Systems, ANSI Z21.22. The T&P Relief
Valve’s relief pressure must not exceed
the working pressure ra ng of the wa-
ter heater as stated on the ra ng plate.
Maintain the T&P Relief Valve properly.
Follow the maintenance instruc ons
provided by the manufacturer of the
T&P Relief Valve (label a ached to T&P
Relief Valve). An explosion could occur
6 • Residen al Standard Gas Water Heater Use and Care Guide
SAFETY
6 • Residen al Standard Gas Water Heater Use and Care Guide
IMPORTANT SAFETY INFORMATION
if the T&P Relief Valve or discharge
pipe is blocked. Do not cap or plug the
T&P Relief Valve or discharge pipe.
Fire and Explosion Risk if Hot Water is
Not Used for Two Weeks or More.
CAUTION! Hydrogen gas builds up
in a hot water system when it is not
used for a long period (two weeks or
more). Hydrogen gas is extremely
fl ammable. If the hot water system
has not been used for two weeks or
more, open a hot water faucet for
several minutes at the kitchen sink
before using any electrical appliances
connected to the hot water system. If
hydrogen is present there will
probably be an unusual sound such as
“air” escaping through the pipe as hot
water begins to fl ow. Do not smoke or
have an open fl ame or other igni on
source near the faucet while it is
open.
Carbon Monoxide Risk
WARNING! This water heater
operates by burning gas. Carbon
monoxide is a colorless, odorless, gas
that is a by-product of burning of fuels
such as coal, wood, charcoal, oil,
kerosene, propane, and natural gas.
Breathing excessive and abnormal
amounts of carbon monoxide can
cause carbon monoxide poisoning,
resul ng in serious injury or death.
This water heater must be supplied
with adequate combus on air and
must be properly
vented to the
outdoors. Have a
qualifi ed person
(licensed plumber,
authorized gas
company personnel, or authorized
service technician) install the ven ng
system using these installa on
instruc ons. When the installa on is
complete, check the vent’s dra using
the instruc ons on pages 23-24.
• Install a fuel gas and carbon mon-
oxide detector in the living areas
of your home.
• Do not install this water heater in
a mobile home or manufactured
housing.
• Failure to follow these instruc-
ons can result in serious injury
or death from carbon monoxide
poisoning.
Burn Risk
This water heater’s vent-
ing system can become
hot enough to burn. Do not touch the
ven ng system while water heater is
on, or un l the water heater is turned
off and the ven ng allowed to cool.
Installa on Accessories
Figure 1 - Gas Water Heater Hook-Up Kit
Figure 2 - Install a Pressure Reducing Valve set
to 50 to 60 PSI.
Residen al Standard Gas Water Heater Use and Care Guide • 7
GETTING STARTED
Residen al Standard Gas Water Heater Use and Care Guide • 7
GETTING STARTED
1
Review all of the instruc ons
before you begin work.
Improper installa on can
damage the water heater, your home
and other property, and can present
risks of serious injury or death.
2
This water heater is design-
cer fi ed by CSA Interna onal
as a Category I, non-direct
vented water heater which takes its
combus on air either from the installa-
on area or from air ducted to the unit
from the outside. This water heater
must be installed according to all local
and state codes or, in the absence of
local and state codes, the “Na onal
Fuel Gas Code”, ANSI Z223.1(NFPA
54)-current edi on. This is available
from the following:
CSA America, Inc.
8501 East Pleasant Valley Road
Cleveland, OH 44131
Na onal Fire Protec on Associa on
1 Ba erymarch Park
Quincy, MA 02269
Check with local code offi cials about
codes governing this installa on. Have
your installa on inspected by a code
offi cial to ensure the installa on meets
all local codes.
NOTICE: If you lack the necessary skills
required to properly install this water
heater, or you have diffi culty follow-
ing the instruc ons, you should not
proceed but have a qualifi ed person
perform the installa on of this water
heater.
Massachuse s code requires this water
heater to be installed in accordance
with Massachuse s 248-CMR 2.00 and
248-CMR 5.00: State Plumbing Code.
Other local and state authori es may
have similar requirements or other
codes applicable to the installa on of
this water heater.
3
Before you start, be sure you
have the following tools and
supplies:
• Common plumbing tools (depend-
ing on what type of water pipes
you have).
• Tefl on® tape or pipe joint com-
pound approved for potable water.
• For homes with copper pipes, you
may purchase a Gas Water Heater
Hook-Up Kit (available at your local
plumbing supplier ) with compres-
sion fi ngs that don’t require
soldering. This kit includes two 12”
fl ex water lines, two compression
fi ngs, an 18” fl exible gas line, two
nipples, and Tefl on® tape.
• For homes with plas c pipe, use
threaded connectors suitable for
the specifi c type of plas c pipe
used: CPVC or PEX (cross-linked
polyethylene). Do not use PVC
pipe.
• Non-corrosive gas leak detec on
solu on made from hand dish-
washing soap mixed with water (1
part soap to 15 parts water) or chil-
dren’s soap bubbles and a small,
so -bristled brush.
• An appliance dolly or hand truck to
move the water heater.
Recommended Accessories:
• A metal drain pan.
• Automa c water leak detec on
and shut-off device.
• Pressure Reducing Valve.
• Thermal Expansion Tank.
• Thermosta c Mixing Valves at each
point-of-use.
• Fuel gas and carbon monoxide
detector.
Combus on and
Ven la on Air Supply
Before installing the water heater, you
must determine the amount of air
needed to supply this water heater
and any other gas appliances in the
same area and provide adequate air for
combus on and ven la on. Consult a
qualifi ed person if you’re unsure of the
proper way to supply air to your water
heater.
WARNING! This gas water heater
requires an adequate source of clean
air for combus on and ven la on.
Without suffi cient air, your water
heater will have frequent pilot outages
and may emit excessive and abnormal
amounts of carbon monoxide.
Before beginning:
Calculate total BTU/HR ra ng of all ap-
pliances.
To calculate the combus on air and
ven la on required, add up the total
BTU/HR ra ngs of all gas burning ap-
pliances (e.g., water heaters, furnaces,
clothes dryers) in the same area.
Your water heater’s BTU/HR ra ng is on
the data plate, located next to the gas
control valve/thermostat. The BTU/HR
ra ngs should be on the other appli-
ances’ data plates. If you have trouble
determining the BTU/HR ra ngs,
contact the manufacturer or have a
qualifi ed person determine the ven la-
on requirements. NOTICE: If you are
replacing your old water heater with
one that has a higher BTU/HR ra ng,
the amount of ven la on required may
be greater.
8 • Residen al Standard Gas Water Heater Use and Care Guide
GETTING STARTED
8 • Residen al Standard Gas Water Heater Use and Care Guide
GETTING STARTED
Example:
Gas Burning Appliance BTU/HR Ra ng
Gas Water Heater 40,000
Furnace 75,000
Dryer 20,000
Total 135,000
Your Appliances:
Gas Burning Appliance BTU/HR Ra ng
Gas Water Heater
Total
Table 2 provides examples of minimum
square footage (area) required for
various BTU/HR totals. Areas used for
storage or which contain large objects
containing less air than is assumed for
the room sizes in Table 2 – see Op on
A for more specifi c calcula ons.
Op on A: Installa on without
outside ven la on (not recom-
mended)
Ven la on with outside air is recom-
mended for all installa ons. Even if
the water heater is installed in a large,
open room inside the house, outdoor
air is usually needed because modern
homes are very ghtly sealed and
o en do not supply enough air to the
water heater. However, when installed
in a large indoor space, it may be pos-
sible to provide enough air without
outside ven la on. If you are unsure if
your installa on loca on has enough
ven la on, contact your local gas
u lity company or code offi cials for a
safety inspec on.
The following instruc ons will help de-
termine if it may be possible to install
without outside ven la on. Even if
this may be possible, you will need to
conduct the vent dra test on pages
23-24 when installa on is fi nished. If
there is not enough ven la on, you
will need to ven late with outside air.
Check for Chemicals:
Installa ons where corrosive chemi-
cals may be present require outside
air. Air for combus on and ven la on
must be clean and free of corrosive or
acid-forming chemicals such as sulfur,
fl uorine, and chlorine. Ven la on with
outside air will reduce these chemicals,
but it may not completely eliminate
them. Failure due to corrosive chemi-
cals is not covered by the warranty.
Examples of loca ons that require
outside air due to chemicals include:
• Beauty salons
• Photo processing labs
• Indoor pools
• Laundry, hobby, or cra rooms
• Chemical storage areas
Products such as aerosol sprays, de-
tergents, bleaches, cleaning solvents,
gasoline, air fresheners, paint and
varnish removers, and refrigerants
should not be stored or used near the
water heater.
A1: Calculate the air volume of
the room
Air requirements depend on the size of
the room.
Floor Area (Square feet) X Ceiling
Height (feet) = Room Volume (cubic
feet)
If there are large objects in the room
(e.g., refrigerator, furnace, car), sub-
tract their volume from the volume of
the room to get a be er es mate of
the air available.
Room Volume – Object Volume = Air
Volume
Table 2
BTU/HR Minimum Square Typical Room
Input Feet with 8’ Ceiling with 8’ Ceiling
30,000 188 9 x 21
45,000 281 14 x 20
60,000 375 15 x 25
75,000 469 15 x 31
90,000 563 20 x 28
105,000 657 20 x 33
120,000 750 25 x 30
135,000 844 28 x 30
Residen al Standard Gas Water Heater Use and Care Guide • 9
GETTING STARTED
Residen al Standard Gas Water Heater Use and Care Guide • 9
GETTING STARTED
A2: Calculate required air volume
A water heater installed in an unconfi ned
a c or garage requires that the space
be at least 50 cubic feet per 1,000 BTU/
HR of the total input for all gas burning
appliances in the same area.
[Total BTU/HR/1000] x 50 = Cubic feet
of air required.
Example:
(135,000 / 1000) x 50 = 6,750
If the air volume of the room is less
than the required air volume, you must
provide two permanent outside air
openings that draw in suffi cient air. Use
Op on B.
If the air volume of the room is greater
than the required air volume, it may
be possible to install the water heater
without outside ven la on.
A3: Check that combus on ven-
la on is adequate
Because modern homes are o en well-
sealed to prevent dra s, even a large
room may not provide enough combus-
on air without ven la on. To con-
fi rm that your installa on has enough
combus on air, conduct the vent dra
test on pages 23-24 when installa on is
fi nished.
Op on B: Install with outside
ven la on
Ven la on with outside air is recom-
mended, and, for most installa ons, is
needed. There may be exis ng ven la-
on that is adequate, or you may need
to add more ven la on.
Supplying outside air to typically requires
two openings. One opening must be
within 12 inches from the fl oor and
the second opening must be within 12
inches from the ceiling. Although a single
opening is not preferred, you may use a
single opening to outside air if the mini-
mum free area is sized according to Table
3. Two openings must be used when
ven la ng with air from another room.
The outside air can be taken from a
crawl space or a c open to the out-
doors and adequately ven lated. You
may use ver cal or horizontal ducts.
B2: Determine type of ven la-
on
There are several types of ven la on
that can be used :
1. Direct to outdoors
2. Ver cal ducts
3. Horizontal ducts
4. Single opening (not recom-
mended; must be at least 100
square inches. Not appropriate
for confi ned spaces smaller than
50 cubic feet per 1,000 BTU/HR as
calculated in sec on A or when
ge ng air from another room.)
5. From a larger room inside the
house (not recommended – refer
to sec on A above to determine if
the combined volume of the rooms
may be adequate).
B3: Determine minimum free
area required for each vent
opening
The size of the vent openings depends
on the total BTU/HR ra ng of all appli-
ances in the space (use your calcula on
from “Before beginning”) and the type
of vent used. Table 3 provides the mini-
mum free area for each vent opening
depending on the type of ven la on.
B4: Calculate minimum size of
vent openings and ducts
The vent cross-sec onal area needed to
provide the free area depends on the
covering on the vent openings. Typical
vents use louvers or grilles to protect
the opening. The louver or grill itself
blocks some of the free area, so the
opening may need to be larger to meet
the minimum free area requirements.
Use the following formula to calculate
the required cross-sec onal area:
Cross-sec onal area = minimum free
area required ÷ percent free area of
Table 3
Minimum Free Area of Permanent Openings for Ven la on and Combus on Air
Supply – All Air from Outdoors Only.
Based on the total BTU/HR input ra ng for all gas burning appliances within a
confi ned space.
Opening Source Minimum Free Area
Per Opening (sq. in.)
*Direct to outdoors 1 sq. in. per 4,000 BTU/HR (see fi gure on page 10)
Ver cal ducts 1 sq. in. per 4,000 BTU/HR (see fi gure on page 10)
Horizontal ducts 1 sq. in. per 2,000 BTU/HR (see fi gure on page 10)
Single Opening 1 sq. in. per 3,000 BTU/HR (see fi gure on page 10)
*These openings connect directly with the outdoors through a ven lated a c, a
ven lated crawl space, or through an outside wall.
10 • Residen al Standard Gas Water Heater Use and Care Guide
GETTING STARTED
10 • Residen al Standard Gas Water Heater Use and Care Guide
GETTING STARTED
covering (in decimals – e.g., 60% = .6)
For example, an installa on area that
requires openings with 100 square
inches of free area would need 134
square inch openings if using metal
louvers rated at 75% free area (100 sq.
in. ÷ .75 = 134 sq. in.).
If you do not know the % free area for
your louver or grill, use the following
values:
• For wood louvers or grilles: 20%
• For metal louvers or grilles: 60%
Follow these rules to ensure that vents
and ducts provide adequate air fl ow:
• Each vent opening must be no
smaller than 100 square inches .
• Ducts must have the same cross-
sec onal area as free area of the
opening.
• Rectangular ducts must have a
minimum dimension of no less
than three inches .
• All screens must have mesh ¼” or
larger.
• Moveable louvers must be locked
open or interconnected with the
equipment so that they open au-
toma cally during opera on.
• Keep louvers and grills clean and
free of debris or other obstruc-
ons.
B5: Check that air source is
clean and free of chemicals
Air for combus on and ven la on
must be clean and free of corrosive
or fl ammable chemicals. A failure due
to corrosive chemicals in the air is not
covered by the warranty. Combus-
on air must be free of acid-forming
chemicals such as sulfur, fl uorine, and
chlorine. Be sure that air at the vent
inlets is free of such chemicals.
B6: Check that combus on
ven la on is adequate
To confi rm that your installa on has
enough combus on air, conduct the
vent dra test on pages 23-24 when
installa on is fi nished.
Combus on Air Supply Op ons
Figure 3 - Direct to outdoors openings
Figure 4 - Vertical duct openings
Figure 5 - Horizontal duct openings
Figure 6 - Single opening
Residen al Standard Gas Water Heater Use and Care Guide • 11
GETTING STARTED
Residen al Standard Gas Water Heater Use and Care Guide • 11
GETTING STARTED
Ven ng
WARNING! Carbon Monoxide
Hazard. This water heater must be
supplied with adequate air and vented
to outdoors. The vent system must be
installed by a qualifi ed person.
Examples of a qualifi ed person include
gas technicians, authorized gas
company personnel, and authorized
service technicians. Failure to properly
vent the water heater can result in
severe injury or death from carbon
monoxide poisoning.
The vent system must be installed
according to local and state codes, or
in the absence of local or state codes,
the current edi on of the Na onal Fuel
Gas Code, ANSI Z223.1 (NFPA 54). Do
not common vent this water heater
with any power vented appliance. Do
not use a vent damper anywhere in the
vent system of this water heater.
To reduce the risk of carbon monoxide
poisoning, install a fuel gas and carbon
monoxide detector. Install and maintain
the detector in accordance with the
manufacturer’s instruc ons and local
codes.
Replacing a Water Heater Using
the Exis ng Vent System
Read the “Installing a New Vent Sys-
tem” sec on of this manual and make
sure your vent system is properly in-
stalled. Inspect the exis ng vent system
for obstruc ons, corrosion, and proper
installa on. Repair or replace if neces-
sary. The exis ng vent system must be
UL listed Type B double wall or single
wall metal vent pipe of either 3 inch or
4 inch diameter and installed according
to the vent manufacturer’s instruc ons
and the terms of its lis ng. Do not use
other materials such as dryer vent hose.
Installing a New Vent System
The vent pipe must meet the following
specifi ca ons:
Type of Material
UL listed Type B double wall or single
wall metal vent pipe must be used.
Local codes may be more restric ve
and may not allow single wall vent pipe.
Single-wall vent pipe cannot be used for
water heaters located in a cs and may
not pass through a c spaces, crawl
spaces, or any confi ned or inaccessible
loca on. Single-wall vent pipe cannot
pass through any interior wall.
Clearance to Combus ble Materials
The vent pipe cannot pass through any
ceiling, fl oor, fi rewall, or fi re par on.
Any part of the vent system must main-
tain the following clearances from any
combus ble materials:
• Single-wall vent pipe must main-
tain a six inch clearance from
combus ble materials.
• The clearance from combus ble
materials of UL listed Type B dou-
ble-wall vent pipe is specifi ed by
the manufacturer of the vent pipe.
UL listed Type B double-wall vent
pipe may pass through walls or par-
ons constructed of combus ble
material if the minimum clearance
specifi ed by the manufacturer of
the vent pipe is maintained.
Vent Installa on
To improve the fl ow of exhaust gases,
we recommend that a minimum of 12
inches of ver cal vent pipe be installed
on the dra hood prior to any elbow.
A por on of the vent pipe (up to 75%
of the total ver cal height) can be
horizontal, but the termina on must
be ver cal. For the horizontal sec on,
install without dips or sags with an
upward slope of at least ¼ inch per
foot. Install pipe avoiding unnecessary
bends. Pipe joints must be fastened by
sheet metal screws or other approved
means. Support the pipe to maintain
clearances and to avoid separa on of
joints or other damage. Vent pipe must
be accessible for cleaning, inspec on,
and replacement.
Termina ons
If local codes allow, this water heater
may be terminated into an exis ng
chimney using the instruc
ons below.
Otherwise, this water heater’s vent
must terminate ver cally (sidewall or
other horizontal termina ons are not
allowed).
Chimney Termina on
Figure 7 - Chimney termination vent system
NOTICE: Before connec ng a vent to
a chimney, make sure the chimney
passageway is clear and free of obstruc-
ons. The chimney must be cleaned if
previously used for ven ng solid fuel
appliances or fi replaces. Also consult lo-
cal and state codes for proper chimney
sizing and applica on or, in the absence
of local and state codes, the “Na onal
Fuel Gas Code”, ANSI Z223.1(NFPA
54)-current edi on.
• The vent pipe must be installed
above the extreme bo om of the
chimney to prevent poten ally
blocking the fl ue gases.
12 • Residen al Standard Gas Water Heater Use and Care Guide
GETTING STARTED
12 • Residen al Standard Gas Water Heater Use and Care Guide
GETTING STARTED
• The vent pipe must be fi rmly at-
tached and sealed to prevent it
from falling out.
• To aid in removing the vent pipe, a
thimble or slip joint may be used.
• The vent pipe must not extend
beyond the inner edge of the
chimney as it may restrict the
space between it and the opposite
wall of the chimney.
Do not terminate the vent pipe in a
chimney that has not been cer fi ed
for this purpose. Some local codes may
prohibit the termina on of vent con-
nectors in a masonry chimney.
Common (combined) ven ng is allow-
able with ver cal Type B vent systems
and lined masonry chimneys as long
as proper dra for the water heater
is established under all condi ons of
opera on. Do not common vent this
water heater with any power vented
appliance.
Ver cal Termina on
NOTICE: The gas vent must be termi-
nated in a ver cal posi on to facilitate
the removal of exhaust gases.
Ver cal exhaust vents must terminate
with a listed cap or other roof assem-
bly and be installed according to their
manufacturer’s instruc ons. An unused
chimney fl ue or masonry enclosure
may be used as a passageway for the
installa on of vent pipe. Do not com-
mon vent this water heater with any
power vented appliance. The follow-
ing fi gures are examples of vent pipe
system installa ons and may or may
not be suitable for your specifi c appli-
ca on. Consult the “Na onal Fuel Gas
Code”, NFPA 54, ANSI Z223.1-current
edi on and local codes.
Figure 8 - Vertical gas vent system with type B
double wall vent pipe
Figure 9 - Venting through a chimney with type
B double wall vent pipe
Gas Piping
Gas piping must be installed accord-
ing to local and state codes or, in the
absence of local and state codes,
the “Na onal Fuel Gas Code”, ANSI
Z223.1(NFPA 54)-current edi on.
NOTICE: When installing gas piping,
apply pipe joint compound or Tefl on®
tape approved for fuel gases.
Figure 10 - Gas Piping
1. Install a readily accessible manual
shut-off valve in the gas supply line
as recommended by the local u l-
ity. Know the loca on of this valve
and how to turn off the gas to this
unit.
2. Install a Sediment Trap as shown
in the Gas Piping fi gure below. The
Sediment Trap must be no less than
three inches long for the accumula-
on of dirt, foreign material, and
water droplets.
3. Install a ground joint union be-
tween the gas control valve and
the manual gas shut-off valve. This
is to allow easy removal of the gas
control valve.
4. Turn the gas supply on and check
for leaks. Use a small, so -bristled
brush to apply a hand dishwash-
ing soap and water mixture (1
part soap to 15 parts water) or
children’s soap bubbles to all con-
nec on points of the gas piping.
Saturate all the connec ons and
check for gas leaks (which will ap-
pear as small bubbles). If any leaks
are detected, ghten the appropri-
ate connec on(s) and re-check.
Gas Pressure
NOTICE: When tes ng gas pipes with
a test pressure of more than ½ psi (3.5
kPa), disconnect the gas line at the
manual shut off valve and cap the gas
line. Do not subject the water heater’s
gas control valve or manual shut off
valve to more than ½ psi (3.5 kPa)
pressure for any reason. If you are
pressure tes ng the gas line with test
pressure of ½ psi (3.5 kPa) or less, you
may isolate the water heater from the
gas line by closing the manual shut off
valve.
Residen al Standard Gas Water Heater Use and Care Guide • 13
GETTING STARTED
Residen al Standard Gas Water Heater Use and Care Guide • 13
GETTING STARTED
Space Hea ng
Some water heater models are equipped
with inlet/outlet connec ons for use with
space hea ng applica ons. If this water
heater is to be used to supply both space
hea ng and domes c potable (drinking)
water, the instruc ons listed below must
be followed.
• This water heater is suitable for
combina on water (potable) hea ng
and space hea ng and not suitable for
space hea ng applica ons only.
• Be sure to follow the manual(s)
shipped with the air handler system.
• This water heater is not to be used as
a replacement for an exis ng boiler
installa on.
• Do not use with piping that has been
treated with chromates, boiler seal or
other chemicals and do not add any
chemicals to the water heater piping.
• If the space hea ng system requires
water temperatures in excess of 120°F,
install a Thermosta c Mixing Valve
in the domes c (potable) hot water
supply at each point-of-use to limit the
risk of scald injury. Install the mixing
valve per its manufacturer’s instruc-
ons.
• Pumps, valves, piping, and fi ngs
must be compa ble with potable
water.
• A properly installed fl ow control valve
is required to prevent thermosiphon-
ing. Thermosiphoning is the result of a
con nuous fl ow of water through the
air handler circuit during the off cycle.
• The domes c hot water line from the
water heater should be ver cal past
any mixing valve or supply line to the
air handler to remove air bubbles from
the system. Otherwise, these bubbles
will be trapped in the air handler heat
exchanger coil, reducing effi ciency.
• Do not connect the water heater to
any system or components previously
used with non-potable water heat-
ing appliances when used to supply
potable water.
Solar Installa on
If this water heater is used as a solar stor-
age heater or as a backup for the solar
system, the water supply temperatures
to the water heater tank may be in excess
of 120°F. A Thermosta c Mixing Valve or
other temperature limi ng valve must be
installed in the water supply line to limit
the supply temperature to 120°F. The unit
must be set to Standard Mode (See Operat-
ing Modes in Opera on sec on on page
24).
NOTICE: Solar water hea ng systems can
o en supply water with temperatures
exceeding 180°F and may result in water
heater malfunc on.
Figure 11 - Combustion Space Heating and Potable Water (Typical Installation)
IN
REMOVE A
MUST BE VERTICAL TO
IR BUBBLES
E
OUT
COIL
AIR
HANDLER
TO
AIR
HANDLER
SHUT-OFF
VALVE
*
EXPANSION TANK
VACUUM
RELIEF
VALVE
COLD WATER INLET
VA
FLOW CONTROL
LV
PUMP
*
SHUT-OFF
CHECK VALVE
†
(1/8” HOLE
DRILLED IN CLAPPER)
VALVE
CHECK
VALVE
†
TEMP/
PRESSURE
RELIEF
VALVE
TEMPERED WATER
TO FIXTURES
(MUST MEET TEMPS LISTED
IN MASS. CODE 248 CMR
†
)
MIXING VALVE
(MUST BE INSTALLED BELOW
TOP OF WATER HEATER
AS PER MANUFACTURER’S
RECOMMENDATIONS)
UNION
UNION
HOT
WATER
OUT
*
MASSACHUSETTS INSTALLATION REQUIREMENTS:
1.) CONNECT ELECTRONICALLY-CONTROLLED TIMER TO AN ALL-BRONZE PUMP. PUMP MUST ACTIVATE EVERY 6 HOURS
FOR 60 SECONDS. TURN PUMP TIMER OFF BEFORE CLOSING PIPING LOOP SHUT-OFF VALVE.
2.) ALL WATER PIPING MUST BE INSTALLED AND INSULATED IN ACCORDANCE WITH MASSACHUSETTS CODE (248 CMR
& 780 CMR).
3.) PIPING LOOP BETWEEN WATER HEATER AND AIR HANDLER MUST BE INSTALLED IN COMPLIANCE WITH 248 CMR.
† REQUIRED FOR MASSACHUSETTS.
‡ PIPING FROM THE TOP OF THE WATER HEATER WITH TEES IS ACCEPTABLE.
WATER HEATER ACCEPTED
BY THE BOARD FOR
INSTALLATION IN
MASSACHUSETTS.
†
TYPICAL MIXING VALVE INSTALLATION
COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM
SEE
NOTE ‡
100’-0” MAXIMUM DISTANCE
FROM WATER HEATER
TO FAN COIL AND BACK
(DEVELOPED LENGTH) NOT
INCLUDING COIL IN HEATING UNIT.
†
14 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
14 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
Step 1:
✓
Verify that your
home is equipped
and up-to-date for
proper opera on
Installing a new water heater is the
perfect me to examine your home’s
plumbing system and make sure the
system is up to current code stan-
dards. There have likely been plumb-
ing code changes since the old water
heater was installed. We recommend
installing the following accessories
and any other needed changes to
bring your home up to the latest code
requirements. Upda ng your plumb-
ing system can help extend the life of
your water heater, avoid damage to
your home and property, and reduce
the risk of serious injuries or death.
Inspect your home and install any de-
vices you need to comply with current
codes and assure that your new water
heater performs at its best. Check
with your local plumbing offi cial for
more informa on.
✓
Water pressure
Most codes allow a maximum
incoming water pressure of 80 psi
(we recommend a working pressure
no higher than 50-60 psi). Check your
home’s water pressure with a pressure
gauge and adjust if necessary. High
water pressure can damage the water
heater, piping, and other appliances.
HOW: Purchase an inexpensive water
pressure gauge at your local plumbing
supplier. Connect the water pressure
gauge to an outside faucet and mea-
sure the maximum water pressure
experienced throughout a 24-hour
period (highest water pressures o en
occur at night).
Figure 12 - Use a Water Pressure Gauge to make
sure your home’s water pressure is not too
high.
To adjust your home’s water pressure:
Locate your home’s Pressure Reduc-
ing Valve (PRV) on the main incoming
(cold) water supply line and adjust the
water pressure control to between
50 and 60 psi. If your home does not
have a Pressure Reducing Valve, install
a PRV on the home’s main water
supply line and set it to between 50
and 60 psi. Pressure Reducing Valves
are available at your local plumbing
supplier.
BACKGROUND: Over the years,
many u li es have increased water
supply pressures so they can serve
more homes. In some homes today,
pressures can exceed 100 psi. High
water pressures can damage water
heaters, causing premature leaks. If
you have replaced toilet valves, had
a water heater leak, or had to repair
appliances connected to the plumb-
ing system, pay par cular a en on
to your home’s water pressure. When
purchasing a PRV, make sure the PRV
has a built-in bypass.
✓
Water pressure
increase caused
by thermal expansion
Verify that you have a properly sized
Thermal Expansion Tank. We recom-
mend installing an expansion tank if
your home does not have one. Plumb-
ing codes require a properly pressur-
ized, properly sized Thermal Expan-
sion Tank in almost all homes.
Figure 13 - A Thermal Expansion Tank helps
protect the home’s plumbing system from pres-
sure spikes.
HOW: Connect the Thermal Expan-
sion Tank (available at most hardware
stores.) to the cold water supply line
near the water heater. The expansion
tank contains a bladder and an air
charge. To work properly, the Thermal
Expansion Tank must be sized accord-
ing to the water heater’s tank capacity
and pressurized to match the home’s
incoming water pressure. Refer to
the instruc ons provided with the
Thermal Expansion Tank for installa-
on details.
BACKGROUND: Water expands when
heated, and the increased volume
of water must have a place to go, or
thermal expansion will cause large
Residen al Standard Gas Water Heater Use and Care Guide • 15
INSTALLATION
Residen al Standard Gas Water Heater Use and Care Guide • 15
INSTALLATION
increases in water pressure (despite
the use of a Pressure Reducing Valve
in the home’s main water supply line).
The Safe Drinking Water Act of 1974
requires the use of backfl ow preven-
ters and check valves to restrict water
from your home reentering the public
water system. Backfl ow preventers are
o en installed in water meters and
may not be readily visible. As a result,
most all plumbing systems today are
now “closed,” and almost all homes
now need a Thermal Expansion Tank.
A Thermal Expansion Tank is a prac -
cal and inexpensive way to help avoid
damage to the water heater, washing
machine, dishwasher, ice maker, and
even toilet valves. If your toilet oc-
casionally runs for no apparent reason
(usually briefl y at night), that may be
due to thermal expansion increasing
the water pressure temporarily.
✓
Water Pipe and
Tank Leaks
Figure 14 - A metal drain pan piped to an ad-
equate drain can help protect flooring from leaks
and drips.
Leaks from plumbing pipes or from the
water heater itself can damage prop-
erty and could cause a fi re risk.
• Install an automa c leak detec-
on and shutoff device (available at
your local plumbing supplier ). These
devices can detect water leaks and
can shut off the water heater’s water
supply if a leak occurs.
• Install a metal drain pan (available at
your local plumbing supplier) under
the water heater to catch condensa-
on or leaks from the piping connec-
ons or tank. Most codes require,
and we recommend, installing the
water heater in a metal drain pan
that is piped to an adequate drain.
The drain pan must be at least two
inches wider than the diameter of
the water heater. Install the drain
pan so the water level would be lim-
ited to a maximum depth of 1-3/4”.
The pan must not restrict air fl ow to
the burner.
✓
Water Tempera-
ture Regula on
Install Thermosta c Mixing Valves to
regulate the temperature of the water
supplied to each point-of-use (for
example, kitchen sink, bathroom sink,
bath, shower). Install and adjust the
mixing valve according to its manufac-
turer’s instruc ons.
WARNING! Even if the water
heater’s thermostat is set to a rela-
vely low temperature, hot water can
scald. Install Thermosta c Mixing
Valves at each point-of-use to reduce
the risk of scalding.
Figure 15 - Thermostatic Mixing Valves installed
at each point-of-use can help avoid scalding
BACKGROUND: A Thermosta c Mixing
Valve, installed at each point-of-use,
mixes hot water from the water heater
with cold water to more precisely
regulate the temperature of hot water
supplied to fi xtures. If you aren’t sure
if your plumbing system is equipped
with properly installed and adjusted
Thermosta c Mixing Valves at each
point where hot water is used, contact
a qualifi ed person.
16 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
16 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
Step 2:
Verify that the loca on
is appropriate
WARNING! Do not store or use
fl ammable materials, vapors, or
liquids in the same loca on where this
water heater is installed.
Before installing your water heater,
ensure that it will be located:
• Indoors in an area with adequate
air supply.
• In an area that will not freeze.
• As close as possible to a chimney
or vent.
• In a metal drain pan piped to an
adequate drain.
• In an area suitable for ver cal
installa on.
• In an area with adequate space
(clearances) for periodic servicing
(there must be a minimum of 24
inches of front clearance).
• In an area that allows a minimum
clearance from combus ble sur-
faces as stated on the data plate.
• On a fl oor that can support the
weight of a water heater full of
water.
You will also want to follow these
guidelines while considering an appro-
priate loca on:
• Do not install near air-moving
devices such as exhaust fans,
ven la on systems, or clothes
dryers.
• Do not obtain ven la ng air for
the furnace/air handler from the
same space as the water heater.
Ensure that any return air ducts
near the water heater are sealed.
• If the water heater is located
in an area subject to lint, dust,
or oily vapors, at least annually
check and clean the air fi lter. See
Maintenance sec on for steps on
cleaning the air fi lter.
• Do not install in a bathroom,
bedroom, or any occupied room
normally kept closed.
• If the water heater is installed di-
rectly on carpe ng, it shall be in-
stalled on a metal or wood panel
extending beyond the full width
and depth of the water heater
by at least 3 in (76.2mm) in any
direc on. If the water heater is
installed in an alcove or closet,
the en re fl oor shall be covered
by the aforestated panel.
• If your area is prone to earth-
quakes, use special straps as
required by local building codes.
NOTICE: The state of California re-
quires bracing, anchoring, or strap-
ping the water heater to avoid its
moving during an earthquake. Contact
local u li es for code requirements in
your area, visit h p://www.dsa.dgs.
ca.gov, or call 1-916-445-8100 and
request instruc ons. Other loca ons
may have similar requirements. Check
with your local and state authori es.
• Do not install in a loca on prone
to physical damage by vehicles,
fl ooding, or other risks.
Vehicle
Stop
Drain
Drain
Pan
Figure 16 - In a garage, install a vehicle stop to
avoid water heater damage.
• Avoid loca ons such as a cs, up-
per fl oors, or where a leak might
damage the structure or furnish-
ings. Due to the normal corrosive
ac on of water, the tank will
eventually leak. To minimize prop-
erty damage from leaks, inspect
and maintain your water heater
in accordance with this manual’s
instruc ons. Install a metal drain
pan under the water heater piped
to an adequate drain. Inspect the
drain pan, pipes, and surrounding
area regularly and fi x any leaks
found.
Step 3:
Removing the old
water heater
1
Read each installa on step and
decide if you have the neces-
sary skills to install the water
heater. Only proceed if you are comfort-
able you can safely perform the work. If
you are not sure, have a qualifi ed person
perform the installa on.
Residen al Standard Gas Water Heater Use and Care Guide • 17
INSTALLATION
Residen al Standard Gas Water Heater Use and Care Guide • 17
INSTALLATION
2
On the old water heater, turn
the control knob on the gas
control valve to the
OFF posi on.
Gas
control
knob
Figure 17 - Turn gas control/temperature knob OFF.
3
Turn the manual gas valve for
the water heater’s supply line
OFF.
4
Open a hot water faucet and
let the hot water run un l it is
cool (This may take 10 min
utes or longer).
Figure 18 - Let the hot water run until it is cool.
WARNING! Be sure the water runs
cool before draining the tank to reduce
the risk of scalding.
5
Connect a garden hose to the
drain valve and place the
other end of the hose in a
drain, outside, or in buckets. (Sedi-
ment in the bo om of the tank may
clog the valve and prevent it from
draining. If you can’t get the tank to
drain, contact a qualifi ed person.)
6
Turn the cold water supply
valve OFF.
Figure 19 - Cold water supply in off position.
7
Using a standard fl at-blade
screwdriver, open the drain
valve. Sediment build up in
the bo om of the water heater may
hinder or prevent draining.
Figure 20 - Draining the old water heater.
8
Also open a hot water faucet
to help the water in the tank
drain faster.
9
When the tank is empty,
disconnect the Temperature &
Pressure (T&P) Relief Valve
discharge pipe. You may be able to
reuse the discharge pipe, but do not
reuse the old T&P Relief Valve. A new
T&P Relief Valve comes with your new
water heater.
Figure 21 - Removing the T&P Relief Valve
discharge pipe.
10
Allow the vent pipe and dra
hood to cool. Once cooled,
disconnect the vent pipe from
the dra hood. You may need to
support the vent pipe un l the new
water heater is in place.
Figure 22 - Disconnect the vent pipe from the
draft hood.
11
Disconnect the water pipes.
Many water pipes are con-
nected by a threaded union
which can be disconnected with
wrenches. If you must cut the water
pipes, cut the pipes close to the water
heater’s inlet and outlet connec ons,
leaving the water pipes as long as
possible. If necessary, you can make
them shorter later when you install the
new water heater.
12
Confi rm the manual gas valve
for the water heater’s supply
18 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
18 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
line is turned off . Disconnect the gas
line from the water heater’s gas
control valve and cap it.
13
Remove the old water heater.
Use an appliance dolly or
hand truck to move the water
heater.
WARNING! Use two or more
people to remove or install a water
heater. Failure to do so can result in
back or other injury.
Step 4:
Installing the New
Water Heater
1
Completely read all instruc-
ons before beginning. If you
are not sure you can safely
complete the installa on, seek assis-
tance from any of the following sources:
• Schedule an appointment with
a qualifi ed person to install your
water heater.
• Call our Technical Assistance Hotline
at 1-800-527-1953 .
2
Install a metal drain pan that
is piped to an adequate drain.
Figure 23 - Metal drain pan piped to drain.
3
Set the water heater in place
taking care not to damage the
drain pan. When installing
directly on carpet, the water heater
must be installed on a wood or metal
base that extends beyond the dimen-
sions of the water heater (width and
depth) by at least 3 inches (76.2 mm)
in any direc on. If the water heater is
installed on carpet in an alcove or
closet, the en re fl oor must be covered
by a wood or metal panel.
NOTICE: Most codes require se ng
the water heater in a metal drain pan
piped to an adequate drain. The drain
pan helps avoid property damage
which may occur from condensa on
or leaks in the piping connec ons or
tank. The drain pan must be at least
two inches wider than the diameter
of the water heater. Install the drain
pan so the water level is limited to a
maximum depth of 1-3/4”.
4
Verify that the water heater is
set in place properly. Check
that:
• There is adequate space to install
the T&P Relief Valve discharge
pipe and that it can be piped to a
separate drain (and not into the
drain pan).
• There is adequate access and
space around the water heater
for future maintenance.
The water heater is installed ver cally.
Step 5:
Air Filter
This water heater is equipped with a
base-ring air filter. Before proceeding
to the next step, visually check the
filter to ensure it is properly seated
in the base-ring. Do not operate the
water heater without the a clean air
filter in place.
Figure 24 - Filter attached to water heater.
Residen al Standard Gas Water Heater Use and Care Guide • 19
INSTALLATION
Residen al Standard Gas Water Heater Use and Care Guide • 19
INSTALLATION
Step 6:
Connect the Tempera-
ture and Pressure (T&P)
Relief Valve/Pipe
Most T&P Relief Valves are pre-
installed at the factory. In some cases,
they are shipped in the carton and
must be installed in the opening
marked “T&P Relief Valve” and accord-
ing to local codes.
Figure 25 - Temperature and Pressure Relief Valve
WARNING! To avoid serious injury
or death from explosion, install a T&P
Relief Valve according to the following
instruc ons:
1
If the T&P Relief Valve was not
factory installed, install the
new T&P Relief Valve that
came with your water heater. Do not
reuse an old T&P Relief Valve.
• The discharge pipe should be at
least 3/4” inside diameter and
sloped for proper drainage. Install
it to allow complete drainage of
both the T&P Relief Valve and the
discharge pipe.
Figure 26 - Temperature and Pressure Relief
Valve Pipe
• The discharge pipe must not be
smaller than the pipe size of the
T&P Relief Valve. The pipe must
also be able to withstand 250°F
(121°C) without distor on. Use
only copper or CPVC pipe. Do not
use any other type of pipe, such as
PVC, iron, fl exible plas c pipe, or
any type of hose.
• Terminate the discharge pipe a
maximum of six inches above a
fl oor drain or outside the building.
Do not drain the discharge pipe
into the drain pan; instead pipe it
separately to an adequate drain.
In cold climates, terminate the dis-
charge pipe inside the building to
an adequate drain. Outside drains
could freeze and obstruct the
drain line—protect the discharge
pipe from freezing.
• Do not place any valve or other
restric on between the tank and
T&P Relief Valve. Do not cap,
block, plug, or insert any valve
between the T&P Relief Valve and
the end of the discharge pipe. Do
not insert or install any reducer in
the discharge pipe.
Step 7:
Install Shutoff and Ther-
mosta c Mixing Valves
1
If one is not already installed,
install a manual shutoff valve
in the cold water line that
supplies the water heater. Install the
shutoff valve near the water heater so
that it is readily accessible. Only use a
full-fl ow ball or gate valve compa ble
with potable water.
2
Install a Thermosta c Mixing
Valve at each point-of-use (for
example, kitchen sink,
bathroom sink, bath, shower) per the
valve manufacturer’s instruc ons.
Figure 27 - Install Thermostatic Mixing Valves at
each point where hot water will be used.
WARNING! Even if the water
heater’s thermostat is set to a rela-
vely low temperature, hot water can
scald. Install Thermosta c Mixing
Valves at each point-of-use to reduce
the risk of scalding.
20 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
20 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
3
For water heaters that are fed
by a solar water hea ng
system (or any other pre-
hea ng system), always install a
Thermosta c Mixing Valve or other
temperature limi ng device in the
inlet water supply line to limit water
supply inlet temperature to 120°F.
Solar water hea ng systems can
supply water with temperatures
exceeding 180°F and may result in
water heater malfunc on.
WARNING! Hot water provided by
solar hea ng systems can cause
severe burns instantly, resul ng in
severe injury or death.
Step 8:
Connect the Water
Supply
Note that all piping and components
connected to the water heater must
be suitable for use with potable water.
1
Determine the type of water
pipes in your home. Most
homes use copper water
pipes, but some use CPVC or cross-
linked polyethylene (PEX). Use fi ngs
appropriate for the type of pipe in
your home. Do not use iron or PVC
pipe.
2
Connect the cold water
supply using 3/4 inch
Na onal Pipe Thread “NPT” to the
fi ng marked “C” (COLD).
For ease of removing the water heater
for service or replacement, con-
nect the water pipes with a coupling
called a union. We recommend using
a dielectric-type union ( available at
your local plumbing supplier). Dielec-
tric unions can help prevent corro-
sion caused by ny electric currents
common in copper water pipes and
can help extend the life of the water
heater
IF YOU HAVE COPPER PIPES:
If your home has copper water pipes,
you can solder the water pipe connec-
ons or use compression fi ngs which
don’t require soldering. Compression
fi ngs are easier to install than solder-
ing pipe. Check with local plumbing
offi cials to determine what types of
pipe materials are suitable for your
loca on. Do not use lead-based solder.
NOTICE: Do not solder pipes while
they are a ached to the water heater.
The water heater’s inlet and outlet
connec ons contain non-metallic parts
which could be damaged. The proper
way to connect the water heater to
copper water pipes is as follows:
• Solder a short length of pipe (about
a foot or so) to a threaded adapter
using only 95/5 n-an mony or
equivalent solder. A ach the thread-
ed adapters to the water heater’s
connec ons (using Tefl on® tape or
pipe joint compound). Connect the
home’s water pipes by soldering,
keeping the connec ons at the water
heater cool with wet rags.
Compression fi ngs don’t require soldering.
Residen al Standard Gas Water Heater Use and Care Guide • 21
INSTALLATION
Residen al Standard Gas Water Heater Use and Care Guide • 21
INSTALLATION
NOTICE: Most water heater models
contain energy saving heat traps in the
inlet and outlet connec ons. Do not
remove the heat traps.
3
Connect the hot water supply
using 3/4 inch NPT to the
fi ng marked “H” (HOT).
4
Install insula on (or heat
tape) on the water pipes
especially if the indoor
installa on area is subject to freezing
temperatures. Insula ng the hot water
pipes can increase energy effi ciency.
5
Adjust (or install) the home’s
Pressure Reducing Valve to
50-60 psi and install a Thermal
Expansion Tank.
Figure 28 - A Pressure Reducing Valve is required
if your home’s water pressure is above 80 psi.
Figure 29 - The Thermal Expansion Tank should
be pressurized with air, using a hand pump, to
match the home’s incoming water pressure.
Step 9:
Verify Connec ons and
Completely Fill Tank
To remove air from the tank and allow
the tank to fi ll completely with water,
follow these steps:
1
Remove the aerator at the
nearest hot water faucet. This
allows debris in plumbing
system to be washed out of the pipes.
2
Turn the cold water supply
back on and fi ll the tank.
3
Open a hot water faucet and
allow the water to run un l it
fl ows with a full stream.
4
Let the water run full stream
for three minutes.
5
Close the hot water faucet
and replace the aerator.
6
Check inlet and outlet connec-
ons and water pipes for leaks.
Dry pipes connec ons so that
any drips or leaks will be apparent.
Repair any leaks. Almost all leaks occur
at connec ons and are not a tank leak.
Step 10:
Install Dra Hood
1
Install the new dra hood by
aligning the legs and inser ng
them into the slots provided on
top of the water heater. Do not reuse the
dra hood from the old water heater,
but rather use the new one that came
with your new water heater.
2
Secure the dra hood using
the four screws provided.
A ach the home’s exis ng vent
pipe to the dra hood outlet using an
approved vent adapter (not supplied).
Figure 30 - Install the new draft hood and secure
with screws.
3
Secure the vent adapter to the
dra hood with sheet metal
screws. Read the Ven ng
sec on on page 11. Make sure your
home’s ven ng system complies with
the instruc ons in this manual and is in
good condi on.
22 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
22 • Residen al Standard Gas Water Heater Use and Care Guide
INSTALLATION
Step 11:
Make Gas Connec ons
The Gas Water Heater Hook-Up Kit
(available at your local plumbing sup-
plier) includes a fl exible gas connector
with compression fi ngs to connect
the home’s gas line to the water
heater’s gas control valve. Follow the
kit’s installa on instruc ons to a ach
the fl exible gas connector.
Figure 31 - Flexible gas line connector.
Once you’ve made the gas connec-
ons, use a small, so -bristled brush
to apply a hand dishwashing soap
and water mixture or children’s soap
bubbles (1 part soap to 15 parts water)
to all connec on points of the gas line
and fl exible gas connector (if used).
Make sure to generously coat all the
connec ons and check for gas leaks
(which will appear as small bubbles).
If any leaks are detected, turn the gas
supply off , ghten the leaking connec-
on and re-check.
BEFORE LIGHTING THE WATER
HEATER...
Make sure all checklist items have
been completed.
Water Heater Loca on
✓ Installa on area free of corrosive
or fl ammable materials, liquids or
vapors.
✓ Proper clearances from combus ble
surfaces maintained and suffi cient
room to service the water heater.
✓ Not installed directly on a carpeted
fl oor.
✓ Metal drain pan installed and piped
to an adequate drain.
✓ Water heater not located near an
air moving device (fan, clothes
dryer).
✓ Not in a loca on with large
amounts of lint, dust, etc. (If so,
the air fi lter or fl ame arrestor
located on the bo om of the water
heater will need to be cleaned
more o en.)
Combus on Air Supply and
Ven la on
✓ Adequate air supply for water
heater and any other nearby gas
appliances.
If the water heater is installed in a
closet or other small, enclosed space
or within the living space of the
house, air supply openings needed.
✓ Are the openings of suffi cient size?
✓ Ductwork is the same cross-sec-
onal area as the openings?
✓ Outside air openings are preferred
and may be required in ghtly built
homes.
Vent Pipe System
✓ New dra hood, properly installed.
✓ Vent pipe securely fastened to
dra hood with screws and sup-
ported properly.
✓ Vent pipe made of approved mate-
rial and either 2” or 3” in diameter.
✓ Vent system installed according
to local and state codes or, in the
absence of local and state codes,
the “Na onal Fuel Gas Code”, ANSI
Z223.1(NFPA 54)-current edi on.
✓ Check exis ng vent system for rust,
restric ons/obstruc ons.
Water System Piping
✓ Temperature and pressure relief
valve properly installed with a
discharge line run to an adequate
drain and protected from freezing.
✓ Water pipes free of leaks.
✓ Water heater completely fi lled with
water.
✓ Thermal Expansion Tank installed
✓ Water Pressure Reducing Valve
installed and adjusted to 50-60 psi.
✓ Thermosta c Mixing Valves in-
stalled at each point-of-use.
Gas Supply and Piping
✓ Gas type is the same as that listed
on the water heater’s data plate.
✓ Gas line equipped with shut-off
valve.
✓ Adequate gas pipe size and ap-
proved gas pipe material.
✓ All gas connec ons and fi ngs leak
checked and any leaks corrected.
Residen al Standard Gas Water Heater Use and Care Guide • 23
OPERATION
Residen al Standard Gas Water Heater Use and Care Guide • 23
OPERATION
Ligh ng Instruc ons
WARNING! Explosion Hazard –
Replace viewport if glass is missing or
damaged. Failure to do so can result
in death, explosion or fi re.
Read and understand these direc ons
thoroughly before a emp ng to light
or re-light the pilot. Make sure the
viewport is not missing or damaged.
Make sure the tank is completely fi lled
with water before ligh ng the pilot.
Check the data plate near the gas
control valve to ensure the correct gas
type. Do not use this water heater with
any gas other than the one listed on the
data plate. If you have any ques ons or
doubts, consult your gas supplier or gas
u lity company.
NOTICE! A newly installed water heater
will have air in the gas line. It may take
several ligh ng a empts to clear all the
air from the gas line and light the pilot.
Follow these steps to light the pilot:
1
Make sure the manual gas
valve for the water heater’s
supply line is ON.
Figure 32 - Gas valve in “on” position
2
Turn the gas control knob to
the PILOT posi on.
Figure 33 - Gas control/valve.
3
Press the gas control knob in
fully and hold it in. While
holding in the gas control
knob, repeatedly click the igniter bu on
(approximately once per second) for up
to 90 seconds or un l the Status Light
starts to fl ash. You can tell the pilot is lit
when the Status Light fl ashes once
every three seconds.
Figure 34 - Status light.
4
Once the Status Light starts
fl ashing, release the gas
control knob. Adjust the gas
control knob to the desired tempera-
ture se ng.
5
If the Status Light doesn’t start
fl ashing a er 90 seconds,
release the gas control knob
and wait 10 minutes.
6
Repeat ligh ng steps 2 through
5 at least two addi onal mes
or un l the Status Light starts
fl ashing once every three seconds. Wait
10 minutes between ligh ng a empts.
7
A solid Status Light means the
pilot was lit but is now off .
Release the gas control knob
and wait 10 minutes. Once the Status
Light goes out, repeat ligh ng steps 2
through 5.
8
If the Status Light doesn’t start
fl ashing a er three ligh ng
a empts, turn the gas control
knob to the OFF posi on and refer to
the “Troubleshoo ng-No Hot Water”
sec on (see page 25).
9
When a gas water heater is fi rst
lit and the tank is cold, conden-
sa on o en forms inside the
water heater. You may hear drips or a
sizzling sound when the water heater is
fi rst lit or, you may see a small puddle on
the fl oor. Condensa on is not a leak and
will go away once the tank reaches
normal opera ng temperature.
10
The air fi lter at the bo om of
the water heater must be
cleaned from me to me. See
the Maintenance sec on for steps on
cleaning the air fi lter. If the air fi lter is
not cleaned as needed, the water
heater’s pilot may go out.
Shut down Instruc ons
Turn the gas control/temperature knob
counterclockwise to the “OFF” se ng.
The status light will stop blinking and stay
on for a short me a er the water heater
is turned off .
Emergency Shut down
Should overhea ng occur or the gas
supply fail to shut off , turn off the water
heater’s manual gas control valve and call
a qualifi ed person.
Checking the Vent
System and Air Supply
Once the water heater is lit and the gas
control knob is set to the desired temper-
ature, the burner will light (if the tank is
cold). Perform an air supply and vent test
to make sure the unit is ven ng properly
and the air supply is adequate:
1
The main burner must be on
for this test. With a newly
installed water heater full of
cold water, turning the temperature
control knob to HOT should cause the
main burner to come on. You can view
the burner through the sight glass at
the base of the water heater.
2
Close all windows and doors
and turn on all gas appliances
and air-moving devices (range
hoods, bathroom exhaust fans, ceiling
fans, etc.) in your home. Also, close any
fi replace dampers.
24 • Residen al Standard Gas Water Heater Use and Care Guide
OPERATION
3
Allow the water heater’s main
burner to operate for fi ve
minutes. Pass a newly ex n-
guished match approximately one inch
from the dra hood’s relief opening.
Smoke from the match should be
steadily drawn into the opening indicat-
ing the water heater is ge ng adequate
air and the vent system is working.
Figure 35 - Test the air supply and vent to make
sure the water heater has adequate air and is
venting properly.
4
If the main burner has been
opera ng for fi ve minutes but
the match smoke dri s around
or is blown away from the opening, turn
the gas control knob OFF. Inspect the
vent system and repair if necessary. In
many cases, failure to pass the air
supply and vent test indicates the water
heater is not ge ng enough air or there
is a problem with the vent system. It
may be necessary to increase the air
supply by ge ng air from outside (see
page 7).
WARNING! Burn Hazard. Do not
touch the vent, doing so can cause
burns. If the dra hood does not draw
in smoke from a match a er fi ve
minutes of main burner opera on,
shut the gas supply off , and do not
operate the water heater un l the vent
system and air supply have been
checked by a qualifi ed person and
repaired if necessary. Con nuing to
operate the water heater in this
condi on could lead to serious injury
or death from carbon monoxide
poisoning.
Temperature Control
System
Adjus ng the Temperature
With the installa on steps completed,
you may adjust the water heater’s tem-
perature se ng if desired.
1
Set the gas valve to the desired
temperature. The “HOT”
se ng sets the water tem-
perature to approximately 120°F,
reducing the risk of scald injury. You
may wish to set a higher temperature to
provide hot water for automa c
dishwashers or laundry machines, to
provide more hot water capacity, and to
reduce bacterial growth. Higher tank
temperatures (140° F) kill bacteria that
cause a condi on known as “smelly
water” and can reduce the levels of
bacteria that cause water-borne
diseases.
Water usage pa erns, as well as heat
from sources such as solar collectors,
ambient air, and the pilot light can
result in temperatures higher than the
thermostat set-point.
WARNING! Higher temperatures
increase the risk of scalding, but even at
120°F, hot water can scald (see Table 1).
Install Thermosta c Mixing Valve(s) at
each point-of-use to reduce the risk of
scalding.
2
To adjust the water heater’s
thermostat:
Figure 36 - Adjust the gas control knob to “HOT”.
Turn the gas control knob on the gas
control valve to the right to the follow-
ing se ngs.
• “A” 128°F
• “B” 138°F
• “C” 147°F
• “VERY HOT” 160°F
NOTICE: The temperatures above are
approximates. The actual temperature
of the heated water may vary.
3
Wait for the water to heat up.
If you have no hot water a er
two hours, refer to the
Troubleshoo ng Sec on (see page 25).
NOTICE: If the tank is full of cold water,
condensa on may form inside the
water heater. This condensa on may
drop on the burner causing a sizzling
sound. In some cases, you may see a
small puddle on the fl oor. Condensa-
on is normal and should go away once
the tank reaches its normal opera ng
procedure.
WARNING! If you have increased
the temperature se ng and the
Thermosta c Mixing Valves are not set
properly (or not installed) you could
scald yourself while checking the
temperature.
4
Check water temperature at
several points of use in your
home (for example, bathtub
faucet, shower, or lavatory sink) and
adjust the Thermosta c Mixing Valves
as needed. If you aren’t sure how to
adjust the Thermosta c Mixing Valve
se ngs, or aren’t sure if you have
Thermosta c Mixing Valves, contact a
qualifi ed person.
Opera ng Modes
The gas control valve has two diff er-
ent opera ng modes: Standard and
Vaca on. The Standard mode allows
you to adjust the water temperature
to your desired se ng. The Vaca on
(VAC) mode sets the thermostat at
approximately 55°F and is recom-
mended when not using hot water for
an extended period of me. The VAC
se ng also reduces energy losses and
24 • Residen al Standard Gas Water Heater Use and Care Guide
OPERATION
Residen al Standard Gas Water Heater Use and Care Guide • 25
TROUBLESHOOTING
Residen al Standard Gas Water Heater Use and Care Guide • 25
TROUBLESHOOTING
keeps the tank from freezing during
cold weather but can cause a Hydrogen
gas build up. See cau on on page 6.
No Hot Water
Use the following step-by-step plan
as a guide to help determine why you
have no hot water:
1
Check the Status Light
The Status Light on the gas
control valve fl ashes once every three
seconds if the pilot is lit and the gas
control valve has not detected any
problems.
Figure 37 - Status light.
If the Status Light is fl ashing once ev-
ery three seconds and you have no hot
water, make sure the gas control knob
is set to HOT.
If the Status Light fl ashes more than
once every three seconds, refer to
the Status Light Code Troubleshoo ng
Chart on page 27.
If the Status Light is not fl ashing, go to
step 2.
2
Status Light is Not
Flashing
If the Status Light isn’t fl ashing, try
ligh ng the pilot using the ligh ng
instruc ons on page 23.
If you have tried ligh ng the pilot and the
Status Light does not fl ash, go to step 3.
If the Status Light fl ashes, go to Step 1.
3
Checking the Pilot Light
Check the spark igniter. Dim
the room lights and look through the
viewport while clicking the igniter
bu on.
If you don’t see a spark through the
viewport, check to make sure the
igniter wire is fi rmly inserted into the
white connector.
If you see a spark, make sure the gas
supply valve is turned on, and try light-
ing the pilot using the ligh ng instruc-
ons on page 23.
If the pilot s ll does not light, call a
qualifi ed person.
Insuffi cient Hot Water
or Slow Hot Water
Recovery
WARNING! Because of the increased
risk from scalding, if you set the water
heater’s gas control knob higher than
120°F, install Thermosta c Mixing
Valves at each point-of-use. Due to the
increased risk of scalding, do not set the
temperature of the Thermosta c
Mixing Valves above 120°F.
If the hot water is simply not warm
enough, there are several possible
causes:
• Faulty Thermosta c Mixing Valve
in a faucet or shower control
(check other faucets in the house
for hot water).
• Water heater’s capacity too small
(or usage too high).
• Reversed plumbing connec ons
or melted dip tube (usually found
soon a er new installa on).
• Plumbing leak.
• Sediment or lime build up in the
bo om of the tank.
Thermosta c Mixing Valves. If the
hot water is simply not warm enough,
make sure the faucet you are checking
doesn’t have a defec ve Thermosta c
Mixing Valve. Many shower controls
now have built-in mixing valves. If
these devices fail, they can reduce the
amount of hot water the shower or
faucet delivers even though there is
plenty of hot water in the tank. Always
check the water temperature at several
faucets to make sure the problem is not
in a faucet or shower control.
Undersized Water Heater. If your water
heater runs out of hot water quickly, it
may be too small for your needs. If the
water heater is old, consider replacing it
with a larger model. If the water heater
is in good condi on, you may be able
to meet your family’s hot water needs
with the exis ng water heater by install-
ing Thermosta c Mixing Valves at each
point-of-use and then turning the gas
control knob to a higher se ng.
You can also reduce your home’s hot
water needs by washing clothes in cold
water, installing fl ow restrictors on
shower heads, repairing leaky faucets,
and taking other conserva on steps.
Reversed Connec ons or Melted Dip
Tube. Check the hot and cold water
connec ons and make sure your
home’s hot water pipe is connected
to the hot water outlet on the water
heater. Usually, reversed connec ons
are found soon a er the installa on
of a new unit. If copper pipes were
soldered while they were a ached to
the water heater, the dip tube may
have melted. The dip tube is a long,
plas c tube inside the tank a ached to
the cold water inlet. If the dip tube has
melted, it can be replaced by removing
the cold water inlet connec on, re-
moving the old dip tube and installing
a new one.
Plumbing Leak. Even a small leak
in the hot water side of the home’s
26 • Residen al Standard Gas Water Heater Use and Care Guide
TROUBLESHOOTING
26 • Residen al Standard Gas Water Heater Use and Care Guide
TROUBLESHOOTING
plumbing system can make it appear
that the water heater is producing
li le to no hot water. In this case, the
burner will be on all or almost all the
me, yet you will have very li le hot
water. Locate and repair the leak.
Sediment or Lime in Tank. With an ex-
is ng water heater, if you have some
hot water but not as much as you’re
used to, there may be a build up of
sediment or lime on the bo om of the
tank. Sediment or lime build up can
reduce the effi ciency of your water
heater. Heavy deposits can damage
the water heater. See the Mainte-
nance sec on for steps on draining
and fl ushing the water heater.
Temperature Too High
Adjust the thermostat on the water
heater to a lower se ng. Install or
adjust Thermosta c Mixing Valves
for each point-of-use (see the valve
manufacturer’s instruc ons).
Low Water Pressure
Check both the cold and hot water
at a sink to determine if the lower
pressure is only on the hot water side.
If both hot and cold faucets have low
pressure, call your local water u lity.
If the low pressure is only on the hot
water side, the primary causes are:
• Melted heat traps or dip tube. Sol-
dering copper pipes while they are
connected to the water heater can
melt the heat traps inside the hot
and cold water connec ons or the
dip tube (cold water side). Melted
heat traps or a melted dip tube
can restrict the fl ow of hot water.
If that’s the case, replace the heat
traps or dip tube.
• Par ally closed supply valve. Open
the water heater’s supply valve fully.
Drips from T&P Relief
Valve Discharge Pipe
A small amount of water dripping
from the Temperature and Pressure
(T&P) Relief Valve usually means the
home’s water pressure is too high
and/or you need a Thermal Expan-
sion Tank. See Step 1 in the Installa-
on sec on of this manual for more
informa on.
A large amount of hot water coming
from the T&P discharge pipe may be
due to the tank overhea ng. If the
T&P relief valve is discharging large
amounts of very hot water, turn the
gas supply valve off and call a quali-
fi ed person.
WARNING! Do not cap or plug the
T&P Relief Valve or discharge pipe,
and do not operate the water heater
without a func oning T&P Relief
Valve—this could cause an explosion.
Water Pressure too High. High water
pressure can cause the T&P Relief
Valve to drip. Install a Pressure Re-
ducing Valve (PRV) on the main cold
water supply line. Adjust the PRV to
between 50 and 60 psi.
Thermal Expansion Tank. Install a
Thermal Expansion Tank. If a Thermal
Expansion Tank is already installed
and the T&P Relief Valve discharge
pipe drips, the home’s water pressure
may be too high or the Thermal Ex-
pansion Tank may be defec ve. Refer
to the instruc ons that came with
the Thermal Expansion Tank for more
informa on.
Debris. In rare cases, debris can s ck
inside the T&P Relief Valve preven ng
the valve from sealing fully. In that
case, the T&P Relief Valve discharge
pipe will drip. You may be able to
clear debris from the T&P Relief Valve
by manually opera ng the valve,
allowing small quan es of water to
fl ush out the debris. See the label on
the T&P Relief Valve for instruc ons.
WARNING! When manually
opera ng the temperature-pressure
relief valve, make sure that no one is
in front of or around the discharge
outlet. The water may be extremely
hot and could cause severe burns.
Also ensure that the water discharge
will not cause property damage.
If the water pressure is between 50
and 60 psi, a Thermal Expansion Tank
is installed and properly pressurized,
and the valve has been cleared of any
debris, and it s ll drips, the valve may
be broken—have a qualifi ed person
replace the T&P Relief Valve.
Water Odor
Harmless bacteria normally present in
tap water can mul ply in water heat-
ers and give off a “ro en egg” smell.
Although elimina ng the bacteria that
causes “smelly water” is the only sure
treatment, in some cases, the stan-
dard anode rod that came with your
water heater can be replaced with a
special zinc anode rod which may help
reduce or eliminate the odor. Contact
a qualifi ed person.
NOTICE: To protect the tank, an anode
rod must be installed in the water
heater at all mes or the warranty is
void.
In cases where the “ro en egg” smell
is very strong, you could increase the
tank temperature to 140°F in order to
reduce bacterial growth in the tank.
WARNING! Because higher
temperatures increase the risk of
scalding, if you set the thermostat(s)
higher than 120°F, Thermosta c
Mixing Valves at each point-of-use
are par cularly important.
Residen al Standard Gas Water Heater Use and Care Guide • 27
TROUBLESHOOTING
Residen al Standard Gas Water Heater Use and Care Guide • 27
TROUBLESHOOTING
28 • Residen al Standard Gas Water Heater Use and Care Guide
MAINTENANCE
28 • Residen al Standard Gas Water Heater Use and Care Guide
MAINTENANCE
Rou ne Maintenance
Rou ne maintenance will help your
water heater last longer and work bet-
ter. If you can’t perform these rou ne
maintenance tasks yourself, contact a
qualifi ed person.
Draining and Flushing the
Water Heater
Tap water contains minerals that can
form sediment in the bo om of the
tank. The amount of sediment formed
depends on the hardness of your tap
water, the temperature se ngs, and
other variables. We recommend drain-
ing and fl ushing the water heater a er
the fi rst six months of opera on to de-
termine the amount of sediment build
up. If there is li le sediment, drain and
fl ush the tank annually. If there is a lot
of sediment, drain and fl ush the tank
more o en. Draining sediment extends
the life of the water heater.
To Drain and Flush the Tank:
1
Turn the gas control knob on
the gas control valve to the
OFF posi on.
Figure 40 - Turn gas control/temperature knob
OFF.
2
Turn the manual gas valve for
the water heater’s supply line
OFF.
3
Open a hot water faucet and
let the hot water run un l it is
cool (This may take 10 min
utes or longer).
Figure 41 - Let the hot water run until it is cool.
WARNING! Be sure the water runs
cool before draining the tank to
reduce the risk of scalding.
4
Connect a garden hose to the
drain valve and place the
other end of the hose in a
drain, outside, or in buckets. Note that
sediment in the bo om of the tank
may clog the valve and prevent it from
draining. If you can’t get the tank to
drain, contact a qualifi ed person.
5
Turn the cold water supply
valve OFF.
6
Open the drain valve on the
water heater.
Figure 42 - Draining the water heater.
7
Also open a hot water faucet
to help the water in the tank
drain faster.
8
Remove and inspect the
anode rod and replace if
depleted. The anode rod
requires a 1-1/16” socket.
Figure 43 - Anode rods from new (top) to par-
tially depleted (middle) to fully depleted stage
(bottom).
Anode Rod. The anode rod is a sacrifi -
cial metal rod that helps avoid corro-
sion and premature failure (leaks) in
the tank. The anode rod is a consum-
able item. Inspect the anode rod a er
the fi rst six months of opera on when
you drain and fl ush the tank. Replace
the anode rod if it is substan ally worn
out or depleted. Therea er, inspect the
anode rod annually or more frequently
if needed. If you use a water so ener,
your anode rod will deplete faster than
normal. Inspect the anode rod more
frequently, replacing the anode rod if
it is depleted. Obtain a new anode rod
from your local plumbing supplier or
have a qualifi ed person replace it. (An-
ode rods are a consumable item and
are not covered under warranty).
9
If a large amount of sediment
was present when the tank
was drained, fl ush the tank by
opening the cold water supply valve
and le ng the water run un l no more
sediment drains from the tank. Close
the drain valve when you are done.
Residen al Standard Gas Water Heater Use and Care Guide • 29
MAINTENANCE
Residen al Standard Gas Water Heater Use and Care Guide • 29
MAINTENANCE
10
Refi ll the tank by opening the
cold water supply valve. Make
sure a hot water faucet is open
and the drain valve is closed. Allow a
hot water faucet to run full for at least
three minutes to make sure the tank
has all the air removed and is complete-
ly full of water. Once you are certain the
tank is completely full of water, close
the hot water faucet.
11
Relight the pilot using the
instruc ons on page 23 and
adjust the gas control knob to
the desired temperature. It may take an
hour or more for the tank of cold water
to heat up.
Visual Inspec on
On an annual basis, visually inspect the
ven ng and air supply system, piping
systems, main burner, pilot burner, and
the air fi lter.
Check the water heater for the following:
• Obstruc ons, damage, or deterio-
ra on in the ven ng system. Make
sure the ven la on and combus-
on air supplies are not obstruct-
ed. Check the air fi lter for dust or
other debris and clean if needed.
• Build up of soot and carbon on the
main burner and pilot burner. The
burner may be cleaned with soap
and hot water.
• Inspect the burner fl ames through
the viewport and compare them
to the drawing below. A properly
opera ng burner should produce a
so blue fl ame. Blue ps with yellow
inner cones are sa sfactory. The ps
of the fl ame may have a slight yellow
nt. 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 sa sfactory.
Figure 44 - Burner Flames
• Leaking or damaged water and gas
piping.
• Remove any fl ammable, corrosive
or combus ble materials near the
water heater.
If you lack the necessary skills required
to properly perform this visual inspec-
on or if the burner needs to be cleaned,
get help from a qualifi ed person.
T&P Relief Valve Maintenance
Figure 45 - T&P Relief Valve.
Read and follow the opera ng and an-
nual maintenance instruc ons provided
by the manufacturer of the T&P Relief
Valve (yellow label a ached to T&P
Relief Valve). Minerals in the water can
form deposits that cause the valve to
s ck or create blocked passages, mak-
ing the T&P Relief Valve inopera ve.
Follow these guidelines:
• At least annually, operate the T&P
Relief Valve manually to ensure the
waterways are clear and the valve
mechanism moves freely (above).
Before opera ng the valve manually,
check that it will discharge in a place
for secure disposal.
WARNING! Hot water will be
released. Before opera ng the T&P
relief valve manually, check that it will
discharge in a safe place. If water does
not fl ow freely from the end of the
discharge pipe, turn the gas control
knob to the OFF posi on and call a
qualifi ed person to determine the
cause.
• At least every fi ve years, have a
qualifi ed person inspect the T&P
Relief Valve and discharge pipe.
Damage caused by corrosive water
condi ons, mineral deposits, or
other problems can only be de-
termined when a qualifi ed person
removes and inspects the valve
and its components.
A dripping T&P Relief Valve is usually
caused by the home’s water pressure
being too high or the lack of a Thermal
Expansion Tank. If your T&P Relief Valve
drips, see page 26.
A T&P relief valve that has been al-
lowed to drip for an appreciable period
of me should be inspected for mineral
buildup. See T&P relief valve tag for
more informa on.
Inspect and Clean the Air Filter
Figure 46 - Clean air filter periodically.
An air fi lter should be installed around
the base of the water heater. At least
annually inspect the air fi lter and check
for a build-up of dust or debris.
Vacuum the fi lter to remove any dust
or debris. If an oily residue is present
on the fi lter, wash it in soap and water,
then dry the fi lter.
30 • Residen al Standard Gas Water Heater Use and Care Guide
MAINTENANCE
30 • Residen al Standard Gas Water Heater Use and Care Guide
Removing and Replacing the
Gas Control Valve/Thermostat
IMPORTANT: The gas control valve/
thermostat is a standard valve with
wire leads that connect to a thermal
switch.
Removing the Gas Control Valve/
Thermostat:
1
Turn the gas control/tem-
perature knob to the “OFF”
posi on.
Figure 48 - Gas control/valve.
2
Turn off the gas at the
manual shut-off valve on the
gas supply pipe.
Figure 50 - Gas valve in “off” position.
3
Drain the water heater. Refer
to the “Draining and Flushing
the Water Heater” sec on (see
page 28) and follow the procedure.
4
Disconnect the
A
igniter
wire from the igniter lead
wire. Use needle nose pliers
to disconnect the
B
red (+) and white
(-) thermopile wires. Disconnect
C
pilot tube (7/16” wrench) and
D
manifold tube (3/4” wrench) at the
gas control valve/thermostat. NOTE:
L.P. Gas systems use reverse (le -hand)
threads on the manifold tube.
A
C
D
B
Figure 52 - Gas valve connections.
5
Disconnect the ground joint
union in the gas piping.
Disconnect the remaining
pipe from the gas control valve/
thermostat.
Figure 54 - Ground joint union connection.
6
To remove the gas control
valve/thermostat, thread a 4”
sec on of gas pipe into the
inlet and use it to turn the FVIR Safety
System Opera onal Checklist TROU-
BLESHOOTING CHART gas control
valve/thermostat (counterclockwise.)
Do not use pipe wrench or equivalent
to grip body. Damage may result,
causing leaks. Do not insert any sharp
objects into the inlet or outlet connec-
ons. Damage to the gas control valve/
thermostat may result.
Figure 56 - Gas control/valve with threaded pipe.
Replacing Gas Control Valve/Thermostat:
To replace the gas control valve/thermo-
stat, reassemble in reverse order. When
replacing the gas control valve/
thermostat, thread a 4” sec on 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 Tefl on® tape
or pipe joint compound on the gas piping
connec ons and fi ng on
the back of the gas control valve that
screws into tank.
• Be sure to remove the pilot ferrule nut
from the new gas control valve/thermo-
stat.
Figure 58 - Gas valve in “on” position.
• Turn the gas supply on and check for
leaks. Test the water heater by brushing
on an approved noncorrosive
leak detec on solu on. Bubbles forming
indicate a leak. Correct any leak found.
• Be sure tank is completely fi lled with
water before ligh ng and ac va ng the
water heater. Follow the
“Ligh ng Instruc ons” on page 23.
• If addi onal informa on is required,
contact the Service Department at:
1-800-527-1953
MAINTENANCE
Residen al Standard Gas Water Heater Use and Care Guide • 31
NOTES
NOTES
32 • Residen al Standard Gas Water Heater Use and Care Guide
NOTES
NOTES
Residen al Standard Gas Water Heater Use and Care Guide • 33
NOTES
NOTES
34 • Residen al Standard Gas Water Heater Use and Care Guide
NOTES
NOTES
Residen al Standard Gas Water Heater Use and Care Guide • 35
REPAIR PARTS
REPAIR PARTS
Item
No.
Parts Description
1 DRAFT HOOD
2
REDUCER RING - SOME MODELS
(NOT SHOWN)
3 FLUE BAFFLE (NOT SHOWN)
4 COMBINATION DIP TUBE/HEAT TRAP NIPPLE
5 HEAT TRAP/NIPPLE
6
ANODE ROD - SOME MODELS
7 COMBINATION HEAT TRAP NIPPLE/ANODE
- SOME MODELS
8 TEMPERATURE & PRESSURE RELIEF VALVE
(LOCATED TOP OR SIDE)
9 DRAIN VALVE
10 GAS CONTROL VALVE/THERMOSTAT
(with thermal switch wire lead)
11
OUTER DOOR
12
PILOT/THERMOPILE ASSEMBLY KIT
13
FINAL BURNER ASSEMBLY
14
MANIFOLD DOOR GASKET
15 BASE RING AIR FILTER
REPAIR PARTS LIST
4
6
1
8
10
9
11
15
5
7
8
Replacement parts may be ordered through your plumber or
the local distributor. Parts will be shipped at prevailing prices
and billed accordingly.
NOTICE: When ordering replacement parts, have the following
informa on ready:
• Model and serial number
• Type of gas used
• Item number
• Parts descrip on
Legend
▲ Special anode rod (see page 26)
■ Temperature and Pressure Relief Valve is required but may
be factory installed
★ Unique: Flammable Vapor Igni on Resistant Safety System
parts
36 • Residen al Standard Gas Water Heater Use and Care Guide
REPAIR PARTS
36 • Residen al Standard Gas Water Heater Use and Care Guide
REPAIR PARTS
Listed Parts Kits and Illustrations
Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas or L.P.)
Item 13: Final burner assembly which contains the burner, orifice, manifold tube, gasket, door, pilot tube, thermopile,
manifold component block with retainer clip, thermal switch, and pilot assembly. (Natural Gas/Low Nox or L.P.)
Item 14: Contains manifold door gasket
Item #12
Item #13 (L.P. Burner)
Item #14
Item #13 (Natural Burner)
®Tefl on is a registered trademark of E.I. Du Pont De Nemours and Company
A.O. Smith Corporation. All Rights Reserved.
Manufactured under license by American Water Heater Company, Tennessee.
Limited Warranty provided by Manufacturer.
