AO Smith GDVNT-50L 100 ProLine® Ultra-Low Nox Direct User Manual

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.

DO NOT RETURN THIS UNIT TO THE STORE

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

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

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

• Call your Local plumbing supplies store to have this water heater installed.

Professional Installaon is available for this product and the work is guaranteed.

• Schedule an appointment with a qualied person to install your water heater.

• Call our Technical Assistance Hotline which is listed on the water heater’s

warranty sheet. We can help you with installaon, operaons, troubleshoong,

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

the water heater’s data plate.

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

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

and explosion, causing serious injury or death.

Residenal Gas

Water Heater

Residenal Direct Vented Gas Water Heater

Not for use in Manufactured (Mobile) Homes

100369451_2000626161_REV.A

Do not store or use gasoline or other

ammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch;

do not use any phone in your build-

ing.

• Immediately call your gas supplier

from a neighbor’s phone. Follow the

gas supplier’s instrucons.

• If you cannot reach your gas suppli-

er, call the re department.

Installaon and service must be per-

formed by a qualied installer, service

agency or the gas supplier.

WARNING: If the informaon in

these instrucons is not followed

exactly, a re or explosion may

result causing property damage,

personal injury or death.

LOW LEAD

NTENT

June, 2023

Table of Contents

Important Safety Informaon .................................................. 3

Geng Started ........................................................................ 7

Installaon ............................................................................. 15

Operaon .............................................................................. 24

Troubleshoong .................................................................... 26

Maintenance ......................................................................... 30

Repair Parts ........................................................................... 33

Notes .................................................................................. 35

2 • Residenal Gas Water Heater Use and Care Guide

COMPLETED INSTALLATION (TYPICAL)

Vent Termination Hood

Wall Plate

Inlet Water

Shut-off Valve

Inlet Water

Shut-off Valve

Temperature and Pressure

Relief Valve

Combo Heating System

Supply Outlet (Optional)

Discharge Pipe

Combo Heating System

Supply Return Inlet (Optional)

Floor Drain

Drain Pan

Manual Gas

Shut-off

Drip Leg

Gas Control Valve/

Thermostat

Hot Outlet

Cold Inlet

Vent Pipe

Residenal Gas Water Heater Use and Care Guide • 3

IMPORTANT SAFETY INFORMATION

SAFETY

Read and follow all safety messages and instrucons in this

manual.

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

potenal physical injury hazards. Obey all safety messages

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.

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

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

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

liquids in the vicinity of this or any other appliance.

An odorant is added by the gas supplier to the gas used by this water heater.

This odorant may fade over an extended period of me. Do not depend upon

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

gas and carbon monoxide detector.

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

0.25% lead content as required in some areas.

DANGER indicates a hazardous

situaon that, if not avoided, will

result in death or serious injury.

WARNING indicates a hazardous

situaon that, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous

situaon that, if not avoided, could

result in minor or moderate injury.

NOTICE indicates pracces not

related to physical injury.

DANGER

WARNING

CAUTION

NOTICE

*Drain and flush tank and remove and

inspect anode rod after first six months

of operation and at least annually

thereafter. Operate the Temperature

and Pressure Relief Valve (T&P) annually

and inspect T&P valve every 2-4 years

(see the label on the T&P valve for

maintenance schedule). If no label is

attached to the T&P Relief Valve, follow

the instructions in the T&P Relief Valve

Maintenance section of this manual.

See the Maintenance section for more

information about maintaining this

water heater.

Important informaon to keep

Fill out this secon and keep this manual

in the pocket of the water heater for

reference.

Date Purchased:

Model Number:

Serial number:

Maintenance performed:* Date:

4 • Residenal Gas Water Heater Use and Care Guide

To reduce the risk of property

damage, serious injury or death, read

and follow the precauons below,

all labels on the water heater, and

the safety messages and instrucons

throughout this manual.

RISKS DURING

INSTALLATION AND

MAINTENANCE

Liing Risk

WARNING! The

water heater is

heavy. Follow these

precauons to reduce the risk of

property damage, injuries from liing

or impact injuries from dropping the

water heater.

• Use at least two people to li the

water heater.

• Be sure you both have a good grip

before liing.

• Use an appliance dolly or hand truck

to move the water heater.

Explosion Risk

WARNING! Read the

water heater’s data

plate to determine the type of gas

required. Failure to follow these

instrucons can result in serious

injury or death from explosion, re

or carbon monoxide poisoning.

• Do not connect a natural gas water

heater to an L.P. gas supply.

• Do not connect an L.P. gas water

heater to a natural gas supply.

• Use a new CSA approved gas supply

line.

• Install a shut-o valve on the gas

supply line.

Gas Pressure

WARNING! The gas supply

pressure must not exceed the

maximum supply pressure as stated

on the water heater’s data plate. The

minimum supply pressure is for the

purpose of input adjustment. L.P.

gas supply pressure must not exceed

13” water column. Have a quali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 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 show-

ering.

• To reduce the risk of scalding, install

Thermostac Mixing Valves (tem-

perature liming valves) at each

point-of-use. These valves automa-

cally mix hot and cold water to limit

the temperature at the tap. Mixing

valves are available at your local

plumbing supplier. Follow the man-

ufacturer’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 temperature 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 more 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

certain 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.

• If the water supplied to the water

heater is pre-heated (by a solar

heang system) the temperature

in the tank may be higher than the

SAFETY

IMPORTANT SAFETY INFORMATION

Residenal Gas Water Heater Use and Care Guide • 5

IMPORTANT SAFETY INFORMATION

SAFETY

water heater’s temperature seng.

• Should overheang occur or the

burner fail to shut o, turn o the

manual gas supply valve to the

water heater and call a qualied

person.

To reduce the risk of unusually hot

water reaching the xtures in the

house, install Thermostac Mixing

Valves at each point-of-use.

If anyone in your home is at parcular

risk of scalding (for example, the

elderly, 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

American Society of Sanitary

Engineering (ASSE 1070) and most

local plumbing codes, the water

heater’s thermostat 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 allow you to set the

tank temperature to a higher seng

without increasing the 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

contaminate the potable water supply.

Do not use piping that has been

treated with chromates, boiler seal, or

other chemicals.

Fire Risk

This water heater

is equipped with a

Flammable Vapor Ignion Resistance

(FVIR) system. FVIR is designed to

reduce the risk of ammable vapor-

related 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 re/explosion if ammable

vapors have accumulated in the

combuson chamber and the water

heater is lit.

Do not aempt to light this appliance

by any means if you suspect

ammable vapors have accumulated

inside or outside the appliance.

Immediately call a qualied person to

inspect the appliance. Water heaters

subjected to a ammable vapors

incident will show a discoloraon

on the ame arrestor and require

replacement of the enre water

heater. Improper installaon or an

inadequate air supply can also cause

the FVIR system to disable 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 re, explosion or excessive

and abnormal producon of carbon

monoxide.

To reduce the risk of a 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

ammable substances in the vicinity

of this or any other appliance.

• Keep the water heater from becom-

ing wet. Immediately shut o the

water heater and have it inspected

by a qualied person if you nd that

the wiring, gas control valve/ther-

mostat or surrounding insulaon

have been exposed to water in any

way (e.g., leaks from plumbing and

leaks from the water heater itself

can damage property and could

cause a re risk). If the water heater

is subjected to ood condions or

the gas control valve/thermostat has

been submerged in water, the enre

water heater must be replaced.

• Replace the water heater’s viewport

if glass is missing or damaged. Re-

pair the combuson chamber door

seals if damaged.

Explosion Risk

High temperatures and

pressures in the water

heater tank can cause an explosion

resulng in property damage, serious

injury 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

laboratory maintains public inspecon

of the valve producon process

and ceres that it meets the

requirements for Relief Valves for Hot

Water Supply Systems, ANSI Z21.22.

The T&P Relief Valve’s relief pressure

must not exceed the working pressure

rang of the water 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).

If no label is aached to the T&P

Relief Valve, follow the instrucons

in the T&P Relief Valve Maintenance

secon of this manual. An explosion

could occur if the T&P Relief Valve

6 • Residenal Gas Water Heater Use and Care Guide

or discharge pipe is blocked. Do not

cap or plug the T&P Relief Valve or

discharge pipe.

Fire and Explosion Risk if Hot Water

is Not Used for Two Weeks or More.

CAUTION! Hydrogen gas builds up

in a hot water system when it is not

used for a long period (two weeks

or more). Hydrogen gas is extremely

ammable. If the hot water system

has not been used for two weeks or

more, open a hot water faucet for

several minutes at the kitchen sink

before using any electrical appliances

connected to the hot water system.

If hydrogen is present there will

probably be an unusual sound such

as “air” escaping through the pipe

as hot water begins to ow. Do not

smoke or have an open ame or

other ignion source near the faucet

while it is open.

Water Contaminaon Risk

WARNING! This water heater

operates by burning gas. Carbon

monoxide is a colorless, odorless,

gas that is a by-product of burning

of fuels such as coal, wood,

charcoal, oil, kerosene, propane,

and natural gas. Breathing excessive

and abnormal amounts of carbon

monoxide can cause carbon

monoxide poisoning,

resulng in serious

injury or death. This

water heater must

be supplied with

adequate combuson

air and must be properly vented to

the outdoors. Have a qualied person

(licensed plumber, authorized gas

company personnel, or authorized

service technician) install the venng

system using these installaon

instrucons. Install a fuel gas and

carbon monoxide 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

venng system can

become hot enough to burn. Do not

touch the venng system while water

heater is on, or unl the water heater

is turned o and 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.

SAFETY

IMPORTANT SAFETY INFORMATION

Residenal Gas Water Heater Use and Care Guide • 7

GETTING STARTED

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.

This water heater is a direct

vented water heater which

takes its combuson air from

the outside of the structure and

exhausts all products of combuson

to the outside of the structure.

This water heater must be installed

according to all local and state codes

or, in the absence of local and state

codes, the “Naonal Fuel Gas Code”,

ANSI Z223.1 (NFPA 54)-current

edion. This is available from the

following:

CSA America, Inc.

8501 East Pleasant Valley Road

Cleveland, OH 44131

Naonal Fire Protecon Associaon

1 Baerymarch Park

Quincy, MA 02269

Check with local code ocials about

codes governing this installaon.

Have your installaon inspected by a

code ocial to ensure the installaon

meets all local codes.

NOTICE: If you lack the necessary

skills required to properly install this

water heater, or you have diculty

following the instrucons, you should

not proceed but have a qualied

person perform the installaon of this

water heater.

Massachuses code requires this

water heater to be installed in

accordance with Massachuses

248-CMR 2.00 and 248-CMR 5.00:

State Plumbing Code. Other local

and state authories may have

similar requirements or other codes

applicable to the installaon of this

water heater.

Before you start, be sure you

have the following tools and

supplies:

• Plumbing tools and supplies appro-

priate for the type of water pipes in

your home.

• Thread sealant tape or pipe joint

compound 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 ngs that do not require

soldering. This kit includes two 12”

ex water lines, an 18” exible gas

line, two nipples, and thread sealant

tape.

• For homes with plasc pipe, use

threaded connectors suitable for the

specic type of plasc pipe used:

CPVC or PEX (cross-linked polyeth-

ylene). Do not use PVC pipe.

• Non-corrosive gas leak detecon

soluon made from hand dishwash-

ing soap mixed with water (1 part

soap to 15 parts water) or children’s

soap bubbles and a small, so-bris-

tled brush.

• An appliance dolly or hand truck to

move the water heater.

Recommended Accessories

• A metal drain pan

• Automac water leak detecon and

shut-o device

• Pressure Reducing Valve

• Thermal Expansion Tank

• Thermostac Mixing Valves at each

point-of-use

• Fuel gas and carbon monoxide

detector

Combuson and

Venlaon Air Supply

Before installing the water heater, you

must determine the amount of air

needed to supply this water heater

and any other gas appliances in the

same area and provide adequate air

for combuson and venlaon.

WARNING! This gas water heater

requires and adequate source

of clean air for combuson and

venlaon. Without sucient air,

your water heater will have frequent

pilot outages and may emit excessive

and abnormal amounts of carbon

monoxide.

Before beginning:

For safe operaon an adequate supply

of fresh, uncontaminated air must be

provided for combuson.

This gas-red water heater is a direct

vent model. It connects directly to

the outside of the building through

the vent terminaon hood. The hood

operates as both the combuson air

intake and the heater exhaust port

(see Figure 4).

All combuson air is obtained from

outside the building through this

hood. Ensure the area around the

terminaon hood is always kept clear

and that the air supply is not exposed

to contaminaon or ammable

vapors.

8 • Residenal Gas Water Heater Use and Care Guide

Venng

WARNING! Carbon Monoxide

Hazard. This water heater must

be supplied with adequate air and

vented outdoors. The vent system

must be installed by a qualied

person. Examples of a qualied

person include gas technicians,

authorized gas company personnel,

and authorized service technicians.

Failure to properly vent the water

heater can result in severe injury

or death from carbon monoxide

poisoning.

The vent system must be installed

according to local and state codes, or

in the absence of local or state codes,

the “Naonal Fuel Gas Code”, ANSI

Z223.1 (NFPA 54)-current edion. 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.

Installing a New Vent System

This direct vent water heater uses a

sealed venng system to supply fresh

combuson air to the heater and to

exhaust the products of combuson

(ue gases) to the outdoors The

venng is a “pipe in a pipe” system.

The inner (3”) piping carries out the

exhaust ue gases while the outer (6”)

piping carries in fresh combuson air.

The corrugated end of the vent piping

connects to the top of the water

heater and the opposite end connects

to the vent terminaon hood which

will be mounted on the exterior wall

(see Figure 4). Figure 4 shows the

hot exhaust gas exit and the locaon

of the combuson air intake. Figure

7 through Figure 13 show how to

assemble and connect the venng

system.

Figure 14 through Figure 18 show

various installaon opons.

Vent Terminal Clearances

The vent system must terminate so

that proper clearances are maintained

as cited in local codes or the current

edion of the “Naonal Fuel Gas

Code”, ANSI Z223.1/NFPA 54 as

follows:

GETTING STARTED

**Minimum 12 in.

Minimum 12 in.

above grade or

anticipated snow

level

Minimum 12 in.

under veranda, porch,

deck or balcony

(see footnote 1)

Minimum

3 ft.

above if within

10 ft.

horizontally to

a mechanical air

supply inlet

Minimum 9 in. to a non mechanical air supply inlet

into building or combustion air inlet to another appliance

Minimum 12 in.

from soffit

*Minimum 9 in. to

a window or door

that may be opened

**Minimum

18 in.

from outside

corner

1. Permitted only if veranda, porch, deck or balcony is fully opened on a minimum of two sides beneath the floor.

2. A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

AREA WHERE TERMINAL IS NOT PERMITTED

VENT TERMINAL AIR SUPPLY INLET

Minimum

3 ft.

clearance to a

service regulator

vent outlet

** Or as required by local authorities.

Figure 3 - Vent Terminaon Hood

Residenal Gas Water Heater Use and Care Guide • 9

GETTING STARTED

DV Terminaon Hood

When the heater is in operaon, the

vent terminaon hood will be hot (see

Figure 4).

HOT

EXHAUST

GAS OUT

FRESH

COMBUSTION

AIR IN

SCREW

Figure 4 - Vent Terminaon Hood

DV Terminaon Safety Cover

A Safety cover (see Figure 5) is

available to prevent accidental contact

with the vent terminal. Contact your

Customer Service Department for

ordering informaon.

Figure 5 - Safety Cover

Alternavely, a wire mesh or louvered

fencing guard can be built around the

terminaon as shown in Figure 6.

NOT TO BE USED AS

A STORAGE AREA

Figure 6 - Fencing Guard/Safety Cover

Vent Connecon

Aer the locaon for the vent

terminal has been selected as outlined

in Figure 3 and Figure 4, use the

following illustraons for installaon:

Locang Clearance Hole for Vent

Cut a clearance hole, approximately

7”in diameter, through the exterior

wall for the vent assembly. The

recommended height is 64” for 40

gallon models or 73” for 50 gallon

models, as measured from the hole

center to boom of water heater.

Where the wall is combusble and

the wall thickness is over 14”, a 1”

clearance to combusble surfaces

around the vent terminal is needed.

The rst 14” is zero clearance (see

Figure 9 on page 10).

Standard Vent Arrangement

* If the horizontal length of the

venng is less than 30” the restricter

plate must be installed (see Figure 10,

Figure 16 through Figure 18).

• Do not use the restricter plate in an

oset installaon (see Figure 14).

• Do not use the restricter plate if the

horizontal length of the venng is

greater than 30”.

• Do not use the restricter plate for

installaons where elevaon is at or

exceeds 5,400 feet.

NOTICE: The length of “unstretched”

corrugated tube could cause the

length of the vent run to exceed the

minimum. In this case cut o a piece

of the corrugated tube to achieve the

17” minimum vent length.

10 • Residenal Gas Water Heater Use and Care Guide

Vent Assembly

The vent piping and the vent

terminaon hood are to be connected

as shown in Figure 7. Maintain

vent clearances to combusbles

as shown in Figure 9. Depending

on your access to where the vent

terminaon passes through the wall,

you may wish to connect the piping

and vent terminaon hood together

rst. Inside the vent piping there are

springs that hold the two corrugated

pipes in posion. When the pipes

are stretched to the required length,

the springs will remain properly

spaced. To connect the vent piping

to the vent terminaon hood, rst

slide the inner (3”) corrugated pipe

over the inner vent terminaon pipe.

Connue this acon unl the locking

clip on the corrugated pipe snaps into

posion in the corresponding groove

(see Figure 7). Secure corrugated

pipe with screw (supplied) inserted

through hole opposite the locking clip.

Repeat this process with the outer

(6”) corrugated pipe and lock it into

posion on the outer pipe on the vent

terminaon (see Figure 7). Secure

corrugated pipe with screw (supplied)

inserted through hole opposite the

locking clip.

NOTICE: To reduce the fricon

between the corrugated pipe and

the O-rings, it is recommended to

dampen the O-rings with water. The

completed connecon is shown in

Figure 8.

Outer

Corrugated

Pipe

Locking

Clip

Inner Vent Termination

Pipe

Outer Vent

Termination Pipe

Inner

Corrugated Pipe

Locking Clip

Groove

O-Ring

Figure 7 - Vent Piping

Screw

Figure 8 - Completed Vent Connecon

Securing Vent Terminaon

Assembly to the Exterior Wall

Some models are supplied with trim

plates which may be used to cover

the holes in the wall (see “Completed

Installaon” on page 2 and

Figure 9). Slide one trim plate (if

supplied) over the outer corrugated

tube, then insert the outer corrugated

tube through the clearance hole from

exterior wall. Secure the trim plate to

the exterior wall, then secure the vent

terminal to the exterior wall with 4

screw anchors (included) appropriate

for the type of wall construcon.

Caulk the juncon of the vent terminal

base plate and the exterior wall with

exterior type sealant (not included).

Slide the trim plate (inside) over the

outer corrugated tube and fasten the

trim plate to the interior wall. Caulk

the juncon of the outer corrugated

tube and the trim plate (inside) with

suitable sealant. The vent terminaon

hood aaches to the vent piping as

shown in Figure 9.

Spring

Trim Plate

(Inside)

Apply

Sealant

Cutaway to

Show Spring

Placement

Apply

Sealant

Trim Plate

(Outside)

1”

Clearance

14” Zero

Clearance

Figure 9 - Trim Plate Install

Vent Restricter Plate

The vent restricter plate (see Figure 10)

is required for short horizontal runs on

low vent installaons (Figure 16) and

high vent installaons (Figure 18).

For short horizontal vent runs (see

Figure 17) place the restricter plate

over the ue tube reducer before

connecng the inner corrugated tube

to the ue tube reducer. DO NOT use

the restricter plate if the horizontal run

is greater than 30”.

For high vercal runs use the restricter

plate only when the vercal run of the

venng above the heater is greater

than 48” (see Figure 18).

Do not use the restricter plate for

short horizontal runs or high vent

installaons where elevaon exceeds

5,400 feet.

Flue Tube

Reducer

Upper Air

Inlet Box

Restricter

Plate

Figure 10 - Restricter Plate

Uncompressing the Corrugated

Tubing

• Pull the inner corrugated tube

towards the water heater and leave

some length over the water heater’s

center for bending (see Figure 11).

• Pull the outer corrugated tube

toward the water heater and leave it

2” shorter than the inner corrugated

tube.

• Make sure there are two springs

evenly spaced at the bend in the

tube.

• Use metal hangers spaced a maxi-

mum of 36” apart to keep venng

level or with a slope upward from the

heater to terminal. It is recommend-

ed to add vibraon isolaon between

the venng and hangers to prevent

vibraon and noise from spreading

to the rest of the building.

GETTING STARTED

Residenal Gas Water Heater Use and Care Guide • 11

GETTING STARTED

Flue Tube

Reducer

Inner

Corrugated

Pipe

Apply

Silicone

Flue Tube

Reducer

Restricter

Plate

Figure 11 - Uncompressing the Corrugated

Tubing

Vent Connecon to the Water

Heater

Bend both the corrugated pipes

toward the ue connecon on the

water heater. Pull and connect the

inner corrugated pipe to the water

heater’s ue tube reducer with hi-

temp red silicone (included) and gear

clamp. Make sure this connecon is

ght and leak proof (see Figure 12).

*The sealant between the inner

corrugated pipe and water heater’s

ue tube reducer must be hi-temp red

silicone or other material suitable for

600°F connuous service.

NOTICE: If you are using the vent

restricter plate, the inner vent pipe is

to go over the side legs and down the

stops.

Smooth

Easy Curve

Restricter

Plate Stop

Cutaway to

Show Details

Gear Clamp

Figure 12 - Vent Connecon to the Water

Heater

Apply hi-temp red silicone (included)

around the collar on air manifold box.

Pull the outer corrugated pipe all the

way on to collar and secure with the

gear clamp. Pull the free end of the

corrugated pipe past the gear clamp

and secure with one sheet metal

screw (see Figure 13).

Smooth

Easy Curve

Apply silicone

to Airbox before

attaching pipe

Secure with

a sheetmetal

screw

Gear Clamp

Figure 13 - Apply Silicone to the Venng

Oset Vent Arrangement

Where a straight vent arrangement is

impossible, a horizontal 90° maximum

bend can be made. Use the water

heater casing outer diameter as a

template to form the corrugated tube.

Smooth

Easy Curve

90°

Maximum

Bend

Figure 14 - Venng Alignment (Top View)

Figure 15 - Bad Venng Conguraons

NOTICE: To ensure good exhaust gas

ow, bend vent piping using a smooth,

easy curve as shown in Figure 12

through Figure 14. Do not use reverse

or compound curves as shown in

Figure 15.

Use Table 2 with Figures 16-18.

Table: 2

DIM. 4036 5038

A 80” MAX.

B 9” MIN.

(RECOMMENDED)

63.63” 73.00”

(MINIMUM)

60.75 69.50

D 14.25” MIN.

NOTICE: Dimension “C” is the height above

to oor to the center of the terminaon hole

through the exterior wall.

Above

anticipated

snow level

or 12” above

grade.

Low Vent Installation

Figure 16 - Low Venng Installaon

Above

anticipated

snow level

or 12” above

grade.

Medium Vent Installation

9”

Figure 17 - Medium Venng Terminaon

12 • Residenal Gas Water Heater Use and Care Guide

12” Min.

Below

Soffit

72”

Max.

High Vent Installation

17”

Min.

1 5

Figure 18 - High Venng Terminaon

NOTES: (applies to Figure 16 through

Figure 18)

1. In any installaon the total of

dimension “A” plus dimension “B”

must not exceed 89”.

2. This heater can be installed with

0” clearance to a wall.

3. Minimum vent pipe clearance to

combusbles is 1” (see Figure 9).

4. Minimum distance from center of

heater to wall is 14.25”.

5. Dimension “A” includes wall

thickness.

6. Hole diameter in wall is 7”.

7. Venng must slope up away from

the heater a minimum of 0.25”

per foot of length to prevent

condensaon from collecng and

to provide sucient dra.

8. Distance above horizontal at full

extension is 2”.

9. Use support stays to hold the

venng to avoid sags or valleys.

Replacing a Water

Heater Using the

Exisng Vent System

Read the “Installing a New Vent

System” secon of this manual

and make sure your vent system

is properly installed. Inspect the

exisng vent system for obstrucons,

corrosion, and proper installaon.

Repair or replace if necessary. The

exisng vent system must be UL listed

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.

See Applicaon A and B to determine

if your new water heater can be

retroed to an exisng vent

terminaon hood:

Vent Terminaon Hood

(Applicaon A)

11-13/16"

Figure 19 - American Vent Terminaon Hood (A)

A current American DV water heater

vent terminaon includes 3 inch inner

piping to carry out the exhaust ue

gases and 5 inch outer piping to carry

in fresh combuson air.

If replacing a current American DV

water heater, a duct reducer and

union adapter must be installed to

connect the exisng vent terminaon

hood to new inner and outer piping.

Use kit number 100366535.

IMPORTANT: A weather shroud

is provided in this kit and must

be installed over the exisng vent

terminaon hood to ensure adequate

protecon from wind and other

weather related hazards. Failure to do

so may result in pilot outages at the

water heater.

Vent Terminaon Hood

(Applicaon B)

8-1/2"

Figure 20 - Bradford White Vent Terminaon

Hood (B)

A Bradford White® DV water heater

vent terminaon includes 3 inch inner

piping to carry out the exhaust ue

gases and 5 inch outer piping to carry

in fresh combuson air.

If replacing a Bradford White DV

water heater, a duct reducer and

union adapter must be installed to

connect the exisng vent terminaon

hood to new inner and outer piping.

Use kit number 100366536.

If you are not sure the exisng vent

terminaon hood is compable

with your new water heater, call our

Technical Assistance Hotline which is

listed on the water heater’s warranty

sheet.

GETTING STARTED

Residenal Gas Water Heater Use and Care Guide • 13

GETTING STARTED

Conned Space

Installaons

This water heater connects to the vent

terminaon hood using the sealed air

intake and exhaust piping.

During operaon this piping

can become hot, especially in

areas experiencing high ambient

temperatures.

When installed in a conned space

such as a closet, it is recommended

that the conned space be venlated

to minimize the buildup of heat

around the water heater. Figure 21

and Figure 22 show examples of

venlang a conned space.

TOP VIEW

OF CLOSET

WITHOUT DOOR

AIR

INTAKE*

TOP VIEW OF

CLOSET WITH

DOOR

0” MIN.

0”

MIN.

5.5” MIN.

* DO NOT BLOCK OR RESTRICT IN

ANY MANNER, THE AIR INTAKES AT

THE BACK OF THE WATER HEATER.

0”

MIN.

Figure 21 - Conned Space Clearances

ROOM

AIR FLOW

ROOM AIR

FLOW

FRONT VIEW

OF DOOR

VENTILATION

AIR

OPENING

Figure 22 - Conned Space Venlaon

Gas Piping

Gas piping must be 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.

NOTICE: When installing gas piping,

apply pipe joint compound or thread

sealant tape approved for fuel gases.

Ground

Joint

Union

Manual Gas

Shut-off

3” Min.

Check with

local utility for

minimum height

Sediment Trap

Figure 23 - Gas Piping

1. Install a readily accessible manual

shut-o valve in the gas supply

line as recommended by the local

ulity. Know the locaon of this

valve and how to turn o the gas

to this unit.

2. Install a Sediment Trap as shown

in the Gas Piping gure below.

The Sediment Trap must be no

less than three inches long for

the accumulaon of dirt, foreign

material, and water droplets.

3. Install a ground joint union be-

tween the gas control valve and

the manual gas shut-o valve.

This is to allow easy removal of

the gas control valve. NOTICE: a

hard line connecon is shown in

Figure 23 (a exible gas line con-

necon may also be used).

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

appear as small bubbles). If any

leaks are detected, ghten the

appropriate connecon(s) and

re-check.

Gas Pressure

NOTICE: When tesng gas pipes with

a test pressure of more than ½ psi (3.5

kPa), disconnect the gas line at the

manual shut-o valve and cap the gas

line. Do not subject the water heater’s

gas control valve or manual shut-o

valve to more than ½ psi (3.5 kPa)

pressure for any reason. If you are

pressure tesng the gas line with test

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

may isolate the water heater from the

gas line by closing the manual shut-o

valve.

14 • Residenal Gas Water Heater Use and Care Guide

Space Heang

REMOVE

ST BE VERTICAL TO

IR BUBBLES

OUT

COIL

AIR

HANDLER

AIR

HANDLER

SHUT-OFF

VALVE

EXPANSION TANK

VACUUM

RELIEF

VALVE

COLD WATER INLET

FLOW CONTROL

PUMP

SHUT-OFF

CHECK VALVE

†

(1/8” HOLE

DRILLED IN CLAPPER)

VALVE

CHECK

VALVE

†

TEMP/

PRESSURE

RELIEF

VALVE

TEMPERED WATER

TO FIXTURES

(MUST MEET TEMPS LISTED

IN MASS. CODE 248 CMR

†

)

MIXING VALVE

(MUST BE INSTALLED BELOW

TOP OF WATER HEATER

AS PER MANUFACTURER’S

RECOMMENDATIONS)

UNION

HOT

WATER

OUT

MASSACHUSETTS INSTALLATION REQUIREMENTS:

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

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

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

& 780 CMR).

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

† REQUIRED FOR MASSACHUSETTS.

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

WATER HEATER ACCEPTED

BY THE BOARD FOR

INSTALLATION IN

MASSACHUSETTS.

†

TYPICAL MIXING VALVE INSTALLATION

COMBINATION SPACE HEATING / POTABLE WATER HEATING SYSTEM

SEE

NOTE ‡

100’-0” MAXIMUM DISTANCE

FROM WATER HEATER

TO FAN COIL AND BACK

(DEVELOPED LENGTH) NOT

INCLUDING COIL IN HEATING UNIT.

†

Figure 24 - Combuson Space Heang and Potable Water (Typical Installaon)

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

heang 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 manufactur-

er’s instrucons.

• Pumps, valves, piping, and ngs

must be compable with potable

water.

• A properly installed ow control

valve is required to prevent ther-

mosiphoning. Thermosiphoning is

the result of a connuous ow of

water through the air handler circuit

during the o cycle.

• The domesc hot water line from

the water heater should be vercal

past any mixing valve or supply line

to the air handler to remove air bub-

bles from the system. Otherwise,

these bubbles will be trapped in

the air handler heat exchanger coil,

reducing eciency.

• Do not connect the water heater to

any system or components previ-

ously used with non-potable water

heang appliances when used to

supply potable water.

GETTING STARTED

Residenal Gas Water Heater Use and Care Guide • 15

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

standards. There have likely been

plumbing 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 plumbing 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 devices you need to comply

with current codes and assure that

your new water heater performs at its

best. Check with your local plumbing

ocial for more informaon.

✓

Water Pressure

Most codes allow a maximum

incoming water pressure of 80 psi

(we recommend a working pressure

no higher than 50-60 psi). Check

your home’s water pressure gauge

and adjust if necessary. High water

pressure can damage the water

heater, piping, and other appliances.

HOW: Purchase an inexpensive

water pressure gauge from your local

plumbing supplier. Connect the water

pressure gauge to an outside faucet

and measure the maximum water

pressure experienced throughout

a 24-hour period (highest water

pressures oen occur at night).

140

100

120

160

180

200

psi

AVOID FREEZING

Figure 25 - 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 Reducing

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 leak, or had to repair

appliances connected to the plumbing

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

recommend installing an expansion

tank if your home does not have one.

Plumbing codes require a properly

pressurized, properly sized Thermal

Expansion Tank in almost all homes.

Figure 26 - A Thermal Expansion Tank helps

protect the home’s plumbing system from

pressure spikes.

HOW: Connect the Thermal Expansion

Tank (available at your local plumbing

supplier) to the cold water supply

line near the water heater. The

expansion tank contains a bladder and

an air charge. To work properly, the

Thermal Expansion Tank must be sized

according to the water heater’s tank

capacity and pressurized to match

the home’s incoming water pressure.

Refer to the instrucons provided

with the Thermal Expansion Tank for

installaon details.

BACKGROUND: Water expands when

heated, and the increased volume

of water must have a place to go, or

thermal expansion will cause large

increases in water pressure (despite

the use of a Pressure Reducing Valve

in the home’s main water supply

line). The Safe Drinking Water Act of

16 • Residenal Gas Water Heater Use and Care Guide

1974 requires the use of backow

preventers and check valves to restrict

water from your home reentering

the public water system. Backow

preventers are oen installed in

water meters and may not be readily

visible. As a result, most all plumbing

systems today are now “closed,” and

almost all homes now need a Thermal

Expansion Tank.

A Thermal Expansion Tank is a

praccal and inexpensive way to help

avoid damage to the water heater,

washing machine, dishwasher, ice

maker, and even toilet valves. If

your toilet occasionally runs for no

apparent reason (usually briey at

night), that may be due to thermal

expansion increasing the water

pressure temporarily.

✓

Water Pipe and

Tank Leaks

Drain

Drain Pan

Discharge Pipe

Figure 27 - A metal drain pan piped to an

adequate drain can help protect ooring from

leaks and drips.

Leaks from plumbing pipes or from

the water heater itself can damage

property and could cause a re risk.

• Install an automac leak detecon

and shut-o device (available at

your local plumbing supplier). These

devices can detect water leaks and

can shut o the water heater’s wa-

ter supply if a leak occurs.

• Install a metal drain pan (available at

your local plumbing supplier) under

the water heater to catch conden-

saon or leaks from the piping

connecons or tank. Most codes

require, and we recommend, install-

ing the water heater in a metal drain

pan that is piped to an adequate

drain. The drain pan must be at least

two inches wider than the diameter

of the water heater. Install the drain

pan so the water level would be

limited to a maximum depth of 1-¾”.

The pan must not restrict air ow to

the burner.

✓

Water Tempera-

ture Regulaon

Install Thermostac Mixing Valves

to regulate the temperature of the

water supplied to each point-of-use

(for example, kitchen sink, bathroom

sink, bath, shower). Install and adjust

the mixing valve according to its

manufacturer’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 (see Table 1).

MIX



Figure 28 - Thermostac Mixing Valves installed

at each point-of-use can help avoid scalding.

BACKGROUND: A Thermostac Mixing

Valve, installed at each point-of-use,

mixes hot water from the water

heater with cold water to more

precisely regulate the temperature of

hot water supplied to xtures. If you

are not sure if your plumbing system

is equipped with properly installed

and adjusted Thermostac Mixing

Valves at each point where hot water

is used, contact a qualied person.

INSTALLATION

Residenal Gas Water Heater Use and Care Guide • 17

INSTALLATION

Step: 2

Verify that the Locaon

is Appropriate

WARNING! Do not store or use

ammable materials, vapors, or

liquids in the same locaon where

this water heater is installed.

Before installing your water heater,

ensure that it will be located:

• Indoors in an area with adequate air

supply.

• In an area that will not freeze.

• In a locaon as close to a wall as

praccable and as centralized with

the water piping system as possible.

• In a metal drain pan piped to an ad-

equate oor drain or external to the

building (Figure 36 on page 19).

• In an area with adequate space

(clearances) for periodic servicing.

There must be a minimum of 5-1/2

inches of front clearance, however,

24 inches of clearance is recom-

mended.

• In an area that allows minimum

clearances between the water

heater and combusbles. Minimum

clearances are 0 inches at the sides

and rear, 5-1/2 inches from the front

and 12 inches from the top. Mini-

mum clearances from vent piping

to combusbles is 1 inch except as

noted in Figure 9.

• On a oor that can support the

weight of a full water heater.

You will also want to follow these

guidelines while considering an

appropriate locaon:

• Do not install near air-moving devic-

es 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.

• Do not install in a bathroom,

bedroom, or any occupied room

normally kept closed.

• If the water heater is installed

directly on carpeng, it shall be

installed on a metal or wood panel

extending beyond the full width

and depth of the water heater by at

least 3 inches in any direcon. If the

water heater is installed in an alcove

or closet, the enre oor shall be

covered by the aforestated panel.

• If your area is prone to earthquakes,

use special straps as required by

local building codes.

NOTICE: The state of California

requires bracing, anchoring, or

strapping 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, ood-

ing, or other risks.

Vehicle

Stop

Drain

Pan

Figure 29 - In a garage, install a vehicle stop to

avoid water heater damage.

• Avoid locaons such as acs, upper

oors, or where leaks might damage

the structure or furnishings. Due

to the normal corrosive acon of

water, the tank will eventually leak.

To minimize property 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 surround-

ing area regularly and x any leaks

found. Drain pans are available at

your local plumbing supplier. Leaks

are frequently in the plumbing sys-

tem itself and not the water heater.

Step: 3

Removing the Old

Water Heater

Read each installaon step

and decide if you have the

necessary skills to install the

water heater. Only proceed if you are

comfortable you can safely perform

the work. If you are not sure, have a

qualied person perform the

installaon.

On the old water heater, turn

the control knob on the gas

control valve to the OFF

posion.

Mechanical Valve

TO LIGHT

HOLD

IGNITER

RELEASE KNO

Electronic Valve

Press down to turn

Turn to

pilot

SCALDING

RISK

INCREASES

WITH

HOTTER

WATER

HOT

LOW

PILOT

OFF

VERY

HOT

VAC

TO LIGHT PILOT:

PRESS

HOLD

KNOBIN

POSITION

PRESS

IGNITER

BUTTON

UNTIL

PILOTLIGHTS

RELEASEKNOB

WHEN

STATUS

LIGHT

BLINKS

STATUS

RED

WHITE

FLAMES

STATUS

LIGHT

CODE

SCALDING

RISK

INCREASES

WITH

HOTTER

WATER

HOT

LOW

PILOT

OFF

VERY

HOT

VAC

PRESS

CAUTION:

RISK OF SCALDING

INCREASES WITH

HOTTER WATER

Figure 30 - Turn gas control/temperature knob

OFF.

18 • Residenal Gas Water Heater Use and Care Guide

Turn the manual gas valve for

the water heater’s supply line

OFF.

Open a hot water faucet and

let the hot water run unl it

is cool.

Figure 31 - Let the hot water run unl it is cool.

WARNING! Be sure the water

runs cool before draining the tank to

reduce the risk of scalding.

Connect a garden hose to the

drain valve and place the

other end of the hose in a

drain, outside, or in buckets (sediment

in the boom of the tank may clog

the valve and prevent it from draining.

If you cannot get the tank to drain,

contact a qualied person).

Turn the cold water supply

valve OFF.

Figure 32 - Cold water supply in OFF posion.

Open the drain valve on the

water heater.

Figure 33 - Draining the old water heater.

Also open a hot water faucet

to help the water in the tank

drain faster.

When the tank is empty,

disconnect the Temperature

& Pressure (T&P) Relief Valve

discharge pipe. You may be able to

reuse the discharge pipe, but do not

reuse the old T&P Relief Valve. A new

T&P Relief Valve comes with your new

water heater.

Figure 34 - Removing the T&P Relief Valve

discharge pipe.

Allow the vent pipe and dra

hood to cool. Once cooled,

disconnect the vent pipe

from the dra hood. You may need to

support the vent pipe unl the new

water heater is in place.

Figure 35 - Disconnect the vent pipe from the

dra hood.

Disconnect the water pipes.

Many water pipes are

connected by a threaded

union which can be disconnected with

wrenches. If you must cut the water

pipes, cut the pipes close to the water

heater’s inlet and outlet connecons,

leaving the water pipes as long as

possible. If necessary, you can make

them shorter later when you install

the new water heater.

Conrm the manual gas valve

for the water heater’s supply

line is turned OFF. Disconnect

the gas line from the water heater’s

gas control valve and cap it.

Remove the old water heater.

Use an appliance dolly or

hand truck to move the water

heater.

WARNING! Use two or more

people to remove or install a water

heater. Failure to do so can result in

back or other injury.

INSTALLATION

Residenal Gas Water Heater Use and Care Guide • 19

INSTALLATION

Step: 4

Installing the New

Water Heater

Completely read all

instrucons before beginning.

If you are not sure you can

safely complete the installaon, seek

assistance from any of the following

sources:

• Schedule an appointment with a

qualied person to install your water

heater.

• Call our Technical Assistance Hotline

which is listed on the water heater’s

warranty sheet.

Install a metal drain pan that

is piped to an adequate drain.

Drain

Drain Pan

Discharge Pipe

Figure 36 - Metal drain pan piped to an ade-

quate drain.

Set the water heater in place

taking care not to damage

the drain pan. When installing

directly on carpet, the water heater

must be installed on a wood or metal

base that extends beyond the

dimensions of the water heater (width

and depth) by at least 3 inches in any

direcon. If the water heater is

installed on carpet in an alcove or

closet, the enre oor must be

covered by a wood or metal panel.

NOTICE: Most codes require seng

the water heater in a metal drain pan

piped to an adequate drain. The drain

pan helps avoid property damage

which may occur from condensaon

or leaks in the piping connecons or

tank. The drain pan must be at least

two inches wider than the diameter

of the water heater. Install the drain

pan so the water level is limited to a

maximum depth of 1-¾”.

Verify the water heater is

properly set in place. Check

that:

• There is adequate space to install

the T&P Relief Valve discharge pipe

and that it can be piped to a sep-

arate drain (and not into the drain

pan, unless otherwise allowed by

local and state codes).

• There is adequate access and space

around the water heater for future

maintenance.

• The water heater is installed ver-

cally.

Step: 5

Connect the

Temperature 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

according to local codes.

Figure 37 - 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.

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. Install a T&P Relief Valve

discharge pipe according to local

codes and the following guidelines:

• The discharge pipe should be at

least ¾” inside diameter and sloped

for proper drainage. Install it to

allow complete drainage of both the

T&P Relief Valve and the discharge

pipe.

20 • Residenal Gas Water Heater Use and Care Guide

• 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, exi-

ble plasc pipe, or any type of hose.

Figure 38 - The T&P Relief Valve discharge pipe

must be installed properly and piped to an

adequate drain.

• Terminate the discharge pipe a

maximum of six inches above a

oor drain or outside the building.

Do not drain the discharge pipe

into the drain pan; instead pipe it

separately to an adequate drain.

In cold climates, terminate the

discharge pipe inside the building to

an adequate drain. Outside drains

could freeze and obstruct the drain

line — protect the discharge pipe

from freezing.

Dicharge

Pipe

Drain

Pipe

6.00"

MAX

Figure 39 - Temperature and Pressure Relief

Valve Discharge Pipe

• Do not place any valve or other re-

stric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 dis-

charge pipe. Do not insert or install

any reducer in the discharge pipe.

Step: 6

Install Shut-O and

Thermostac Mixing

Valves

If one is not already installed,

install a manual shut-o valve

in the cold water line that

supplies the water heater. Install the

shut-o valve near the water heater

so that it is readily accessible. Only

use a full-ow ball or gate valve

compable with potable water.

Install a Thermostac Mixing

Valve at each point-of-use

(for example, kitchen sink,

bathroom sink, bath, shower) per the

valve manufacturer’s instrucons.

MIX



Figure 40 - Install Thermostac 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 scalding.

INSTALLATION

Residenal Gas Water Heater Use and Care Guide • 21

INSTALLATION

IF YOU HAVE COPPER PIPES:

If your home has copper water

pipes, you can solder the water pipe

connecons or use compression

ngs which do not require

soldering. Compression ngs

are easier to install than soldering

pipe. Check with local plumbing

ocials to determine what types of

pipe materials are suitable for your

locaon. Do not use lead-based

solder.

Compression ngs don’t require soldering.

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 adapt-

er using only 95/5 n-anmony

or equivalent solder. Aach the

threaded adapters to the water

heater’s connecons (using thread

sealant tape or pipe joint com-

pound). Connect the home’s water

pipes by soldering, keeping the

connecons at the water heater

cool with wet rags.

Step: 7

Connect the Water

Supply

Note that all piping and components

connected to the water heater must

be suitable for use with potable water.

Determine the type of water

pipes in your home. Most

homes use copper water

pipes, but some use CPVC or cross-

linked polyethylene (PEX). Use ngs

appropriate for the type of pipe in

your home. Do not use iron or PVC

pipe – they are not suitable for

potable water.

Connect the cold water

supply using ¾ inch Naonal

Pipe Thread “NPT” to the

cold water inlet nipple.

For ease of removing the water heater

for service or replacement, connect

the water pipes with a coupling called

a union. We recommend using a

dielectric-type union (available at your

local plumbing supplier). Dielectric

unions can help prevent corrosion

caused by ny electric currents

common in copper water pipes and

can help extend the life of the water

heater.

NOTICE: Most water heater models

contain energy saving heat traps in

the inlet and outlet connecons. Do

not remove the heat traps.

Connect the hot water supply

using ¾” NPT to the hot water

outlet. Follow the same

connecon guidelines as for the cold

water supply.

Install insulaon (or heat

tape) on the water pipes

especially if the indoor

installaon area is subject to freezing

temperatures. Insulang the hot

water pipes can increase energy

eciency.

Adjust (or install) the home’s

Pressure Reducing Valve to

50-60 psi and install a

Thermal Expansion Tank.

Figure 41 - A Pressure Reducing Valve is re-

quired if your home’s water pressure is above

80 psi.

Figure 42 - The Thermal Expansion Tank should

be pressurized with air to match the home’s

incoming water pressure.

22 • Residenal Gas Water Heater Use and Care Guide

Step: 8

Verify Connecons and

Completely Fill Tank

To remove air from the tank and allow

the tank to ll completely with water,

follow these steps:

Remove the ow restrictor at

the nearest hot water faucet.

This allows debris in the

plumbing system to be washed out of

the pipes.

Turn the cold water supply

back on and ll the tank.

Figure 43 - Fully open the cold water supply

valve.

Open a hot water faucet and

allow the water to run unl it

ows with a full stream.

Let the water run full stream

for three minutes.

Close the hot water faucet

and replace the ow

restrictor.

Check the inlet and outlet

connecons and water pipes

for leaks. Dry pipe

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: 9

Install Vent Pipe

Install the new vent pipe on

top of the water heater. Do

not reuse the vent pipe from

the old water heater, but rather use

the new one that came with your new

water heater. Follow “Venng” on

page 8.

Step: 10

Make Gas Connecons

The Gas Water Heater Hook-Up Kit

(available at your local plumbing

supplier) includes a exible gas

connector with compression ngs

to connect the home’s gas line

to the water heater’s gas control

valve. Follow the kit’s installaon

instrucons to aach the exible gas

connector.

Figure 44 - Flexible Gas Line Connector

Once you have made the gas

connecons, use a small, so-bristled

brush to apply a hand dishwashing

soap and water mixture or children’s

soap bubbles (1 part soap to 15 parts

water) to all connecon points of the

gas line and exible gas connector (if

used). Make sure to generously coat

all the connecons and check for

gas leaks (which will appear as small

bubbles). If any leaks are detected,

turn the gas supply o, ghten the

leaking connecons and re-check.

INSTALLATION

Residenal Gas Water Heater Use and Care Guide • 23

INSTALLATION

BEFORE LIGHTING THE WATER

HEATER...

Make sure all checklist items have

been completed.

Water Heater Locaon

✓ Centrally located with the water

piping system. Located as close to

gas piping and vent pipe system as

possible.

✓ Installaon area free of corrosive

or ammable materials, liquids or

vapors.

✓ Proper clearances from combusble

surfaces maintained and sucient

room to service the water heater.

✓ Not installed directly on a carpeted

oor.

✓ Metal drain pan installed and piped

to an adequate drain.

Vent Pipe System

✓ 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.

✓ Evenly stretched out between water

heater and vent terminaon hood.

✓ Smooth bends with adequate

support to prevent sagging, 0.25”

per foot.

✓ Inside pipe (3”) and outside pipe

(6”) securely fastened to vent termi-

naon hood.

✓ Vent restricter plate installed on

heater ue outlet as applicable.

✓ Inside pipe (3”) and outside pipe

(6”) securely fastened to water

heater with silicone and gear

clamps.

✓ Not obstructed in any way.

Vent Terminaon Hood

✓ Securely fastened to exterior wall.

✓ Above ancipated snow level or 12”

above grade.

✓ Proper clearances from windows,

doors, corners, other vent openings

etc..

✓ Area around vent terminaon hood

clear and unobstructed.

✓ No ammable vapor eming prod-

ucts stored nearby.

✓ Safety covers in place (when appli-

cable).

Water System Piping

✓ Temperature and Pressure Relief

Valve properly installed with a dis-

charge line run to an adequate drain

and protected from freezing.

✓ Water pipes free of leaks.

✓ Water heater completely lled with

water.

✓ Thermal Expansion Tank installed.

✓ Water Pressure Reducing Valve

installed and properly adjusted to

50-60 psi.

✓ Thermostac Mixing Valves installed

at each point-of-use.

Gas Supply and Piping

✓ Gas type is the same as that listed

on the water heater’s data plate.

✓ Gas line equipped with shut-o

valve.

✓ Adequate gas pipe size and ap-

proved gas pipe material.

✓ All gas connecons and ngs leak

checked and any leaks corrected.

INSTALLATION

24 • Residenal Gas Water Heater Use and Care Guide

Lighng Instrucons

WARNING! Explosion Hazard —

Replace viewport if glass is missing or

damaged. Failure to do so can result

in death, explosion or re.

Read and understand these direcons

thoroughly before aempng to light

or re-light the pilot. Make sure the

viewport is not missing or damaged.

Make sure the tank is completely

lled with water before lighng the

pilot. Check the data plate near the

gas control valve to ensure the correct

gas type. Do not use this water heater

with any gas other than the one listed

on the data plate. If you have any

quesons or doubts, consult your gas

supplier or gas ulity company.

NOTICE: A newly installed water

heater will have air in the gas line. It

may take several lighng aempts to

clear all the air from the gas line and

light the pilot.

Follow these steps to light the pilot:

Make sure the manual gas

valve for the water heater’s

supply line is ON.

Turn the gas control knob to

the PILOT posion.

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 ash. You can

tell the pilot is lit when the Status

Light ashes once every three

seconds.

Once the Status Light starts

ashing, release the gas

control knob. Adjust the gas

control knob to the desired

temperature seng.

If the Status Light doesn’t

start ashing aer 90

seconds,release the gas

control knob and wait 10 minutes.

Repeat lighng steps 2

through 5 at least two

addional mes or unl the

Status Light starts ashing once every

three seconds. Wait 10 minutes

between lighng aempts.

A solid Status Light means the

pilot was lit but is now o.

Release the gas control knob

and wait 10 minutes. Once the Status

Light goes out, repeat lighng steps 2

through 5.

If the Status Light doesn’t

start 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 26).

When a gas water heater is

rst lit and the tank is cold,

condensaon oen forms

inside the water heater. You may hear

drips or a sizzling sound when the

water heater is rst lit or, you may see

a small puddle on the oor.

Condensaon is not a leak and will go

away once the tank reaches normal

operang temperature.

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 o.

Emergency Shut Down

Should overheang occur or the gas

supply fail to shut o , turn o the

water heater’s manual gas control

valve and call a qualied person.

Check the Vent System

and Air Supply

WARNING! Burn Hazard. Do not

touch the vent, doing so can cause

burns.

Check for obstrucons and/or

deterioraon of the intake air and/

or vent piping and the intake air and

vent terminaons. The combuson

and venlaon air ow must not be

obstructed. Repair and/or replace

immediately as necessary.

NOTICE: Do not reach inside the vent

terminaon while the heater is in

operaon.

Remove any debris that may have

accumulated on the screen in the vent

terminaons.

OPERATION

Residenal Gas Water Heater Use and Care Guide • 25

OPERATION

Check all vent system connecons for

damage or deterioraon which could

cause improper venng or leakage of

combuson products. Repair or reseal

as necessary.

Be sure the vent piping is properly

connected to prevent escape of

dangerous ue gases which could

cause deadly asphyxiaon.

Obstrucons and deteriorated vent

systems may present serious health

risk or asphyxiaon.

Chemical vapor corrosion of the ue

and vent system may occur if air for

combuson contains certain chemical

vapors. Spray can propellants,

cleaning solvents, refrigerator and air

condioner refrigerants, swimming

pool chemicals, calcium and sodium

chloride, waxes, bleach and process

chemicals are typical compounds

which are potenally corrosive.

If aer inspecon of the vent system

you found soong or deterioraon,

something is wrong. Call the local

gas ulity to correct the problem and

clean or replace the ue and venng

before resuming operaon of the

water heater.

Temperature Control

System

Adjusng the Temperature

With the installaon steps completed,

you may adjust the water heater’s

temperature seng if desired.

Set the gas valve to the

desired temperature. The

“HOT” seng sets the water

temperature 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. Install

Thermostac Mixing Valve(s) at each

point-of-use to reduce the risk of

scalding.

To adjust the water heater’s

thermostat:

HOT

LOW

PILOT

OFF

VERY

HOT

VAC

TO LIGHT PILOT:

PRESS

HOLD

KNOB IN

POSITION

PRESS

IGNITER

BUTTON

UNTIL

PILOT LIGHTS

RELEASE KNOB

WHEN

STATUS

LIGHT

BLINKS

Figure 45 - Adjust the gas control knob to “HOT”.

Turn the gas control knob on the

gas control valve to the right to the

following sengs.

• “A” 128°F

• “B” 138°F

• “C” 147°F

• “VERY HOT” 155°F

NOTICE: The temperatures above are

approximates. The actual temperature

of the heated water may vary.

Wait for the water to heat

up. If you have no hot water

aer two hours, refer to the

Troubleshoong Secon (see page

26).

NOTICE: If the tank is full of cold

water, condensaon may form inside

the water heater. This condensaon

may drop on the burner causing a

sizzling sound. In some cases, you

may see a small puddle on the oor.

Condensaon is normal and should go

away once the tank reaches its normal

operang procedure.

WARNING! If you have increased

the temperature seng and the

Thermostac Mixing Valves are not

set properly (or installed) you could

scald yourself while checking the

temperature.

Operang Modes

The gas control valve has two

dierent 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 recommended when not using

hot water for an extended period of

me. The VAC seng also reduces

energy losses and keeps the tank from

freezing during cold weather but can

cause a Hydrogen gas build up. See

cauon on page 6.

OPERATION

26 • Residenal Gas Water Heater Use and Care Guide

No Hot Water

Use the following step-by-step plan

as a guide to help determine why you

have no hot water:

Check the Status Light

The Status Light on the gas

control valve ashes once every three

seconds if the pilot is lit and the gas

control valve has not detected any

problems.

SCALDING

RISK

INCREASES

WITH

HOTTER

WATER

HOT

LOW

PILOT

OFF

VERY

HOT

VAC

TO LIGHT PILOT:

PRESS

HOLD

KNOB IN

POSITION

PRESS

IGNITER

BUTTON

UNTIL

PILOT LIGHTS

RELEASE KNOB

WHEN

STATUS

LIGHT

BLINKS

STATUS

RED

WHITE

FLAMES

STATUS

LIGHT

CODE

Figure 46 - Status Light

Status Light is Not

Flashing

If the Status Light is ashing once

every three seconds and you have no

hot water, make sure the gas control

knob is set to HOT.

If the Status Light ashes more than

once every three seconds, refer to

the Status Light Code Troubleshoong

Chart on page 28.

If the Status Light is not ashing, go to

step 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 rmly inserted into the

white connector.

If you see a spark, make sure the gas

supply valve is turned on, and try

lighng the pilot using the lighng

instrucons on page 24.

If the pilot sll does not light, call a

qualied person.

Insucient Hot Water

or Slow Hot Water

Recovery

WARNING! Because of the

increased risk from scalding, if you

set the water heater’s thermostat(s)

higher than 120°F, Thermostac

Mixing Valves at each point-of-use

are parcularly important.

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 buildup 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 installing

Thermostac Mixing Valves at each

point-of-use and then turning the gas

control knob to a higher seng.

You can also reduce your home’s hot

water needs by washing clothes in

cold water, installing ow restrictors

on shower heads, repairing leaky

faucets, and taking other conservaon

steps.

Reversed Connecons or Melted Dip

Tube. Check the hot and cold water

connecons and make sure your

home’s hot water pipe is connected

to the hot water outlet on the water

heater. Usually, reversed connecons

are found soon aer the installaon

of a new unit. If copper pipes were

soldered while they were aached to

the water heater, the dip tube may

have melted. The dip tube is a long,

plasc tube inside the tank aached

to the cold water inlet. If the dip

tube has melted, it can be replaced

by removing the cold water inlet

connecon, removing the old dip tube

and installing a new one.

TROUBLESHOOTING

Residenal Gas Water Heater Use and Care Guide • 27

TROUBLESHOOTING

Plumbing Leak. Even a small leak

in the hot water side of the home’s

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

exisng water heater, if you have

some hot water but not as much

as you are used to, there may be a

build up of sediment or lime on the

boom of the tank. Sediment or lime

buildup can reduce the eciency of

your water heater. Heavy deposits

can damage the water heater. See

the Maintenance secon for steps

on draining and ushing the water

heater.

Temperature Too High

Adjust the gas control valve/

thermostat on the water heater

to a lower seng. Install or adjust

Thermostac Mixing Valves at

each point-of-use (see the valve

manufacturer’s instrucons).

Low Water Pressure

Check both the cold and hot water

at a sink to determine if the lower

pressure is only on the hot water side.

If both hot and cold faucets have low

pressure, call your local water ulity.

If the low pressure is only on the hot

water side, the primary causes are:

• Melted heat traps or dip tube. Sol-

dering copper pipes while they are

connected to the water heater can

melt the heat traps inside the hot

and cold water connecons or the

dip tube (cold water side). Melted

heat traps or a melted dip tube can

restrict the ow of hot water. If that

is 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 Expansion

Tank. See Step 1 in the Installaon

secon of this manual for more

informaon.

A large amount of hot water coming

from the T&P discharge pipe may be

due to the tank overheang. If the

T&P Relief Valve is discharging large

amounts of very hot water, turn the

gas supply valve o and call a qualied

person.

WARNING! Do not cap or plug

the T&P Relief Valve or discharge

pipe, and do not operate the water

heater without a funconing T&P

Relief Valve — this could cause an

explosion.

Water Pressure Too High. High

water pressure can cause the T&P

Relief Valve to drip. Install a Pressure

Reducing 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

Expansion 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 seang fully. In that

case, the T&P Relief Valve discharge

pipe will drip. You may be able to clear

debris from the T&P Relief Valve by

manually operang the valve, allowing

small quanes of water to ush out

the debris. Refer to the T&P Relief

Valve Maintenance secon of this

manual.

WARNING! When manually

operang the Temperature Pressure

Relief Valve, make sure that no one

is in front of or around the discharge

outlet. The water may be extremely

hot and could cause severe burns.

Also ensure that the water discharge

will not cause property damage.

If the water pressure is between 50

and 60 psi, a Thermal Expansion Tank

is installed and properly pressurized,

and the valve has been cleared of any

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

be broken — have a qualied person

replace the T&P Relief Valve.

Water Odor

Harmless bacteria normally present

in tap water can mulply in water

heaters and give o a “roen egg”

smell. Although eliminang the

bacteria that causes “smelly water”

is the only sure treatment, in some

cases, the standard anode rod that

came with your water heater can be

replaced with a special zinc anode rod

which may help reduce or eliminate

the odor. Contact a qualied person.

NOTICE: To protect the tank, an anode

rod must be installed in the water

heater at all mes or the warranty is

void.

In cases where the “roen egg” smell

is very strong, you could increase the

tank temperature to 140°F in order

to reduce the 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.

TROUBLESHOOTING

28 • Residenal Gas Water Heater Use and Care Guide

Status Light and Diagnosc Code Troubleshoong Chart

LED STATUS OR ERROR CODE INDICATES CORRECTIVE ACTION

0 FLASHES (LED NOT LIT) Pilot light is not lit or thermopile has not yet

reached normal operang temperature.

Turn Gas Control Valve/Thermostat knob to “OFF”.

Wait 10 minutes, then aempt to relight Pilot by

following the lighng instrucons on the water

heater’s label. Unl the thermopile reaches its

normal operang temperature, the Status Light

will not blink, even if the Pilot is lit. It may take

up to 90 seconds of connuous Pilot operaon

before the thermopile reaches normal operang

temperature and the Status Light starts to blink. If

the Status Light does not blink aer three lighng

aempts, check to make sure unit is geng

gas. Remove the outer door. Press reset buon.

Replace outer door. Turn Gas Control Valve/

Thermostat knob to “OFF”. Wait 10 minutes, then

aempt to light Pilot by following the lighng

instrucons on the water heater’s label. Look

through the view port for the Pilot ame. If Pilot

is not visible, the spark igniter or gas supply to the

Pilot should be checked. If the Pilot is visible and

the Status Light does not blink aer 90 seconds

of connuous Pilot operaon, the Pilot ame may

not be heang the thermopile suciently (weak

Pilot), the thermopile may be defecve, or wiring

connectors may be loose.

RED LIGHT ON (SOLID) Pilot light was recently exnguished and the

thermopile is cooling down.

Turn Gas Control Valve/Thermostat knob to “OFF”.

Wait 10 minutes for the thermopile to cool, then

aempt to relight Pilot by following the lighng

instrucons on the water heater’s label.

NOTE: This gas control valve/thermostat has

built-in circuitry that requires waing 10 minutes

between lighng aempts.

Unl the thermopile reaches its normal operang

temperature, the Status Light will not blink, even

if the Pilot is lit. It may take up to 90 seconds of

connuous Pilot operaon before the thermopile

reaches normal operang temperature and the

Status Light starts to blink.

1 FLASH (EVERY 3 SECONDS) Normal Operaon No correcve acon necessary.

2 FLASHES Pilot is lit but the thermopile is not producing the

required output voltage.

Turn Gas Control Valve/Thermostat knob to “OFF”.

The thermopile is probably defecve, but loose

wiring connecons or a weak Pilot ame can also

cause this symptom.

4 FLASHES The Gas Control Valve’s temperature sensor has

detected that the water temperature was too high.

Once this condion occurs, the Main Burner and

the Pilot Light will be shut o. Since the Pilot light

will be o, should this condion occur, this Flash

Code will only be displayed immediately aer

the Pilot has been relit. Turn Gas Control Valve/

Thermostat knob to “OFF”.

Relight pilot and verify 4 ashes. If 4 ashes are

observed, turn Gas Control Valve/Thermostat knob

to “OFF”. Turn Main Gas Supply “OFF.” Replace the

Gas Control Valve/Thermostat. See “Removing and

Replacing the Gas Control Valve/Thermostat.”

5 FLASHES The temperature sensor (thermistor) is defecve. Turn Gas Control Valve/Thermostat knob to “OFF”.

Replace the temperature sensor (thermistor).

7 FLASHES Gas Control Valve failure. Turn Gas Control Valve/Thermostat knob to “OFF”.

Turn Main Gas Supply “OFF”. Replace the Gas

Control Valve/Thermostat. See “Removing and

Replacing the Gas Control Valve/Thermostat.”

TROUBLESHOOTING

Residenal Gas Water Heater Use and Care Guide • 29

TROUBLESHOOTING

LED STATUS OR ERROR CODE INDICATES CORRECTIVE ACTION

8 FLASHES This condion only appears if the gas control/

temperature knob has been turned o and the

thermopile connued to produce electric power.

This condion can occur if the thermopile does not

cool down as quickly as expected when the unit

is shut o. This condion can also occur if the gas

control/temperature knob has been turned o and

the pilot connues to operate because the pilot

valve is stuck in the open posion.

Make sure that the gas control valve/thermostat

knob is set to “OFF”. Wait one minute. Remove

the outer door. Look through the sight glass for a

pilot ame. If a pilot ame is observed with the

gas control valve/thermostat knob set to the “OFF”

posion, the pilot valve is stuck open. Turn the

main gas supply “OFF”. Replace the gas control

valve/thermostat. For instrucons, see “Removing

and Replacing the Gas Control Valve/ Thermostat.”

If the pilot ame is not observed when the gas

control valve/thermostat knob is set to the “OFF”

posion, wait 10 minutes for the thermopile to

cool, then aempt to relight the pilot by following

the lighng instrucons on the water heater’s

label. If this condion returns, replace the gas

control valve/thermostat. See “Removing And

Replacing The Gas Control Valve/Thermostat” for

instrucons.

TROUBLESHOOTING

30 • Residenal Gas Water Heater Use and Care Guide

Roune Maintenance

Roune maintenance will help your

water heater last longer and work

beer. If you cannot perform these

roune maintenance tasks yourself,

contact a qualied person.

Draining and Flushing the

Water Heater

Tap water contains minerals that can

form sediment in the boom of the

tank. The amount of lime deposits or

sediment depends on the hardness

of your tap water. The rate at which

sediment builds up depends on water

quality and hardness in your area,

the temperature sengs, and other

variables. We recommend draining

and ushing the water heater aer

the rst six months of operaon to

determine the amount of sediment

build up. Draining sediment extends

the life of the tank and drain valves.

To Drain and Flush the Tank:

Turn the gas control knob on

the gas control valve to the

OFF posion.

HOT

LOW

PILOT

OFF

VERY

HOT

VAC

TO LIGHT PILOT:

PRESS

HOLD

KNOB IN

POSITION

PRESS

IGNITER

BUTTON

UNTIL

PILOT LIGHTS

RELEASE KNOB

WHEN

STATUS

LIGHT

BLINKS

Figure 47 - Turn gas control/temperature knob

OFF.

Turn the manual gas valve for

the water heater’s supply line

OFF.

Open a hot water faucet and

let the hot water run unl it

is cool.

Figure 48 - Let the hot water run unl it is cool.

WARNING! Be sure the water

runs cool before draining the tank to

reduce the risk of scalding.

Connect a garden hose to the

drain valve and place the

other end of the hose in a

drain, outside, or in buckets. Note

that sediment in the boom of the

tank may clog the valve and prevent it

from draining. If you cannot get the

tank to drain, contact a qualied

person.

Turn the cold water supply

valve OFF.

Open the drain valve on the

water heater.

Figure 49 - Draining the water heater.

Open a hot water faucet to

help the water in the tank

drain faster.

NOTICE: DO NOT aempt to light

the water heater unless the tank is

completely full of water.

Remove and inspect the

anode rod and replace if

depleted. The anode rod

requires a 1-1/16” socket.

Figure 50 - Anode rods from new (top) to par-

ally depleted (middle) to fully depleted stage

(boom).

Anode Rod. The anode rod is a

sacricial metal rod that helps avoid

corrosive and premature failure

(leaks) in the tank. The anode rod

is a consumable item. Inspect the

anode rod aer the rst six months of

operaon when you drain and ush

the tank. Replace the anode rod if it

is substanally worn out or depleted.

Thereaer, inspect the anode rod

annually or more frequently if

needed. If you use a water soener,

your anode rod will deplete faster

than normal. Inspect the anode

rod more frequently, replacing the

anode rod if it is depleted. Obtain

a new anode rod at your local

plumbing supplier or have a qualied

person replace it. (Anode rods are a

consumable item and are not covered

under warranty).

If a large amount of sediment

was present when the tank

was drained, ush the tank

by opening the cold water supply

valve and leng the water run unl

no more sediment drains from the

tank. Close the drain valve when you

are done.

MAINTENANCE

Residenal Gas Water Heater Use and Care Guide • 31

MAINTENANCE

NOTICE: Do not aempt to light

the water heater unl the tank is

completely full of water. For complete

instrucons on lling the tank, follow

Step 8 in the “Installaon” secon.

Rell the tank by opening the

cold water supply valve.

Make sure a hot water faucet

is open and the drain valve is closed.

Allow a hot water faucet to run full for

at least three minutes to make sure

the tank has all the air removed and is

completely full of water. Once you are

certain the tank is completely full of

water, close the hot water faucet.

Relight the pilot using the

instrucons on page 24

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, and pilot

burner.

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 obstructed.

• Buildup of soot and carbon on the

main burner and pilot burner. The

burner may be cleaned with soap

and hot water.

• Inspect the burner ames through

the viewport and compare them

to the drawing above. A properly

operang burner should produce a

so blue ame. Blue ps with yellow

inner cones are sasfactory. The ps

of the ame may have a slight yel-

low nt. The ame should not be all

yellow or have a sharp blue-orange

color. Contaminated air may cause

an orange colored ame. Contact a

qualied technician if the ame is

not sasfactory.

Correct Flame

Soft Blue

Figure 51 - Burner Flames

• Leaking or damaged water and gas

piping.

• Remove any ammable, corrosive

or combusble materials near the

water heater.

If you lack the necessary skills

required to properly perform this

visual inspecon or if the burner

needs to be cleaned, get help from a

qualied person.

T&P Relief Valve Maintenance

Figure 52 - T&P Relief Valve

Read and follow the operang and

annual maintenance instrucons

provided by the manufacturer of

the T&P Relief Valve (yellow label

aached to T&P Relief Valve). If no

label is aached to the T&P Relief

Valve, follow the instrucons in this

secon.

Minerals in the water can form

deposits that cause the valve to sck

or create blocked passages, making

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 opening the valve manually,

check that it will discharge in a place

for secure disposal.

• Aer manually operang T&P Relief

Valve, remove any water in the drain

pan and wipe away any water from

the heater.

WARNING! Hot water will be

released. Before opening the T&P

Relief Valve manually, check that it

will discharge in a safe place. If water

does not ow freely from the end

of the discharge pipe, turn the gas

control knob to the OFF posion and

call a qualied person to determine

the cause.

• At least every ve years, have a

qualied person inspect the T&P

Relief Valve and discharge pipe.

Damage caused by corrosive water

condions, mineral deposits, or

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Manual - ProLine-Direct Vent Ultra-Low NOx manual (100369451)

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