AO Smith GCF-40 101 ProLine XE 40-Gallon High Efficiency 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

with the Flammable Vapor Ignion Resistant Safety System

Not for use in Manufactured (Mobile) Homes

100400765_2000621411

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.

November 2025

Table of Contents

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

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

Installaon ............................................................................. 13

Installaon ............................................................................. 21

Operaon .............................................................................. 22

Troubleshoong .................................................................... 25

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

Repair Parts ........................................................................... 37

LOW LEAD

CONTENT

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

COMPLETED INSTALLATION (TYPICAL)

To Vent Termination

On Roof

Vent Pipe

Cold Inlet

Hot Outlet

Inlet Water

Shut-off Valve

Thermal

Expansion Tank

Temperature and Pressure

Relief Valve

Discharge Pipe

Drain Valve

Floor Drain

Drain Pan

Drip Leg

Manual Gas

Shut-off

Gas Control Valve/

Thermostat

Draft Hood

Gas Supply

Piping

Transformer

Ground Joint Union

TCO SWITCH

Flue Damper

NOTICE: If copper piping is used, then unions must be dielectric at inlet and outlet.

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, clean condensate

pan, and remove and inspect anode

rod after first six months of operation

and at least annually thereafter. Inspect

and operate the Temperature and

Pressure Relief Valve (T&P) annually

(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) 1-½ 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 1-½ 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 (page 23).

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

water heater’s temperature seng.

SAFETY

IMPORTANT SAFETY INFORMATION

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

IMPORTANT SAFETY INFORMATION

SAFETY

• 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/

thermostat or surrounding insula-

on have been exposed to water in

any way (e.g., leaks from plumbing,

leaks from the water heater itself

can damage property and could

cause a re risk). If the water heater

is subjected to ood condions or

the 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.

Carbon Monoxide Risk

WARNING! This water heater

operates by burning gas. Carbon

monoxide is a colorless, odorless,

gas that is a by-product of burning

of fuels such as coal, wood,

charcoal, oil, kerosene, propane,

and natural gas. Breathing excessive

and abnormal amounts of carbon

monoxide can cause carbon

monoxide poisoning,

resulng in serious

injury or death. This

water heater must

be supplied with

adequate combuson

air and must be properly vented to

the outdoors. Have a qualied person

(licensed plumber, authorized gas

company personnel, or authorized

service technician) install the venng

system using these installaon

instrucons. When the installaon is

complete, check the venng system

using the instrucons on page 23.

• Install a fuel gas and carbon mon-

oxide detector in the living areas of

your home.

• Do not install this water heater in

a mobile home or manufactured

housing.

• Failure to follow these instrucons

can result in serious injury or death

from carbon monoxide poisoning.

Burn Risk

This water heater’s

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.

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, one 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.

• Safety gloves.

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.

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 design-

cered by CSA Internaonal

as a Category I, non-direct

vented water heater which takes its

combuson air either from the

installaon area or from air ducted to

the unit from the outside.

This water heater must be installed

according to all local and state codes

or, in the absence of local and state

codes, the “Naonal Fuel Gas Code”,

ANSI Z223.1 (NFPA 54)-current

edion. This is available from the

following:

CSA America, Inc.

8501 East Pleasant Valley Road

Cleveland, OH 44131

Naonal Fire Protecon Associaon

1 Baerymarch Park

Quincy, MA 02269

Check with local code ocials about

codes governing this installaon.

Have your installaon inspected by a

code ocial to ensure the installaon

meets all local codes.

NOTICE: If you lack the necessary

skills required to properly install this

water heater, or you have diculty

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.

Combuson and

Venlaon Air Supply

Before installing the water heater, you

must determine the amount of air

needed to supply this water heater

and any other gas appliances in the

same area and provide adequate

air for combuson and venlaon.

Consult a qualied person if you are

unsure of the proper way to supply air

to your water heater.

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:

Calculate total BTU/HR rang of all

appliances.

To calculate the combuson air and

venlaon required, add up the total

BTU/HR rangs of all gas burning

appliances (e.g., water heaters,

furnaces, clothes dryers) in the same

area.

Your water heater’s BTU/HR rang

is on the data plate, located next to

the gas control valve/thermostat.

The BTU/HR rangs should be on the

other appliances’ data plates. If you

have trouble determining the BTU/HR

rangs, contact the manufacturer or

have a qualied person determine the

venlaon requirements.

NOTICE: If you are replacing your

old water heater with one that has a

higher BTU/HR rang, the amount of

venlaon required may be greater.

See the following page for calculaon

examples.

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

GETTING STARTED

Example:

Gas Burning Appliance BTU/HR Rang

Gas Water Heater 40,000

Furnace 75,000

Dryer 20,000

Total 135,000

Your Appliances:

Gas Burning Appliance BTU/HR Rang

Gas Water Heater

Total

Table 2 provides examples of

minimum square footage (area)

required for various BTU/HR totals.

Areas used for storage or which

contain large objects containing less

air than is assumed for the room sizes

in Table 2 — see Opon A for more

specic calculaons.

Opon A: Installaon without

outside venlaon (not

recommended)

Venlaon with outside air is

recommended for all installaons.

Even if the water heater is installed in

a large, open room inside the house,

outdoor air is usually needed because

modern homes are very ghtly sealed

and oen do not supply enough air

to the water heater. However, when

installed in a large indoor space, it

may be possible to provide enough air

without outside venlaon. If you are

unsure if your installaon locaon has

enough venlaon, contact your local

gas ulity company or code ocials

for a safety inspecon.

The following instrucons will help

determine if it may be possible to

install without outside venlaon.

Even if this may be possible, you

will need to conduct the vent dra

test on page 23 when installaon

is nished. If there is not enough

venlaon, you will need to venlate

with outside air.

Check for Chemicals:

Installaons where corrosive

chemicals may be present require

outside air. Air for combuson and

venlaon must be clean and free of

corrosive or acid-forming chemicals

such as sulfur, uorine, and chlorine.

Venlaon with outside air will reduce

these chemicals, but it may not

completely eliminate them. Failure

due to corrosive chemicals is not

covered by the warranty. Examples of

locaons that require outside air due

to chemicals include:

• Beauty salons

• Photo processing labs

• Indoor pools

• Laundry, hobby, or cra rooms

• Chemical storage areas

Products such as aerosol sprays,

detergents, bleaches, cleaning

solvents, gasoline, air fresheners,

paint and varnish removers, and

refrigerants should not be stored or

used near the water heater.

A1: Calculate the air volume of

the room

Air requirements depend on the size

of the room.

Floor Area (square feet) x Ceiling

Height (feet) = Room Volume (cubic

feet)

If there are large objects in the

room (e.g., refrigerator, furnace,

car), subtract their volume from the

volume of the room to get a beer

esmate of the air available.

Room Volume – Object Volume = Air

Volume

Table 2:

BTU/HR

Input

Minimum Square Feet

with 8’ Ceiling

Typical Room

with 8’ Ceiling

30,000 188 9 x 21

45,000 281 14 x 20

60,000 375 15 x 25

75,000 469 15 x 31

90,000 563 20 x 28

105,000 657 20 x 33

120,000 750 25 x 30

135,000 844 28 x 30

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

GETTING STARTED

A2: Calculate required air

volume

A water heater installed in an

unconned ac or garage requires

that the space be at least 50 cubic feet

per 1,000 BTU/HR of the total input

for all gas burning appliances in the

same area.

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

of air required.

Example:

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

If the air volume of the room is less

than the required air volume, you

must provide two permanent outside

air openings that draw in sucient air.

Use Opon B.

If the air volume of the room is

greater than the required air volume,

it may be possible to install the water

heater without outside venlaon.

A3: Check that combuson

venlaon is adequate

Because modern homes are oen

well-sealed to prevent dras, a

large room may not provide enough

combuson air without venlaon.

To conrm that your installaon has

enough combuson air, conduct the

vent dra test on page 23 when

installaon is nished.

Opon B: Installaon with

outside venlaon

Venlaon with outside air is

recommended, and for most

installaons, is needed. There may be

exisng venlaon that is adequate,

or you may need to add more

venlaon.

Supplying outside air typically requires

two openings. One opening must be

within 12 inches from the oor and

the second opening must be within

12 inches from the ceiling. Although

a single opening is not preferred, you

may use a single opening to outside

air if the minimum free area is sized

according to Table 3. Two openings

must be used when venlang with

air from another room.

B1: Determine type of

venlaon

There are several types of venlaon

that can be used:

1. Direct to outdoors

2. Vercal ducts

3. Horizontal ducts

4. Single opening (not recommend-

ed; must be at least 100 square

inches. Not appropriate for

conned spaces smaller than 50

cubic feet per 1,000 BTU/HR as

calculated in secon A or when

geng air from another room.

5. From a larger room inside the

house (not recommended —

refer to secon A to determine

if the combined volume of the

room may be adequate)

B2: Determine minimum free

area required for each vent

opening

The size of the vent openings depends

on the total BTU/HR rang of all

appliances in the space (use your

calculaon from “Before Beginning”)

and the type of vent used. Table 3

provides the minimum free area for

each vent opening depending on the

type of venlaon.

B3: Calculate minimum size of

vent openings and ducts

The vent cross-seconal area needed

to provide the free area depends on

the covering on the vent openings.

Typical vents use louvers or grilles to

protect the opening. The louver or

grille itself blocks some of the free

area, so the opening may need to be

larger to meet the minimum free area

requirements.

See the following page for examples

instrucng how to calculate the

required cross-seconal area.

Table 3:

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

Air Supply — All Air from Outdoors Only.

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

conned space.

Opening Source Minimum Free Area Per Opening (sq. in.)

*Direct to outdoors 1 sq. in. per 4,000 BTU/HR (see Figure 3 on page 10)

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

Horizontal ducts 1 sq. in. per 2,000 BTU/HR (see Figure 5 on page 10)

Single Opening 1 sq. in. per 3,000 BTU/HR (see Figure 6 on page 10)

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

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

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

Use the following formula to calculate

the required cross-seconal area:

Cross-seconal area = minimum free

area required ÷ percent free area of

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

For example, an installaon area that

requires openings with 100 square

inches of free area would need 134

square inch openings if using metal

louvers rated at 75% free area

(100 sq. in. ÷ .75 = 134 sq. in.).

If you do not know the % free area for

your louver or grille, use the following

values:

• For wood louvers or grilles: 20%

• For metal louvers or grilles: 60%

Follow these rules to ensure that

vents and ducts provide adequate air

ow:

• Each vent opening must be no small-

er than 100 square inches.

• Ducts must have the same cross-sec-

onal area as free area of the

opening.

• Rectangular ducts must have a

minimum dimension of no less than

three inches.

• All screens must have mesh ¼” or

larger.

• Movable louvers must be locked

open or interconnected with the

equipment so that they open auto-

macally during operaon.

• Keep louvers and grilles clean and

free of debris or other obstrucons.

B4: Check that air source is

clean and free of chemicals

Air for combuson and venlaon

must be clean and free of corrosive

or ammable chemicals. A failure due

to corrosive chemicals in the air is not

covered by the warranty. Combuson

air must be free of acid-forming

chemicals such as sulfur, uorine, and

chlorine. Be sure that air at the vent

inlets is free of such chemicals.

B5: Check that combuson

venlaon is adequate

To conrm that your installaon has

enough combuson air, conduct the

vent dra test on page 23 when

installaon is nished.

Combuson Air Supply Opons

Figure 3 - Direct to Outdoors Openings

Figure 4 - Vercal Duct Openings

Figure 5 - Horizontal Duct Openings

Figure 6 - Single Opening

Venng

WARNING! Carbon Monoxide

Hazard. This water heater must

be supplied with adequate air and

vented to outdoors. The vent system

must be installed by a qualied

person. Examples of a qualied

person include gas technicians,

authorized gas company personnel,

and authorized service technicians.

Failure to properly vent the water

heater can result in severe injury

or death from carbon monoxide

poisoning.

The vent system must be installed

according to local and state codes, or

in the absence of local or state codes,

the “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.

GETTING STARTED

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

GETTING STARTED

To reduce the risk of carbon monoxide

poisoning, install a fuel gas and

carbon monoxide detector. Install and

maintain the detector in accordance

with the manufacturer’s instrucons

and local codes.

Replacing a Water Heater

Using the Exisng Vent System

Read the “Installing a New Vent

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 Type B double-wall or single-

wall metal vent pipe of either 3 inch

or 4 inch diameter and installed

according to the vent manufacturer’s

instrucons and the terms of its

lisng. Do not use other materials

such as dryer vent hose.

Installing a New Vent System

The vent pipe must meet the

following specicaons:

Type of Material

UL listed Type B double-wall or single-

wall metal vent pipe must be used.

Local codes may be more restricve

and may not allow single-wall vent

pipe. Single-wall vent pipe cannot

be used for water heaters located in

acs and may not pass through ac

spaces, crawl spaces, or any conned

or inaccessible locaon. Single-wall

vent pipe cannot pass through any

interior wall.

Clearance to Combusble Materials

NOTICE: Minimum clearances from

combusble surfaces are stated on

the rang plate adjacent to the gas

control valve/thermostat of the water

heater.

All parts of the vent system must

maintain the following clearances

from any combusble materials:

• Single-wall vent pipe must maintain

a 6 inch clearance from combusble

materials. The single-wall vent pipe

cannot pass through any ceiling,

oor, rewall, or re paron.

• The clearance from combusble

materials of UL listed Type B dou-

ble-wall vent pipe is specied by the

manufacturer of the vent pipe. UL

listed Type B double-wall vent pipe

may pass through walls or parons

constructed of combusble material

if the minimum clearance specied

by the manufacturer of the vent

pipe is maintained.

Vent Installaon

To improve the ow of exhaust gases,

we recommend that a minimum of

12 inches of vercal vent pipe be

installed on the dra hood prior to

any elbow. A poron of the vent pipe

(up to 75% of the total vercal height)

can be horizontal, but the terminaon

must be vercal. For the horizontal

secon, install without dips or sags

with an upward slope of ¼” per foot.

Install pipe avoiding unnecessary

bends. Pipe joints must be fastened by

sheet metal screws or other approved

means. Support the pipe to maintain

clearances and to avoid separaon

of joints or other damage. Vent pipe

must be accessible for cleaning,

inspecon, and replacement.

Terminaons

If local codes allow, this water heater

may be terminated into an exisng

chimney using the instrucons below.

Otherwise, this water heater’s vent

must terminate vercally (sidewall or

other horizontal terminaons are not

allowed).

Chimney Terminaon

Figure 7 - Chimney Terminaon Vent System

NOTICE: Before connecng a vent to

a chimney, make sure the chimney

passageway is clear and free of

obstrucons. The chimney must be

cleaned if previously used for venng

solid fuel appliances or replaces.

Also consult local and state codes for

proper chimney sizing and applicaon

or, in the absence of local and state

codes, the “Naonal Fuel Gas Code”,

ANSI Z223.1 (NFPA 54)-current

edion.

• The vent pipe must be installed

above the extreme boom of the

chimney to prevent potenally

blocking the ue gases.

• The vent pipe must be rmly at-

tached and sealed to prevent it from

falling out.

• To aid in removing the vent pipe, a

thimble or slip joint may be used.

• The vent pipe must not extend be-

yond the inner edge of the chimney

as it may restrict the space between

it and the opposite wall of the

chimney.

Do not terminate the vent pipe in a

chimney that has not been cered

for this purpose. Some local codes

may prohibit the terminaon of vent

connectors in a masonry chimney.

GETTING STARTED

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

Common (combined) venng is

allowable with vercal Type B vent

systems and lined masonry chimneys

as long as proper dra for the

water heater is established under

all condions of operaon. Do not

common vent this water heater with

any power vented appliance.

Vercal exhaust vents must

terminate with a listed cap or other

roof assembly and be installed

according to their manufacturer’s

instrucons. An unused chimney ue

or masonry enclosure may be used as

a passageway for the installaon of

vent pipe. Do not common vent this

water heater with any power vented

appliance. The following gures

are examples of vent pipe system

installaons and may or may not be

suitable for your specic applicaon.

Consult the “Naonal Fuel Gas Code”,

ANSI Z223.1 (NFPA 54)-current edion

and local codes.

Figure 8 - Vercal gas vent system with Type B

double-wall vent pipe.

Figure 9 - Venng through a chimney with Type

B double-wall vent pipe.

NOTICE: The gas vent must be

terminated in a vercal posion to

facilitate the removal of exhaust

gases.

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.

Figure 10 - 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 above.

The Sediment Trap must be no

less than three inches long for

the accumulaon of dirt, foreign

material, and water droplets.

3. Install a ground joint union be-

tween the gas control valve and

the manual gas shut-o valve.

This is to allow easy removal of

the gas control valve.

4. Turn the gas supply on and check

for leaks. Use a small, so-bris-

tled brush to apply a hand dish-

washing 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,

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 pressure for any

reason. If you are pressure tesng

the gas line with test pressure of ½

psi or less, you may isolate the water

heater from the gas line by closing the

manual shut-o valve.

Solar Installaon

If this water heater is used as a solar

storage heater or as a backup for the

solar water heang system, the water

supply temperatures to the water

heater tank may be in excess of 120°F.

A Thermostac Mixing Valve or other

temperature liming valve must be

installed in the water supply line to

limit the supply temperature to 120°F.

The unit must be set to Standard

Mode (see the “Operang Modes”

secon on page 24).

NOTICE: Solar water heang

systems can oen supply water

with temperatures exceeding 180°F

and may result in water heater

malfuncon.

GETTING STARTED

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

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 available at 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 11 - 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 12 - 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

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.

INSTALLATION

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

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.

NOTICE: Expansion tanks are pre-

charged with a minimum of 12 psi

air charge. The expansion tank’s air

pressure must be adjusted to match

the inlet pressure of your home but

must not be higher than 80 psi.

✓

Water Pipe and

Tank Leaks

METAL

DRAIN

PAN

AT LEAST 2” GREATER THAN THE

DIAMETER OF THE WATER HEATER.

PIPED TO AN

ADEQUATE DRAIN

6” MAXIMUM

AIR GAP

DISCHARGE PIPE

(DO NOT CAP OR PLUG)

Figure 13 - 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

2 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 14 - 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.

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.

WARNING! To reduce the risk of

carbon monoxide poisoning, install

a fuel gas and carbon monoxide

detector if the water heater is

installed in a bathroom, bedroom,

or any occupied room normally

kept closed. Install and maintain

the detector in accordance with the

manufacturer’s instrucons and local

codes.

Before installing your water heater,

ensure that it will be located:

• Indoors in an area with adequate air

supply.

• Indoors in an area that will not

freeze.

• As close as possible to a chimney or

vent.

• In a metal drain pan piped to an

adequate oor drain or external to

the building (Figure 13).

• In an area suitable for vercal instal-

laon.

• In an area with adequate space

(clearances) for periodic servicing

There must be a minimum of 24

inches of front clearance.

• In an area that allows a minimum

clearance from combusble surfaces

as stated on the rang plate.

• On a oor that can support the

weight of a full water heater.

• Within 6 feet of a 120VAC outlet.

DO NOT use an extension cord.

INSTALLATION

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

INSTALLATION

You will also want to follow these

guidelines while considering an

appropriate locaon:

• This water heater is not for use in

manufactured (mobile) homes or

outdoor installa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.

• If the water heater is located in an

area subject to lint, dust, or oily

vapors, at least annually check and

clean the air lter. See the Mainte-

nance secon for steps on cleaning

the air lter.

• 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 15 - 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 16 - 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 17 - 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).

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

Turn the cold water supply

valve OFF.

Figure 18 - Cold water supply in OFF posion.

Open the drain valve on the

water heater.

Figure 19 - Draining the old water heater.

Also open a hot water faucet

to help the water in the tank

drain faster.

Figure 20 - Open hot water to drain tank faster.

When the tank is empty,

disconnect the Temperature

& Pressure (T&P) Relief Valve

discharge pipe. You may be able to

reuse the discharge pipe, but do not

reuse the old T&P Relief Valve. A new

T&P Relief Valve comes with your new

water heater.

Figure 21 - Removing the T&P Relief Valve

discharge pipe.

Allow the vent pipe and dra

hood to cool. Once cooled,

disconnect the vent pipe

from the dra hood. You may need to

support the vent pipe unl the new

water heater is in place.

Figure 22 - Disconnect the vent pipe from the

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.

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.

METAL

DRAIN

PAN

AT LEAST 2” GREATER THAN THE

DIAMETER OF THE WATER HEATER.

PIPED TO AN

ADEQUATE DRAIN

Figure 23 - Metal drain pan piped to an ade-

quate drain.

INSTALLATION

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

INSTALLATION

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

2 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

Check the Air Filter

This water heater is equipped with a

base-ring air lter. Before proceeding

to the next step, visually check the

ler to ensure it is properly seated

in the base-ring. Do not operate the

water heater without a clean air lter

in place.

Step: 6

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 and state codes.

WARNING! To avoid serious injury

or death from explosion, install a

T&P Relief Valve according to the

following instrucons.

Figure 24 - Temperature and Pressure Relief

Valve

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.

• The discharge pipe must not be

smaller than the pipe size of the T&P

Relief Valve.

• The pipe must also be able to with-

stand 210°F without distoron. Use

only copper or CPVC pipe approved

for discharge use. Do not use any

other type of pipe, such as PVC,

iron, exible plasc pipe, or any type

of hose.

Figure 25 - The T&P Relief Valve discharge pipe

must be installed properly and piped to an

adequate drain.

• Terminate the discharge pipe a max-

imum of 6 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.

6.00"

MAX

Discharge

Pipe

Drain

Pipe

Figure 26 - 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.

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

Step: 7

Install Shut-O and

Thermostac Mixing

Valves

Install a manual shut-o valve

(available at your local

plumbing supplier) on 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 valves that are

compable with potable water. Use

only full-ow ball or gate valves.

Other types of valves may cause

excessive restricon to the water ow.

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 27 - Install Thermostac Mixing Valves at

each point-of-use.

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.

For water heaters that are fed

by a solar water heang

system (or any other pre-

heang system), always install a

Thermostac Mixing Valve or other

temperature liming device in the

inlet water supply line to limit water

supply inlet temperature to 120°F.

Solar water heang systems can

supply water with temperatures

exceeding 180°F and may result in

water heater malfuncon.

WARNING! Hot water provided

by solar heang systems can cause

severe burns instantly, resulng in

serious injury or death.

Step: 8

Connect the Water

Supply

Note that all piping and components

connected to the water heater must

be suitable for use with potable water.

Determine the type of water

pipes in your home. Most

homes use copper water

pipes (see following page), 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.

The water inlet and outlet threaded

connecons are steel. When

connecng the unit to piping made of

a dierent material, use of a dielectric

ng or a dielectric union conforming

to ASSE 1079 is recommended to

prevent corrosion and potenal

subsequent water leaks at or near the

connecon. Dielectric ngs may be

required by local plumbing codes.

IMPORTANT! A dielectric waterway

nipple is dierent than a dielectric

nipple and does not perform the same

funcon. A dielectric waterway nipple

will not protect the water heater from

corrosion.

Connect the cold water

supply using ¾” Naonal Pipe

Thread (“NPT”) to the cold

water inlet nipple.

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 nipple.

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 28 - A Pressure Reducing Valve is re-

quired if your home’s water pressure is above

80 psi.

Figure 29 - The Thermal Expansion Tank should

be pressurized with air to match the home’s

incoming water pressure.

INSTALLATION

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

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

12 inches) to a threaded adapter

using only 95/5 n-anmony

or equivalent solder. Aach the

threaded adaptors to the water

heater’s connecons (using

thread sealant tape or pipe joint

compound). Connect the home’s

water pipes by soldering, keeping

the connecons at the water heater

cool with wet rags. DO NOT over

apply joint compound.

Step: 9

Verify Connecons and

Completely Fill Tank

To remove air from the tank and allow

the tank to ll completely with water,

follow these steps:

Remove the 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 30 - 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: 10

Install Dra Hood

Install the new dra hood by

aligning the legs and inserng

them into the slots on the

ue damper’s ange (see Figure 31).

Do not reuse the dra hood from the

old water heater, but rather use the

new one that came with your new

water heater.

Secure the dra hood by

bending the leg ps, but do

not alter the dra hood in

any way.

Draft Hood

Flue Damper

Draft Hood

Leg Tip*

* Twist or bend the leg tips to secure the draft

hood to the flue damper.

* Damper orientation may vary.

Figure 31 - Install the new dra hood.

Aach the home’s exisng

vent pipe to the dra hood

outlet using an approved vent

adapter (not supplied). Read the

Venng secon on page 10 of this

manual. Make sure your home’s

venng system complies with the

instrucons in this manual and is in

good condion.

Step: 11

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 32 - 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.

Step: 12

Electrical Connecons

Before plugging in the water heater,

always make sure:

• The voltage and frequency corre-

spond to that specied on the water

heater.

• The electrical outlet has the proper

overload fuse or breaker protecon.

• Water heater to be located within 6

feet of 120VAC outlet.

• Unit is to connect to a 120VAC elec-

trical supply outlet (extension cord

is not allowed).

• The water heater and the outlet are

properly grounded.

• Installed in accordance with prevail-

ing provisions of local codes, or in

the absence of such, the Naonal

Electric Code, ANSI/NFPA 70 current

edion.

• See Figure 60 on page 36 for Wire

Diagram.

WARNING! Electric Shock Hazard:

Disconnect power before servicing.

Replace all parts and panels before

operang. Failure to do so can result

in death or electric shock.

WARNING! Electric Shock Hazard:

Plug into a grounded 3 prong outlet.

Do not remove ground prong. Do

not use an adapter. Do not use an

extension cord. Failure to follow

these instrucons can result in death,

re, or electrical shock.

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

INSTALLATION

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

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 or

chimney 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.

✓ Water heater not located near an

air moving device (fan, clothes

dryer).

✓ Not in a locaon with large amounts

of lint, dust, etc. (if so, the air lter

or ame arrestor located on the

boom of the water heater will

need to be cleaned more oen).

✓ Located indoors and in a vercal

posion. Protected from freezing

temperatures.

Combuson Air Supply and

Venlaon

✓ Adequate air supply for water

heater and any other nearby gas

appliances. If the water heater is

installed in a closet or other small,

enclosed space or within the living

space of the house, air supply open-

ings needed.

✓ Openings are of sucient size.

✓ Ductwork is the same cross-secon-

al area as openings.

✓ Outside air openings are preferred

and may be required in ghtly built

homes.

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.

✓ New dra hood, properly installed.

✓ Vent pipe securely fastened to dra

hood with screws and supported

properly.

✓ Check exisng vent system for rust,

restricons and obstrucons.

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, union and sediment trap.

✓ Adequate gas pipe size and ap-

proved gas pipe material.

✓ Approved pipe joint compound or

tape used.

✓ All gas connecons and ngs leak

checked and any leaks corrected.

INSTALLATION

22 • 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.

Figure 33 - Manual Gas Valve in ON posion.

Plug the water heater into a

grounded 120 VAC outlet.

Move the ON/OFF switch on

the gas valve to the ON

posion.

SCALDING

RISK

INCREASES

WITH

HOTTER

WATER

OFF

STATUS

24V

HOT

VERY

HOT

VAC

LOW

Figure 34 - Move switch to ON posion.

Turn the gas valve thermostat

seng to the LOW

temperature seng.

The water heater will light

automacally. DO NOT try to light

the pilot by hand.

SCALDING

RISK

INCREASES

WITH

HOTTER

WATER

OFF

STATUS

24V

HOT

VERY

HOT

VAC

LOW

Figure 35 - Set knob to LOW seng.

When the pilot is lit, the

status light will blink a

heartbeat (bright, dim, bright,

dim, etc.).

Adjust the gas control knob

to the HOT seng. Follow the

procedure below if you

receive a ash code (six ashes

followed by a single ash):

a. Turn the power switch on the gas

valve to the OFF posion.

b. Unplug the water heater from the

wall outlet.

c. Wait 10 minutes.

d. Repeat Steps 1-4.

Follow the procedure below

if the Status Light does not

start ashing a “heartbeat”

aer three lighng aempts:

a. Turn OFF gas to the water heater

at the manual shut-o valve.

b. Move the gas valve’s ON/OFF

switch to the OFF posion.

c. Refer to “No Hot Water” in the

Troubleshoong secon on page

25.

• 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 tempera-

ture.

• The air lter at the boom of the

water heater must be cleaned from

me to me. See the Maintenance

secon on page 32 for steps on

cleaning the air lter.

Shut Down Instrucons

Move the ON/OFF switch on the gas

control valve/thermostat to the OFF

posion. The status light will stop

blinking and stay on for a short me

aer the water heater is turned o.

Emergency Shut Down

Should overheang occur or the gas

supply fails to shut o, follow these

steps:

a. Turn OFF gas to the water heater

at the manual shut-o valve.

b. Move the gas valve’s ON/OFF

switch to the OFF posion.

c. Turn OFF all electric power to the

water heater (unplug it from the

120 VAC outlet).

OPERATION

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

OPERATION

Check the Vent System

and Air Supply

WARNING! Burn Hazard – DO NOT

touch the vent, doing so can cause

burns.

Once the water heater is lit and the

gas control knob is set to the desired

temperature, the burner will light (if

the tank is cold). Perform an air supply

and vent test to make sure the unit is

venng properly and the air supply is

adequate.

The main burner must be on

for this test. With a newly

installed water heater full of

cold water, turning the temperature

control knob to HOT should cause the

main burner to come on. You can view

the burner through the sight glass at

the base of the water heater.

Close all windows and doors

and turn on all gas appliances

and air-moving devices in

your home (range hoods, bathroom

exhaust fans, ceiling fans, etc.). Also,

close any replace dampers.

Allow the water heater’s

main burner to operate for

ve minutes. Pass a newly

exnguished match approximately

one inch from the dra hood’s relief

opening. Smoke from the match

should be steadily drawn into the

opening indicang the water heater is

geng adequate air and the vent

system is working.

Match

Relief

Opening

Draft Hood

Figure 36 - Test the air supply and vent to make

sure the water heater has adequate air and is

venng properly.

If the main burner has been

operang for ve minutes but

the match smoke dris

around or is blown away from the

opening:

a. Turn OFF gas to the water heater

at the manual shut-o valve.

b. Move the gas valve’s ON/OFF

switch to the OFF posion.

c. Turn OFF all electric power to the

water heater (unplug it from the

120 VAC outlet).

Inspect the vent system and repair

if necessary. In many cases, failure

to pass the air supply and vent

test indicates the water heater is

not geng enough air or there is

a problem with the vent system. It

may be necessary to increase the air

supply by geng air from outside (see

page 7).

WARNING! Burn Hazard – Do

not touch the vent. Doing so can

cause burns. If the dra hood does

not draw in smoke from a match

aer ve minutes of main burner

operaon, shut o the gas supply,

and do not operate the water heater

unl the vent system and air supply

have been checked by a qualied

person and repaired if necessary.

Connuing to operate the water

heater in this condion could lead to

serious injury or death from carbon

monoxide poisoning.

Temperature Control

System

Adjusng the Temperature

With the installaon steps completed,

you may adjust the water heater’s

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 and ambient air, 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:

Turn the gas control knob on the

gas control valve to the right to the

following sengs:

• “VAC” 55°F

• “LOW” 91°F

• “HOT 120°F

• “A” 130°F

• “B” 140°F

• “C” 150°F

• “VERY HOT” 155°F

NOTICE: The temperatures above are

approximates. The actual temperature

of the heated water may vary.

HOT

VERY

HOT

VAC

LOW

Figure 37 - Adjusng the gas control knob.

OPERATION

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

Wait for the water to heat up.

If you have no hot water aer

two hours, refer to the

Troubleshoong Secon (see page

25).

NOTICE: If the tank is full of cold

water, condensaon may form inside

the water heater. This condensaon

may drop on the burner causing a

sizzling sound. In some cases, you

may see a small puddle on the 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.

Check water temperature at

several points of use in your

home (for example, bathtub

faucet, shower, or lavatory sink) and

adjust the Thermostac Mixing Valves

as needed. If you are not sure how to

adjust the Thermostac Mixing Valve

sengs, or are not sure if you have

Thermostac Mixing Valves, contact a

qualied person.

Operang Modes

Standard Mode - The controller

adjusts the water heater to maintain

the temperature set by the user.

Vacaon - 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

Troubleshoong &

Maintenance

If you are not qualied or are not

comfortable performing any of

the troubleshoong, repair or

maintenance procedures that follow,

call our Technical Assistance Hotline

for further assistance, or contact a

qualied person.

No Hot Water

Use the following step-by-step plan

as a guide to help determine why you

have no hot water:

Check the Status Light

The Status Light on the gas

control valve ashes once every four

seconds when there are no problems

and there is no call for heat.

SCALDING

RISK

INCREASES

WITH

HOTTER

WATER

OFF

24V

HOT

VERY

HOT

VAC

LOW

STATUS

Figure 38 - Status Light

If the Status Light is ashing once

every four seconds and you have no

hot water, make sure the gas control

knob is set to HOT.

If the Status Light ashes a dierent

paern than is described above, refer

to “Gas Control Valve/Thermostat -

Status Light Codes” starng on page

27.

If the Status Light is not ashing, go to

Step 2.

Status Light is Not

Flashing

If the Status Light on the gas valve

does not ash, the system may be

locked out. Refer to “Gas Control

Valve/Thermostat - Status Light

Codes” on page 27. Be sure to read

the notes at the top of the owchart.

Insucient Hot Water

or Slow Hot Water

Recovery

WARNING! Because of the

increased risk from scalding, if you

set the water heater’s gas control

knob higher than 120°F, install

Thermostac Mixing Valves at each

point-of-use. Due to the increased

risk of scalding, DO NOT set the

temperature of the Thermostac

Mixing Valves above 120°F.

If the hot water is simply not warm

enough, there are several possible

causes:

• Faulty Thermostac Mixing Valve in

a faucet or shower control (check

other faucets in the house for hot

water).

• Water heater’s capacity too small

(or usage too high).

• Reversed plumbing connecons or

melted dip tube (usually found soon

aer new installaon).

• Plumbing leak.

• Sediment or lime 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.

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.

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

TROUBLESHOOTING

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 on page 13 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.

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

TROUBLESHOOTING

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

TROUBLESHOOTING

Status Light and Diagnosc Code Troubleshoong Chart

NOTICE:

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

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

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

The pattern will then repeat.

*So Lockout - 20 minute wait before returning to normal operang mode.

LED STATUS OR ERROR CODE INDICATES CORRECTIVE ACTION

Short Flash once every four seconds IDLE (no call for heat, no fault condions)

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

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

operate)

1) Turn the power switch on the gas control valve/thermostat to the “OFF” posion and unplug the power

cord from the power outlet.

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

supply pressure is adequate, proceed to Step 3.

3) Check all wiring connecons and ensure all harness and wire connecons are seated rmly and provide

proper electrical contact. If no connecon problems are found, proceed to Step 4. Firmly seat any loose

connecons found. If any connecons are found to be damaged, consult the replacement parts list for the

appropriate replacement. Aer any connecon problems are xed, restart the water heater by following

the lighng instrucons on page 22. If the problem persists, proceed to Step 4.

4) Check the condion of the base ring lter and ame arrestor. If they are clogged, follow the instrucons

for cleaning on page 35. If parts are not clogged, proceed to Step 5. Aer cleaning, follow the

instrucons for lighng on page 22. If problem persists, proceed to Step 5.

5) Follow the instrucons on page 34 to remove the burner assembly. Once the burner assembly has

been removed, inspect the manifold tube and burner for any obstrucons. If any clogs or obstrucons

are present, clear them. Inspect the pilot assembly’s electrode/ame sense rod for corrosion buildup,

degradaon, or damage. If there is evidence of any damage to the electrode/ame sense rod, replace

the igniter/pilot assembly. Follow the direcons on page 34 to re-install the burner assembly into the

combuson chamber. Follow the instrucons for lighng on page 22. If the problem persists, contact a

qualied service representave.

Two Flash, three second pause End Switch Failed Closed 1) Look at the top of the water heater to see if the damper is open (Figure 31 on page 19). If the damper

is open, ensure there is no obstrucon that would prevent the damper from closing. If there are any

obstrucons, turn the power switch on the gas control valve/thermostat to the “OFF” posion, then

remove the obstrucon. If the damper closes, turn the power switch on the gas control valve/thermostat

to the “ON” posion. If there are no obstrucons present, turn the power switch on the gas control valve/

thermostat to the “OFF” posion. Observe the damper to see if the damper closes. If the damper does

not close, unplug the power cord from the power outlet and proceed to Step 2. If the damper closes, turn

the power switch on the gas control valve/thermostat to the “ON” posion.

2) Check all wiring connecons to ensure all harness and wire connecons are seated rmly and provide

proper electrical contact. If no connecon problems are found, replace the damper. Firmly seat any loose

connecons found. If any connecons are found to be damaged, consult the replacement parts list on

page 37 for the appropriate replacement. Aer any connecon problems are xed, restart the water

heater by following the lighng instrucons on page 22. If the problem persists, replace the damper.

Three Flash, three second pause End Switch Failed Open or TCO (Thermal

Cuto) Limit Lockout

1) Turn the power switch on the gas control valve/thermostat to the “OFF” posion and unplug the power

cord from the power outlet.

2) Aempt to depress the TCO door switch buon (see “Completed Installaon” illustraon on page 2).

If the TCO door switch buon depresses, follow the instrucons for cleaning the lter and ame arrestor

on page 35. Aer cleaning is completed, follow the lighng instrucons on page 22. If the TCO door

switch buon does not depress, proceed to Step 3.

3) Follow the lighng instrucons on page 22. Observe the damper during inial startup. If there is a call

for heat and the damper opens, allow the unit to connue to perform and monitor any change in status.

If there is a call for heat and the damper does not open, proceed to Step 4.

4) Check all wiring connecons and ensure all harness and wire connecons are seated rmly and provide

proper electrical contact. If no connecon problems are found, replace the damper. Firmly seat any loose

connecons found. If any connecons are found to be damaged, consult the replacement parts list on

page 37. Aer any connecon problems are xed, restart the water heater by following the lighng

instrucons on page 22. If the problem persists, replace the damper.

Four Flash, three second pause ECO Limit Lockout Turn the power switch on the gas control valve/thermostat to the “OFF” posion, wait 10-20 seconds, then

turn the power switch on the gas control valve/thermostat to the “ON” posion. If the problem persists,

replace the gas control valve/thermostat (see page 33).

Five Flash, three second pause Flame Out Sequence Turn the power switch on the gas control valve/thermostat to the “OFF” posion. Wait 10 minutes, then

follow the lighng instrucons on page 22. If the problem persists, replace the gas control valve/

thermostat (see page 33).

TROUBLESHOOTING

LED STATUS OR ERROR CODE INDICATES CORRECTIVE ACTION

Six-One Flash, three second pause So Lockout* - Retry Limit - Failed TFI (Trial

for Ignion)

1) Turn the power switch on the gas control valve/thermostat to the “OFF” posion. Unplug the water heat-

er from the wall outlet. Plug the power cord back in, then follow the lighng instrucons on page 22.

If that does not work, turn the power switch on the gas control valve/thermostat to the “OFF” posion,

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